M/S.

RUNGTA MINES LIMITED

KARAKENDRA, BARBIL, INDIA

SPECIFICATION NO: 1167/RMLKK/TS/ELE-001

FOR
FURNACE TRANSFORMERS
FOR
INDUCTION MELTING FURNACES (SMS)

FEBRUARY, 2019

AE - 767, Sec - 1, Salt Lake City, Kolkata 700 064

Ph:+91 33 2337 5484/ 85
Fax: +91 33 2334 0083
E-mail:[email protected]
 PART – I

TECHNICAL SPECIFICATION

PAGE 2 OF 16
 TECHNICAL SPECIFICATION
for
FURNACE TRANSFORMERS
for
INDUCTION FURNACES (SMS)
of
M/S. RUNGTA MINES LIMITED, DHENKANAL, ODISHA

1.0 SCOPE

The specification covers design, manufacture, quality assurance, testing at

manufacturer’s works, delivery, supervision of erection and commissioning
of 2 sets of Transformers. Induction Furnaces of 15 T capacity to be located
in the Steel Melting Shop (SMS) of M/s. Rungta Mines Ltd., krakendra the
details given hereinafter in this specification.

2.0 DESIGN BASIS

2.1 The transformers and their accessories shall be designed for operating in
tropical humid climate at the required capacities in an ambient air
temperature of 500C maximum and 450C average over 24 hours. Since
the transformers will be located below the furnace platform inside the
shop, the derating shall be done for an ambient temperature of 500C.

2.2 In the design of equipment due consideration shall be given to the dust
laden atmosphere normally experienced in steel plants.

2.3 The variation of voltage and frequency of the 33KV system will be + 10%
and + 5% respectively.

2.4 The auxiliary power supply voltage shall be 415/240V, 3Phase, 4 wire
AC.

3.0 TECHNICAL SPECIFICATION

3.1 This specification shall be read in conjunction with the General Specification
for Transformer and the technological requirements as furnished by the
Furnace Supplier.

3.2 The transformers shall be designed, manufactured and tested for supplying
power to 24 pulse bridge rectifier associated with Induction Melting
Furnaces. Two Transformers (3375KVA) (Total 6750 KVA) shall be placed
in ONE TANK having TWO INDEPENDENT CORES as per following
specifications: common H.V. connections should be brought out & four
secondary terminals separately brought out:

PAGE 3 OF 16
Transformer Specification
7500KW- 24 pulse TOTAL KVA 8440KVA
TRANSFORMER : 01

TRANSFORMER-1 TRANSFORMER-2

1.Continious Rating 3375 kVA 3375 kVA

2.Primary Winding
a). Rated Voltage 33 kV 33 kV
b). No of Phases 3 3
c). Frequency. 50 Hz 50 Hz
d). Inter phase Extended Delta(+7.5°) Extended Delta (-7.5°)
Connection
3.Secondary Winding Secondary-1 Secondary-2
a). Terminal Voltage at 575 Volts. 575Volts.
0.95 P.F. at F.L.
b). No. of Phases 6 6
c). Inter phase
Connection.

Secondary I Delta Delta

Secondary II Star Star

Full load Rated Full load Rated

Current=1694Amps. Max Current=1694Amps. Max
4.Current per Phase
current at -10% of rated current at -10% of rated
voltage=1882Amps voltage=1882Amps
Transformer should be Transformer should be capable
capable to deliver rated kVA to deliver rated kVA on -10%
5.Current rating on -10% rated voltage also rated voltage also hence
hence current rating should current rating should be 10%
be 10% more. more
6.Percentage Regulation 5% 5%
7.Tappings
a). Type of Tap OFF. CKT. TYPE. OFF. CKT. TYPE.
Changer.
b). Controls of Tap Externally Manual. Externally Manual
Changer.
c). Taps/Steps on (+)5% to (-)5% in steps of (+)5% to (-)5% in steps of 2.5%

PAGE 4 OF 16
H.V.Winding. 2.5%
8.Vector Group ED(+7.5°)doy11 ED(-7.5°)doy11
9.Temp.Rise over
ambient temp of 50°C
a). Oil 45°C.
b). Winding 55°C.
10.Impedance Voltage % 8.35%
11.Type of Cooling ONAN
12.Installation INDOOR
13.Terminal
Arrangements
a). Primary Side Bare Bushing/Cable Box.
b). Secondary Side Bus Duct.
14.Component Losses
(Subject to IS/IEC
Tolerance)
a). No Load Losses at Total losses should be less than 1.5% of rated kVA up to
Rated Voltage & Frequency 1000kva.
b). Load Losses at F.L. at Total losses should be less than 1% of rated kVA above
75°C 1000kva to 20000kva

3.3 Other Important Notes FOR FURNACE DUTY TRANSFORMER:

a) The effect of Harmonics due to 12 Phase Full Wave bridge rectifier must
be taken care in specified KVA Rating.
b) Tap changer switch should be designed so as to get same 7.5° on each
tap.
c) The Transformer should be capable to deliver Rated KVA at –10% of rated
voltage.
d) Neutral Terminal shall not be grounded internally or externally and shall
not be brought out.
e) An appropriate Electrostatic Shield (Earth Screen) shall be provided
between Primary and Secondary Winding. Its Terminal shall be brought out
on an insulator and shall not be internally grounded.
f) Insulation between Secondary Winding and Earth Screen shall have 10 KV
RMS with stand capacity at all the times to cope with a maximum short term
fault voltage of 4.2 KV RMS relative to ground and 15 KV impulse relative to
ground for 2 secs.
g) The off load tap changing device shall be reliable for frequent operations.
h) The transformer should be provided with all standard and required
fittings and protection as per IS 2026.
i) The transformer should be provided with intermediate class of Lightening
arrester (This is an optional requirement).

PAGE 5 OF 16
 j) First filling of transformer oil (suitable flash tested) as per relevant IS/IEC
to be provided.
k) Transformer should be designed and constructed in accordance with IS-
2026.
l) In case the Transformer is water cooled, then oil circulating pump (1
working + 1 standby) & shell & tube type heat exchanger (1 working +
1standby) with suitable valve arrangements shall be provided.
m) Fault duration 50 ms approx.
n) The unbalance of Current between two secondary should be less than 5%.
(Each secondary should have equal impedance and design such that during
loading, current unbalance between two secondary should be less than 5%).
o) Transformer should be designed and constructed as per IS2026/IEC
60076.
p) The maximum flux density in core should be 1.6 Tesla at 110% above and
rated voltage.
q) Tight voltage tolerance of ±0.14% (0.28% overall) between two secondary
windings with full load to be maintained.
r) Short circuit test should be performed (a) both LV short (b) star LV short-
delta open (c) Delta LV short and star open. And short circuit current &
impedance between both LV and difference should be less than 5%.

Note:

During an induction power unit fault, each transformer secondary could be

subjected to repeated short term overloads of 7 kA peak for up to 10 Milli-
seconds. Although it is expected that such overloads should be infrequent,
the Transformer should be designed to withstand a nominal maximum at
five over loads within an hour, while operating at its rated kVA and to be
capable of withstanding hundreds of such overloads during its working life,
without significant deterioration in its performance.

4.0 QUANTITY

4.1 2 sets each of Transformer for 2 nos. of Induction Furnaces

5.0 The tenderer shall furnish the following details/documents along with their
offer :

5.1 Guaranteed Technical Particulars (GTP) of the transformer shall

include but not be limited to the following:

a) List of Fittings and Accessories

b) Approximate Overall Dimension (L x B x H)

c) Approximate Weights
(a) Core & Coil
(b) Tank & Fittings
(c) Oil

PAGE 6 OF 16
 (d) Total Weight

d) Regulation

e) Loss Figures

a. At No Load
b. At Full Load

f) Efficiency figures

• At 100% load
• At 75% load
• At 50% load
• At 25% load
• Load at which maximum efficiency occurs

g) Percentage Impedances at rated load of the individual

transformers

h) Flux density

i) No-load current at rated voltage and rated frequency

j) Insulation levels

k) Details of transformer tanks viz thickness of side and bottom

plates, cover and radiator tubes.

5.2 Documents

Type test certificate of identical rating of transformer supplied is

desirable.

6.0 In the event of an order the Tenderer/Supplier shall furnish the following in
quadruplicate for the review/approval of the Purchaser/Consultant.

1. GA drawing indicating:

a. Overall dimensions
b. Distance between two wheels
c. Arrangement for cable entry in HV/side//Bus duct on LV side
d. All accessories
e. Weights:
• Core and winding
• Tank and accessories
• Oil
• Total

f. Clearances for HV and LV windings:

PAGE 7 OF 16
 • Phase to Phase
• Phase to Earth
2. Foundation details
3. GA drawing of HV cable chamber and LV Bus duct with the terminal
arrangement.
4. GA of Marshalling Box along with scheme of connections.
5. Rating and Diagram plate.
6. Connection diagram
7. Operation & Maintenance Manuals

7.0 TESTS

Transformers should be tested for all routing tests as per IS 2026. The copy of
test certificate should be provided. Copy of the type test certificate the identical
transformer should also be provided.

8.0 PRICE

8.1 The price to be quoted shall be firm and inclusive of:

I. Commissioning spares
II. Two (2) years of recommended spares
III. 10% of extra oil
IV. Paint for touch-up
V. Unit rates for bus-ducts viz straight length, bends etc.

9.0 GUARANTEE

The tenderer/supplier shall provide guarantee for smooth operation of the

complete transformer supplied by them for twelve (12) months from the date
of successful commissioning.

PAGE 8 OF 16
 PART – II

GENERAL SPECIFICATION

PAGE 9 OF 16
 GENERAL SPECIFICATION FOR TRANSFORMER

1.0 SCOPE

This specification covers the design, manufacture, testing and supply of

Power Transformers with necessary accessories and documentation in accordance
with this specification.

2.0 STANDARDS:

The transformers shall be manufactured and tested in line with the latest
revisions of the following Indian Standards and any International Standards as
applicable:

Sl. No. Description

Standard
1 Power Transformer 2026
2 Fittings and Accessories 3639
3 Guide for Loading Oil Immersed 6600
Transformer.
4 Transformer Oil 335
5 Bushings 2099
6 Tests 2026
7 Tolerance on Guaranteed Particulars 2026
8 Buchholz Relay 3637
9 Electrical Insulation classified by
Thermal Stability 1217
10 On –load Tap Changer 8468

3.0 SPECIAL FEATURES:

3.1 Over Voltage Withstand Capability under Load Rejection Conditions:

The transformers shall be capable of withstanding 1.4 times the rated

voltage for at least 10 sec.

3.2 Short Circuit Withstand Capability:

The transformers complete with tap changer switch shall be designed

and constructed to withstand without damage the thermal and
dynamic effects of terminal short circuits at rated voltages. The
duration of short circuits shall be for 3 secs. The short circuit may
be three phase, line to line, double line to earth and line to earth.

3.3 Thermal withstand Ability:

PAGE 10 OF 16
 The Thermal withstand ability of the transformers during short circuit
condition shall be demonstrated by calculations.

3.4 Losses:

The following loss figures shall be quoted and guaranteed with

tolerance as per applicable Indian Standards at rated Voltage and
Frequency and at 75° C.

a. Rated Output
b. 25% of the rated output.
c. 50% of the rated output.
d. 75% of the rated output.
e. 125% of the rated output.

If subsequently the test figures exceed the values guaranteed, the

Purchaser has the right to reject the transformer even without levying
the penalty.

3.5 Noise Level:

Special care shall be taken to ensure low noise level. The Noise Level
shall not be more than 80db when measured in accordance with
ANSI/IEEE C.57.12.90/1980.

4.0 CONSTRUCTIONAL FEATURES:

4.1 Transformer Tank:

The tank shall be made out of low carbon steel and shall be of welded
construction and provided with gasketed steel cover plates. The tank cover
shall be bolted to the tank. The base shall be provided with suitable
reinforcement to prevent any distortion during lifting. The tank shall have
sufficient strength to withstand without distortion the filling with oil by
vacuum. Adequate space shall be provided between core and winding and
also in the bottom of tank for collection of any sediment.

4.1.1 Tank Cover, Inspection Openings and Seals:

All covers and seals shall be oil and air tight and shall not be affected by
mineral or synthetic oil action. Detachable radiators equipped with air vent,
drain plugs and lifting lugs shall be provided with cut-off Valves to permit
removal of any radiator unit without emptying the tank. Radiators shall be
securely braced to prevent undue vibration. The surface of the tank cover
shall be such that water will not be collected on the top of it at any point.

PAGE 11 OF 16
 The inspection openings shall be provided as necessary to give easy access
to bushings, core, windings, OLTC, earth connections etc. The tank cover
and inspection covers shall be provided with suitable lifting arrangements.
The tank covers shall be fitted with transformer pockets and care shall be
taken to prevent ingress of water.

The tank of the transformer along with radiators, conservator, bushings and
other fittings shall withstand full vacuum of 760mm of Hg while filling the oil
under vacuum and also on excess internal pressure of 0.35Kg/sqcm.

4.1.2 Tank Base:

The base of the tank shall be so designed that it shall be possible to move
the complete transformer without injury using plates and rails. Base
channels shall be provided with skids and pulling eyes to facilitate easy
handling.

4.1.3 Lifting and Hauling:

The tanks shall be provided with Lifting Lugs suitable for lifting the
transformer complete with oil. Pulling eyes shall be provided to facilitate
movement of transformer and they shall be suitably braced in vertical
direction so that bending does not occur when the pull has a vertical
component. The transformer tank shall be fitted with lugs in such a way for
lifting the transformer by cranes or by jacks. At least four (4) Jacking pads
are to be are to be provided in suitable locations so that the transformer can
be raised or lowered using hydraulic or screw jacks. Fasteners and bolts etc
shall be galvanized or Zinc passivated.

4.1.4 Axles and Wheels:

Transformer shall be provided with bi-directional flanged wheels and axles

so supported that under any service conditions they shall not deflect and
interfere the movement of the transformer. All wheels shall be detachable
and shall be provided with bearings and provisions shall be made for
lubrication of bearings. The wheels have to be paced to suit their movement.

4.2 Oil Conservator and Accessories:

4.2.1 The conservator shall be complete with oil filing plug and cap, oil drain valve
and oil level gauge in addition to magnetic oil level gauge. The conservator
shall be designed to have enough capacity to meet the requirements of the
expansion of the oil in the transformer and the cooling equipment. The
transformer shall be so designed that it can be drained completely by means
of a drain valve when in service.

4.2.2 Magnetic Oil Level Gauge:

PAGE 12 OF 16
 A dial type Magnetic Oil Level Gauge indicating minimum and maximum oil
level. Necessary potential free contacts shall be provided for low level alarm
and tripping.

4.2.3 Silica Gel Breather:

The conservator shall be fitted with Silica Gel Breather and the same shall
be mounted at such a height that the change in colour of the Silica Gel
Breather is visible when one stands close to the transformer from the ground
level.

4.3 Painting:

All surfaces shall be thoroughly treated by standard process ensuring

complete derusting and degreasing. The initial coating of paint shall not
react or from scals with the transformer oil. Care shall be taken to ensure
that all iron and steel parts not in contact with the oil shall be adequetly
protected against rust and likely damage during transportation to site. All
surfaces shall be painted with two finished coats of epoxy paints.

4.4 Insulating oil:

The insulating oil shall be of the best quality and shall conform to IS
standard. Each transformer will be supplied with first filling of oil and 10%
extra oil to account for leakage etc. The oil shall be free from moisture band
uniform quality throughout.

4.5 Core:

The core shall be built up with high-grade non aging, low loss, high
permeability, cold rolled grain oriented silicon steel laminations. The
laminations should not have waxy formations and shall be free from burns.
The insulation coating shall not react with transformer oil cold or hot. The
core shall be rigidly clamped and bolted to ensure adequate mechanical
strength so as to prevent vibrations during operation. The bolts used in the
core assembly shall be suitably insulated and clamping structures shall be
so constructed that the eddy currents are minimum. It is to be ensured that
lifting of the core assembly is smooth and shifting of the core assembly will
not occur during movement of the transformer as well as in the event of
short circuit. The design and construction shall be such that there will be
minimum humming and noise.

4.6 Windings:

The winding material shall be of electrolytic grade copper. The entire winding
shall not suffer any dimensional changes or deformations while in service
and maintain their initial consolidated form during transshipment or due to

PAGE 13 OF 16
 short circuit conditions. The windings shall be so designed that all coil
assemblies of identical ratings shall be interchangeable and field repair to
the windings can be made without any special equipment. The assembled
core and windings shall be vacuum dried and suitably impregnated before
removal from the treating equipment.

4.7 Coil Insulation:

The insulation used for winding shall have adequate electrical properties.
The insulation and other associated materials shall be insoluble, non
catalytic and chemically inactive in transformer oil and shall in no way be
affected under operating and abnormal conditions.

4.8 Terminals and Bushings:

HV terminals are to be terminated through bare porcelain or located inside

cable box for outdoor use. The bare porcelain shall be located on the top of
the tank. LV terminals shall be provided with disconnecting chamber, such
that transformer removal is possible with the cables left intact in their own
position.

4.9 Marshalling Box:

The Marshalling Box shall be complete in with WTI,OTI, alarm and trip
contacts and all control cables shall be neatly terminated on terminal box.
Removal of gland plate shall be easy. Double compression type glands shall
be provided. Internal wiring shall be done with 4 sqmm copper PVC cables
for CT circuits and 2.5 sqmm copper PVC cables shall be used for other
circuits. The external wiring between accessories and Marshalling Box shall
be by means of armoured cables. The Marshalling Box shall be by means of
armoured cables. The Marshalling Box shall be constructed out of CRCA
steel sheet of 2mm thickness on the sides and 3mm thickness on the front
door. The door shall have a locking arrangement. The class of protection
shall be IP55.The glass panes shall be leak-proof.

4.10 On Load Tap Changer (OLTC):

The OLTC (wherever specified) shall be on the HV side for varying the
transformation ratio without producing phase displacement during
operation. The OLTC shall be operated by RTCC panel during remote
operation and shall be complete with AVR and VRR for automatic changing
of taps. The tap-changer shall be capable of permitting parallel operation
with other transformers of the same type. The indication of number of tap
shall be provided at local/remote.

5.0 ACCESSORIES AND FITTINGS:

PAGE 14 OF 16
The transformer shall include, but not be limited to the following accessories and
fittings:

Sl. No. Description Quantity

1. Rating and Diagram Plate 1No

2. Earthing Terminals 2Nos
3. Lifting Lugs for Transformers 2Nos
4. Jacking pads 4Nos
5. Drain valve with plug 1No
6. Filter valve with plug 1No
7. Conservator tank 1No
8. Oil Level Gauge 1No
9. Oil filling hole with plug 1No
10. Air release plug 1No.
11. Thermometer Pocket 2Nos.
12. Detachable Radiator Banks with valves. No.asper
manufacturer’s design
13. Silica Gel Breather 1No
14. Pressure relief valve 1No
15 Tap-changer/switch 1 Set
16 LV Terminal Box 1No
17 HV Terminal Box 1No
18 Bi-directional Roller 4Nos
19 Dial Type Oil Temperature Indicator 1No
20 Dial Type Winding Temperature Indicator 1No
21 Marshalling Box 1No
22. Magnetic Oil Level Gauge with low level alarm 1No
Contact.
23. Buchholz relay 1No

24. Shut off valve between Conservator and Main 1No

Tank.
25. Drain cum Sampling Valve with plug. 1No
26. WTI CT Secondary Terminal Pocket 1No
27. Inspection opening with cover. 1No
28. Skid under base with haulage holes 1Set
29. Name Plate 1No

6.0 TESTS:

6.1 Routine Tests:

All the routine tests as per IS-2026 shall be conducted on all the transformers
in the presence of Purchaser’s representative and test reports shall be submitted.

6.2 Type Tests:

The Type Test Certificate of identical rating of Transformers shall be furnished.

Otherwise all the type tests as per relevant standard shall be carried out.

PAGE 15 OF 16
Temperature Rise Test on one of each rating of transformer shall be carried out
as per standard.

PAGE 16 OF 16