TranGrid

KSEBL

Chapter 5 A
TECHNICAL SPECIFICATION – 220/66KV
TRANSFORMER
Claus
Description
e No.
Scope
Transportation
Codes and standards
Performance
Tertiary Winding cancelled
Radio Interference and Noise Level.
7. Dynamic Short Circuit Test Requirement
Paint system and procedures
8. Transformer Losses and Bid Acceptance Inhibited Insulating Oil
9. Measurable Defects Preparation of spare units
10. Design review
11. Construction Details- Neutral Formation and Earthing Arrangement.
12. Insulating OIL
13. Bushings
14. Terminations
15. Cooling equipment and its control
16. Valves

cabling

18. Tap changing equipment

19. Constructional features of panels
20. Fitting and Accessories
21. Bushing current transformers
22.
General Guaranty

23. Hand Tools

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24. Centre of gravity

25. Inspection and Testing
An
nex
Technical Particulars / Parameters of Transformers
ure
–A
An
nex
Unused uninhibited Insulating Oil Parameters
ure
–B
An
nex
Design Review Document
ure
–C
An
nex
Painting Procedure
ure
–D
An
nex
Test plan
ure
–E

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TECHNICAL SPECIFICATION

1. SCOPE

1.1 This specification covers the design, engineering, manufacture, inspection, testing at
manufacturer’s works and delivery including unloading at site installation and
supervision of erection & commissioning at destination station of 1 No. 63 MVA,
220/66 kV (For replacing the existing 50 MVA Transformer), Three Phase, Two
winding transformer ???(Autotransformer ) without Tertiary winding connected in
YNynO vector group as detailed in the Technical particulars (requirements) and
guarantee for satisfactory performance for a period of 12/84 months from the date of
commissioning or 18/90 months from the date of acceptance by consignee whichever
is earlier. The Manufacturer/ Supplier shall inspect the site before starting
design/engineering to assess the space availability and to find out the maximum size
of the transformer that can be accommodate in the place of existing 50 MVA
Transformer bay keeping the clearance from the existing structures/equipments as
per standards and to check the existing rail track arrangement. It is preferred to use
the existing external cooler bank foundations to the new transformer

1.2 The transformer shall in general have constant percentage impedance between HV and
LV on all taps ???

1.3 External or internal reactors shall not be used to achieve the specified HV and LV
impedances..

2. TRANSPORTATION

2.1 The Contractor/manufacturer shall be responsible to select and verify the

route, mode of transportation and make of all necessary arrangement with the
appropriate authorities for the transportation of the equipment. The dimension of the
equipment shall be such that when packed for transportation, it will comply with the
requirements of loading and clearance restrictions for the selected route. It shall be
the responsibility of the contractor/manufacturer to coordinate the arrangement for
transportation of the transformer for all the stages from the manufacturer’s work to

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site and safe unloading the same at site as per the direction of the authorised officers
of the consignee.
2.11. The contractor shall carry out the route survey along with the transporter and finalise
the detail methodology for transportation of transformer and based on route
survey;anymodification/ extension/ improvement toexisting road,brid g e s , c u l v e r
t s e t c , if required, shall be in the scope of the bidder. 2.2 The main tank
of the transformer shall be inland transported on low bed trailers. There should be
provision for real time tracking the location of consignment at all times during
transportation from manufacturer’s works to designated site (GPS). The
contractor/manufacturer shall intimate KSEB Limited about the details of
transporter engaged for transportation of the Transformer for tracking the
Transformer during transit.

2.3 All metal blanking plates and covers which are specifically required to transport and
storage of the transformer shall be considered as part of the transformer and handed
over to the consignee. Bill of quantity of these items shall be included in the relevant
drawing/document. For easy identification the blanking plate shall be painted by
yellow paint.

2.4 The Contractor/manufacturer shall dispatch the transformer filled with Oil/Nitrogen
/Dry air gas with necessary arrangement to take care of pressure drop of nitrogen /Dry
air during transit and storage till completion of oil filling during erection. A N2 /Dry
air cylinder with regulator, gas pressure testing valve with necessary pressure gauge
and adaptor valve shall be provided. As the packing is liable to be stored in the open,
the packing shall be suitable for outdoor storage under humid atmospheric conditions.
All parts shall be adequately marked to facilitate erection at site.
Each consignment shall be accompanied by a detailed packing list. Any material
found short/damaged in the consignment shall be supplied or made good by the
contractor/manufacturer without any extra cost to KSEB Limited with in a time period
of maximum 15 days

In case, turrets are having insulation assembly and are transported separately then the
same shall also be filled with Nitrogen.

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2.5 Transformer shall also be fitted with sufficient number of Electronic impact recorders
(Minimum 2 numbers -on returnable basis), mounted diagonally on opposite sides,
during transportation to measure the magnitude and duration of the impact in all three
directions.

3. CODES & STANDARDS:

The transformer shall be manufactured and tested according to the latest revisions of
IS 2026 /IEC 60076.
The Material, equipment and methods used in the manufacture of power
transformer shall conform to the latest edition of following.

Standard Standard’s
Name / Description
No

Indian Standard

IS 335 Insulating oil

IS 1271 Thermal evaluation and classification of electrical insulation

IS 2099 Bushing for Alternating voltage above 1000V

IS 2705 Current Transformers

IS 3347 Dimensions for porcelain Transformer bushing

IS 3637 Gas operated relays

IS 3639 Fitting &Accessories for power transformers

IS 4201 Application guide for CT’s

IS 6600 Guide for loading of oil immersed transformers

IS 8478 Application guide for On-load tap changer

IS 8468 On-load tap changer

Code of practice for selection, installation
IS 10028 &maintenance of transformers

IS 13947 LV switchgear and control gear part-1

IS 2026 Power transformers

IS 6272 Industrial Cooling Fans

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IS5 Colors for ready mix paints

IS5561 Electrical power connectors

Indian electricity act &CEA Regulations.

CBIP manual on transformers- Publication 295

IEC Standards

IEC 60034 Rotating Electrical Machines. (E.g. For Cooler Fan, Motors.)

IEC 60038 Standard Voltages.

IEC 60071 Co-ordination of Insulation.

IEC 60076 Power transformers

IEC 60137 Insulating bushings for alternating voltages above 1000V

IEC 60156 Method for Determination of the Electric Strength for Insulating
Oils.
IEC 61869-1 Instrument transformers - Part 1: General requirements
IEC 61869-2 Instrument transformers - Part 2: Additional requirements for
current transformers

IEC 60044 Current Transformers.

IEC 60214 On-Load Tap- Changers

Specification for Unused Mineral Insulating Oils for
IEC 60296 Transformer and switchgear.

Identification of Equipment Terminals and of Terminations of

IEC 60445 Certain Designated Conductors, Including General Rules for an
Alphanumeric System.

IEC 60529 Degrees of Protection Provided by Enclosures (IP Code)

IEC 60542 Application Guide for On-Load Tap- changers.

IEC Determination of Transformer and Reactor Sound Levels.

60076-10

IEC 60076- Application Guide for Power Transformer.

8
IEC 62155 Hollow pressurized and unpressurized ceramic and glass
insulators for use in electrical equipment with rated voltages
greater than
1000 V.

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British Standards

BS 2562 Cable Boxes for Transformers and Reactors.

Unfilled enclosures for the Dry Termination of HV Cables for
BS 6435 Transformers and Reactors.

In the event of direct conflict between various order documents, the precedence of
authority of documents shall be as follows:
1) Approved Guaranteed Technical Particulars (GTP)
2) This Specification
3) Referred Standards
4) Approved Vendor Drawings -required

4. PERFORMANCE

4.1 The transformers shall be suitable for bi-directional flow of rated power. The
major technical parameters of the transformers are defined in the Standard
Technical Parameters for 220/66 kV Transformer.

4.2 Transformer shall be capable of operating under natural cooled condition up to

75/60% load. The forced cooling equipment shall come into operation by
pre-set contacts of winding temperature indicator and the transformer shall operate
as a forced cooling unit after 75/60 % load. Cooling shall be so designed that
during total failure of power supply to cooling fans, the transformer shall be able to
operate at full load for at least ten (10) minutes without exceeding the calculated
winding hot spot temperature. The manufacturer shall submit supporting
calculations for the above and the same shall be reviewed during design review. If
the Transformer is fitted with two coolers, each capable of dissipating 50 per cent
of the loss at continuous maximum rating, it shall be capable of operating for 20
minutes in the event of failure of the oil circulating pump or blowers associated
with one cooler without the calculated winding hot spot temperature exceeding
140 deg C at continuous max rating. The contractor shall submit supporting
calculations for the above and the same shall be reviewed during design review
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4.3 Transformer and associated equipment shall be designed in such a manner as to meet
the requirements in this specification and Standard Technical Data Sheets at ambient
site conditions. Therefore the temperature-rise limits given in IEC 60076-2 and IEC
60076-7 (i.e. hotspot) shall not be exceeded.

4.31 The transformer shall be free from any electrostatic charging tendency (ECT) under
all operating conditions and maximum oil velocity shall be such that it does not
lead to static discharges inside the transformer while all coolers (including spare)
are in operation.

4.4 All metal parts of the transformer with the exception of the individual core
laminations, core bolts and associated individual side plates shall be maintained at
the same fixed potential. The earthing structure shall be designed to carry, without
damage, the maximum possible earth fault current for a duration of at least equal to
the short circuit withstand period of the main windings.

4.5 The transformer shall be capable of being continuously operated at the rated MVA
without danger, at any tapping with voltage variation of 10% corresponding to the
voltage of that tapping.

4.7 The transformers shall be capable of being over loaded in accordance with IS 6600-
latest amendments. There shall be no limitation imposed by bushings, tap changers
etc. or any other associated equipment.

4.7.1 Tank hotspot shall not exceed 130 Deg. Celsius. Maximum ambient temperature
shall be considered as 50 Deg. C. The hotspot temperature in any location of the
tank shall not exceed 95 deg. Celsius at rated MVA. This shall be measured during
temperature rise test at manufacturer’s works.

4.8 The transformer when operating on any tapping position according to requirements
of IEC 60076-5, and all its accessories including bushing/ built in CTs etc. shall be
designed to withstand without damage, the thermal and mechanical effects of

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any external short circuit to earth and of short circuits at the terminals of any
winding for a period of 2 sec. after long-time emergency cyclic loading
conditions as specified in IEC60076-7 under thermal steady state conditions (to be
verified by thermal short-circuit calculations and steady state heat run test). The
short circuit level of the HV & LV System to which the transformers will be
connected is as follows:

220kV system -50 kA (sym, rms, 3 phase fault)

66 kV system -25 kA/31.5kA (sym, rms, 3 phase fault)

However, for transformer design purpose, the through fault current shall be
considered limited by the transformer self-impedance only (i.e. Z = 0).
s

4.9 Transformer shall be capable of withstanding thermal and mechanical stresses caused
by symmetrical or asymmetrical faults on any terminals. Mechanical strength of
the transformer shall be such that it can withstand 3-phase and 1- phase through
fault for transformer rated voltage applied to HV / LV terminals of transformer.

The transformer shall be designed to withstand for short circuit duration of

1/2seconds for thermal stress and the same shall be verified during design review.

4.10 The maximum flux density in any part of the core and yoke at the rated MVA,
voltage and frequency shall be such that under 10 % continuous over-voltage
condition it does not exceed 1.76/1.9 Tesla at all tap positions. Maximum current
density on any portion of the winding (HV/LV) shall not exceed 2.50 Amp/Sq.mm
at rated tap.

4.11 Transformers shall withstand without damage, heating due to the combined voltage
and frequency fluctuations which produce the following over fluxing conditions:
110 % for continuous
125 % for 1 minute
140 % for 5 seconds.
4.12 The transformers will be evaluated against no load and load losses guaranteed by the
manufacturers with capitalisation of losses as per CBIP guidelines for loss
capitalisation. The corresponding capitalisation figures for no load, load losses and

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cooler aux. loads shall be as per clause 16.1, 16.2 & 16.3 of STP respectively. In the
event of measured loss figures during testing exceeding the guaranteed loss figures
of the successful manufacturer penalty shall be levied at a rate of 2.0 times the
figures mentioned above for no load, load loss and cooler aux. losses. The quoted
losses shall be considered as maximum without any positive tolerance.

The continuous rating of transformers shall be 75% (i.e. 47.25MVA with ONAN),
and 100% (i.e. 63MVA with ONAN). The required fans, and cooler control cubicle
shall be provided. The temperature rise of the transformer shall be within the values
specified at 20.1, 20.2 of the STP. Please note the existing 50 MVA Transformer is
provided with external cooler unit with 10 Nos. Cooling Fins Bank & 4 Nos.
Cooling fans, so it is required to design the new cooler unit to utilize the existing
cooler bank supporting foundations in order to reduce the shutdown time during the
replacement.

5.0 NO TERTIARY WINDING

No stabilizing winding is required. But the core shall be 3 limbed Core type with
the maximum flux density in any part of the core and yoke at the rated MVA,
voltage and frequency shall be as stated in clause 4.11 of the specification.
??is tertiary is required

6. RADIO INTERFERENCE AND NOISE LEVEL.

The transformers shall be designed with particular attention to the

suppression of harmonic voltage, especially the third, fifth and seventh so as to
minimize interference with communication circuit.

The noise level of transformer, when energized at normal voltage and frequency
with fans running shall not exceed the values specified, when measured under
standard conditions, as stipulated in NEEMA TR-1

7. DYNAMIC SHORT CIRCUIT TEST REQUIREMENT

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Manufacturer should have successfully carried out Dynamic Short Circuit Test on
the 63 MVA, 220/66kV transformer as on the originally scheduled date of bid
opening and shall enclose the valid Test Certificate along with bid. The validity of
dynamic short circuit test certificate shall be 5 years as on the date of originally
scheduled date of bid opening. In case the manufacturer has not successfully
carried out Dynamic Short Circuit Test on a 63 MVA, 220/66kV transformer, the
manufacturer may submit valid dynamic test report for 220/66kV transformers of
higher rating of identical design .

8 TRANSFORMER LOSSES AND BID ACCEPTANCE

The transformers will be evaluated against no load, load losses and auxiliary losses
with capitalization of losses as per CBIP guidelines for loss capitalization.

Following shall be the losses.

·Guaranteed Maximum No Load Loss on principal tap at Rated Voltage and

frequency, in KW (Without any positive tolerance: As per clause 15.1 of STP

·Guaranteed Maximum Load Losses (Copper + stray loss) at rated current on

principal tap at 75 o C, without any positive tolerance: As per clause 15.2 of
STP.

·Guaranteed Maximum Auxiliary/Cooler Loss in KW: As per clause 15.3 of

STP.

a) The Transformers are to be designed with maximum permissible losses as

indicated above.
b) The manufacturer must clearly specify that the offered losses are "Maximum" and
no further positive tolerance as per IS/IEC will be applicable on the offered values
during evaluation as well as during testing of transformer.

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c) Bids offering with losses beyond the maximum limits mentioned above shall be
treated as non-responsive and rejected.
Loss Capitalization shall be done with the accepted bids with loss values within
specified limit. For the purpose of evaluation of bids, the capitalized cost of iron
loss, load loss and auxiliary loss (KW) shall be added to the quoted price of the
transformer at the following rates:

I) Capitalized value of No Load loss per KW – As per clause 16.1 of STP

ii) Capitalized value of load loss per KW - As per clause 16.2 of STP
iii) Capitalized value of Auxiliary loss per KW- As per clause 16.3 of STP

e) However once a manufacturer becomes successful on the basis of loss

capitalization with certain declared loss value, they have to strictly achieve the same
loss value during the course of testing of transformers, offered for supply. No
positive tolerance as per IS/IEC will be applicable.
f) If they fail to do so, the offered transformer will be rejected if any of the measured
loss exceeds 5% of the declared maximum loss. The rejected transformer will be
retained by KSEBL to avoid delay project, which shall be replaced with transformer
meeting the specifications in all respects at contractor/manufacturer’s risk and cost.
g) In this process, the delay so occurred will be on the manufacturer/contractor’s
account.
h) If the manufacturer/contractor fails to achieve the declared loss during second
time, the contract will be terminated at the manufacturer/contractor’s risk and cost.

The KSEBL reserves the right to witness all the special tests and Routine tests.
The contractor shall submit schedule at least 30 days in advance for conducting
type test and do all the facilities for inspection team on the transformer under the
contract.

9. MEASURABLE DEFECTS.

The following shall constitute a Measurable Defects for the purpose of Defect
Liabilities.

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a) Repair, inside the Transformer and OLTC (including oil migration) either
at site or at factory is carried out after commissioning.

b) The concentration of any fault gas is more than values as of

condition-1 indicated in clause no 6.5 of IEEE-C57.104-1008, which
are as detailed below.

H C C2 C2 C2 C C TDC
2 H4 H2 H4 H6 O O2 G
1 1 1 5 6 3 25 7
0 2 0 5 5 00 2
0 0 0 0

c) The winding tan delta goes beyond 0.005 or shows an increasing trend
more than 0.001 annually.

d) The moisture content goes above 12 ppm at any temperature during

operation including full load.

10. DESIGN REVIEW

10.1. The transformer shall be designed, manufactured and tested in accordance with the
best international engineering practices under strict quality control to meet the
requirement stipulated in the technical specification. The manufacturer shall be
required to demonstrate the adequate safety margin w.r.t thermal, mechanical,
dielectric and electrical stress etc. The same shall be maintained during design,
selection of raw material, manufacturing process etc. in order to achieve long life of
transformer with least maintenance and to take into account the uncertainties of his
design and manufacturing processes. The scope of such design review shall include
but not limited to the requirement as mentioned at
Annexure – C.

10.2 Raw material and sub-vendors opt by transformer manufacturer shall be from the
declared list / approved list of KSEBL. For the time being PGCIL approved list for
vendors/sub vendors/ materials/equipment/instrument etc. with reference of the

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transformer under the scope of this specification shall be used .

10.3 Design reviews shall be conducted by the contractor/KSEBL during the

procurement process for transformer; however the entire responsibility of design
review shall be with the Contractor in presence /knowledge of KSEBL. KSEBL
will visit the manufacturer’s works to inspect design, manufacturing and test
facilities at any time.

10.4 The design review will commence after placement of award with the successful
manufacturer and shall be finalized before commencement of manufacturing
activity after the site visit. These design reviews shall be carried out in detail to
the specific design with reference of the transformer under the scope of this
specification.
10.5. The manufacturer shall also provide all necessary information and
calculations to demonstrate that the transformer meets the requirements for short
circuit strength and durability. The latest recommendations of IS/IEC/CEA and
CIGRE SC 12 shall be applied for short circuit withstand evaluation.

11. CONSTRUCTION DETAILS

The construction details and features of transformer shall be in accordance with the
requirement stated hereunder. The components and fitting associated with
transformers are subject to KSEBL’s approval.

11.1 TANK

11.1.1 Tank shall be of bolted construction and fabricated from tested quality low carbon
steel sheets of adequate thickness. Unless otherwise approved, metal plate, bar
and sections for fabrication shall comply with IS 2062 /BS-4360 . Material
Samples, technical literature, drawings, test reports and list of the names of the
principal users with experience gained shall be supplied as per approved QAP.

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11.1.2 All seams and joints which are not required to be opened at site, shall be
factory welded, and wherever possible they shall be double welded. Welding shall
conform to IS 9595/ BS-5135. After fabrication of tank and before painting, dye
penetration test shall be carried out on welded parts of jacking bosses, lifting lugs
and all load bearing members. The requirement of post weld heat treatment of
tank/stress relieving shall be based on recommendation of BS-5500 table 4.4.3.1/IS
10801.

11.1.3 Tank stiffeners shall be provided for general rigidity and these shall be designed to
prevent retention of water. The tank shall be designed and fabricated for
withstanding 760 mmHg of vacuum.

11.1.4 The tank shall be of proven design conventional type with bolted top cover. Bell
tank construction is not acceptable. The joint shall be provided with a suitable
gasket to prevent weld splatter inside the Tank. Proper tank shielding shall be
provided to prevent excessive temperature rise at the Joint.
• All bolted connections to tank shall be fitted with suitable oil-tight gasket,
which shall give satisfactory service under the operating conditions. Special
attention shall be given to the methods of making the hot oil-tight joints
between the tank and cover as also between the core and the bushings and all
other to ensure that the joints can be remade satisfactorily and with ease, with
the help of semi-skilled labours. Where compressible gaskets are used, steps
shall be provided to prevent over compression. Bushings, turrets, cover of
accessories, holes and other devices shall be designed to prevent any leakage
of water into or oil from the tank. There should not be any leakage for three
year and this should be guaranteed. All the gaskets to be provided
shall be of RC70C or RC80C grade. Necessary tests certificates from
manufacturer shall be submitted along with acceptance test report. The gasket
to be used shall not be older than One year.

• The tank shall be provided with two suitable copper alloy or any other suitable
material lugs for the purpose of grounding.

• (i)  One drain valve of adequate size with eccentric reducer and flange, located
on the low voltage side of the transformer. This valve shall be equipped with a
small sampling cock. The draining valve must be at bottommost location of the
tank.

• (ii)  One filter valve of adequate size with eccentric reducer and flange, located
at the top of tank on the high voltage side. The opening of this valve shall be
baffled to prevent airation of oil.

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• (iii)  One filter valve of adequate size with eccentric reducer and flange, located
on the high voltage side the transformer above the bottom of the tank.

• (iv)  Suitable valves shall be provided to take sample of oil from the OLTC
chamber during operation of transformer.

• (vi)  Pressure relief valve of adequate size & number/s shall be provided on
main tank as well as for OLTC.
• (vii)  All hardware used shall be cadmium plated / electro galvanised.

• (viii)  Necessary provision for installation of ‘HYDRAN – M2’ or equivalent On

Line monitoring system, shall be made for satisfactory performance through
out the life of transformer. Location and size of the same shall
be finalized during detailed engineering.
• (ix)  Necessary provision shall be made for installation of Nitrogen Injection
Fire Prevention cum Extinguishing System. Location and size of the same shall
be finalized during detailed engineering.

11.1.5 Tank shall be provided with:

a. Lifting lugs: Four symmetrically placed lifting lugs shall be provided so that it
will be possible to lift the complete transformer when filled with oil without
structural damage to any part of the transformer. The factor of safety at any
point shall not be less than 2.5.

b. A minimum of four jacking pads in accessible position to enable the transformer

complete with oil to be raised or lowered using hydraulic jacks.

c. Each jacking pad shall be designed to support with an adequate factor of safety
at least half of the total mass of the transformer filled with oil allowing in
addition to maximum possible misalignment of the jacking force to the center of
the working surface.

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d. Suitable haulage holes shall be provided. Adequate space shall be given at the
bottom for collection of sediments.

e. Adequately sized inspection openings/manholes; one at each end of the tank,

shall be provided for easy access to all HV and LV bushings and OLTC
connections. The inspection covers shall not weigh more than 25 kg. Handles
shall be provided on the inspection cover to facilitate lifting.

11.1.6 The tank shall be designed in such a way that it can be mounted on rollers.

11.1.7 The base of each tank shall be so designed that it shall be possible to move
the complete transformer unit by skidding in any direction without damage when
using plates or rails.

11.2 TANK COVER

11.2.1 The tank cover shall be designed to prevent retention of water and shall not distort
when lifted. The internal surface of the top cover shall be shaped to ensure efficient
collection and direction of free gas to the buchholz relay.

11.2.2 At least one adequately sized inspection opening shall be provided for easy access
to earth connections. The inspection covers shall not weigh more than 25 kg.
Handles shall be provided on the inspection cover to facilitate lifting.

11.2.3 The tank cover shall be provided with pockets for oil and winding
temperature indicators. The location of pockets (for OTI, WTI & ) shall be in
the position where oil reaches maximum temperature. Further, it shall be possible
to remove bulbs of OTI/WTI without lowering the oil in the tank. The thermometer
shall be fitted with a captive screw to prevent the ingress of water.

11.2.4 Bushing turrets, covers of inspection openings, thermometer pockets etc. shall be
designed to prevent ingress of water into or leakage of oil from the tank.

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11.2.5 To allow for the effect of possible induced and capacitive surge current flow, the
tank cover and bushing turret shall be fixed to the transformer in such a way that
good electrical contact is maintained around the perimeter of the tank and turrets.

11.2.6 The transformer shall be provided with a suitable diameter pipe flange, butterfly
valve, bolted blanking plate and gasket shall be fitted at the highest point of the
transformer for maintaining vacuum in the tank.

11.2.7 Gas venting - The transformer cover and generally the internal spaces of
the transformer and all pipe connections shall be designed so as to provide efficient
venting of any gas in any part of the transformer including bushing turrets and
OLTC fixing pockets etc. to the Buchholz relay. The space created under
inspection /manhole covers shall be filled with suitable material to avoid
inadvertent gas pockets. The covers shall be vented at least at both longitudinal
ends. The design for gas venting shall take into accounts the slopes of the plinth (if
any) on which the transformer is being mounted.
Over the tank cable routing fittings shall be provided to all electrical connection
points

11.3 GASKET FOR TANK & COVER

All gasket joints shall be designed, manufactured and assembled to ensure long-
term leak and maintenance free operation. All gasket joints shall preferably of O-
ring and groove type. The Gaskets / O-Ring in contact with oil shall be Nitrile
rubber bonded cork gasket / nitrile rubber O-ring. For the band- gasket, metallic
stops/other suitable means shall be provided to prevent over-compression of the
gasket.

The properties of all the above gaskets / O-Rings shall comply with the
requirements of IS-4253. Gaskets and O-rings shall be replaced every time
whenever the joints are opened.

11.4. ROLLER ASSEMBLY AND ANTI EARTHQUAKE CLAMPING DEVICE

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The roller mounted transformers are to be provided with flanged bi-directional

wheels and axles. These sets of wheels and axles shall be suitable for fixing to the
under carriage of transformer to facilitate its movement on rail track. Suitable
locking arrangement along with foundation bolts shall be provided for the
wheels to prevent accidental movement of transformer.The existing rail track
guage shall be utilised (with 2 rails for longer axis and for shorter axis 2 rails) and
the wheels and axles design shall be suitable for it.

All wheels should be detachable and shall be provided with suitable bearings which
shall be rust and corrosion resistant. Fittings for lubrication shall also be provided.
The flanged wheels shall be suitable for use on gauge track and movement of the
transformer.

To prevent transformer movement during earthquake, suitable clamping devices

shall be provided for fixing the transformer to the foundation.

11.5 CONSERVATOR

11.5.1 Main tank conservator shall have air cell type constant oil pressure system to
prevent oxidation and contamination of oil due to contact with moisture.
Conservator shall be fitted with magnetic oil level gauge with potential free high
and low oil level alarm Contacts and prismatic oil level gauge.

11.5.2 Conservator tank shall have adequate capacity with highest and lowest visible-levels
to meet the requirements of expansion of total cold oil volume in the transformer
and cooling equipment from minimum ambient temperature to top oil temperature
of 110 deg C. The capacity of the conservator tank shall be such that the
transformer shall be able to carry the specified overload without overflowing of oil.

11.5.3 The conservator shall be fitted with lifting lugs in such a position so that it can be
removed for cleaning purposes. Suitable provision shall be kept to replace air cell
and cleaning of the conservator as applicable. Provide ladder with platform for easy
access to conservator

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11.5.4 Conservator shall be positioned so as not to obstruct any electrical

connection to transformer.

11.5.5 The connection of air cell to the top of the conservator shall be by air proof seal to
prevent entrance of air into the conservator. The main conservator tank shall be
stenciled on its underside with the words “Caution: Air cell fitted”. Lettering of at
least 150 mm size shall be used in such a way to ensure clear legibility from ground
level when the transformer is fully installed. To prevent oil filling into the air cell,
the oil filling aperture shall be clearly marked. Separate valve schedule plate with
instruction and the valves position for air cell applications shall be fitted next to the
Rating and diagram plate.

11.5.6 Contact of the oil with atmosphere is prohibited by using a flexible air cell of nitrile
rubber reinforced with nylon cloth. The internal side of the air cell shall be
atmospheric air and ozone resistant. The temperature of oil in the conservator is
likely to rise up to 110°C during operation. As such air cell used shall be suitable
for operating continuously at this temperature.

11.5.7 The transformer manual shall give full and clear instructions on the
operation, maintenance, testing and replacement of the air cell. It shall also indicate
shelf life, life expectancy in operation, and the recommended replacement intervals.

11.5.8 The conservator tank and piping shall be designed for complete vacuum / filling of
the main tank and conservator tank. Provision must be made for equalizing the
pressure in the conservator tank and the air cell during vacuum / filling operations
to prevent rupturing of the air cell.

11.5.9 The manufacturer shall furnish the leakage rates of the rubber bag/ air cell for oxygen
and moisture. It is preferred that the leakage rate for oxygen from the air cell into
the oil will be low enough so that the oil will not generally become saturated with
oxygen. Air cells with well proven long life characteristics shall be preferred.

11.5.10 The manufacturer shall provide an air cell rupture warning relay. The relay shall be
provided with two sets of potential free contacts (suitable for 2.5sq.mm control
cable) for alarm on rupture of the air cell.

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OEM Shall send erection engineer for Aircel commissioning work with all required valves, dry
air or N2 and regulator.

11.5.11. OLTC shall have conventional type conservator (without air cell) with magnetic
oil level gauge with potential free oil level alarm contact and prismatic oil level
gauge. The prismatic oil level gauge shall be flush fitted to conservator without any
slitting on the conservator plate.

11.5.12 Piping works for conservator

11.5.12.1 Pipe work connections shall be of adequate size preferably short and direct. Only
radius elbows shall be used.

11.5.12.2 The feed pipe to the transformer tank shall enter the transformer cover plate at its
highest point and shall be straight for a distance not less than five times its internal
diameter on the transformer side of the Buchholz relay, and straight for not less
than three times that diameter on the conservator side of the relay. Gas-venting
pipes shall be connected to the final rising pipe between the transformer and
Buchholz relay as near as possible in an axial direction and preferably not less
than five times pipe diameters from the Buchholz relay.

11.5.12.3. This pipe shall rise towards the oil conservator, through the Buchholz relay, at an
angle between 5(five) degrees to 7 (seven) degrees to horizontal.

11.5.12.4. A double flange valve of preferably 50 mm and 25 mm size shall be provided to

fully drain the oil from the main tank conservator and OLTC conservator tank
respectively.

11.5.12.5. The feed pipe diameter for the main conservator shall be not less than 80mm.

11.5.12.6. Pipe work shall neither obstruct the removal of tap changers for maintenance or the
opening of inspection or manhole covers.

11.5.12.7 The bare minimum fittings and accessories on the Main Conservator tank.

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a. Prismatic (non-breakable &non blister type) oil gauge fitted to conservator end
plate with NORMAL, MINIMUM and MAXIMUM marking.
b. Magnetic oil gauge with High & Low Level Alarm contacts.
c. Silica Gel dehydrating breathers with Oil seal and dust filter with clear
transparent window cover blister free & resistant to UV rays.
d. Drain cum filling valve (gate valve) with locking rod and position Indicator made
of brass, with Cover plate
e. Shut off valve (gate valve) with Position indicator made of Brass Located before
and after Bucholz relay, 75mm
f. Air release valve on conservator (gate valve) made of Brass, 25 mm with cover
plate
g. Valve on the breather pipe near to conservator tank for filling /Nitrogen to the air
Cell.
h. Provision to fix one pressure gauge in between the conservator tank and the valve
mentioned above (item g).
i. Air cell rupture relay.

11.5.12.8 The bare minimum fittings and accessories on OLTC Conservator.

1) Blister free Prismatic oil gauge with NORMAL, MINIMUM and

MAXIMUM marking.
2) Oil filling hole with cap
3) Magnetic oil gauge with LOW LEVEL Alarm contact
4) Silica gel dehydrating breather with oil seal and dust filter with clear
transparent window cover resistant to UV rays
5) Drain valve (gate valve) with locking rod and position Indicator made of
Brass, 25mm with cover plate
6) Shut off valve (gate valve) with Position indicator made of Brass located
before oil surge relay, 25 mm
7) Air release plug as required

11.6 DEHYDRATING SILICA GEL FILTER BREATHER (ORANGE)

Conservator of Main Tank and OLTC shall be fitted with dehydrating silica gel
filter breather more than . Connection shall be made to the air cell flange by
means of a pipe with a minimum diameter of 25 mm. Breathers and
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connecting pipes shall be securely clamped and supported to the transformer, or

other structure supplied by the manufacturer, in such a manner so as to eliminate
undesirable vibration and noise. The design shall be such that:

a. Passage of air is through silica gel.

b. Breather piping shall not have any Valve placed in between to avoid breathing of
air through the valve
c. Silicagel is isolated from atmosphere by an oil seal.
d. Moisture absorption indicated by a change in color of the crystals. Cobalt
chloride shall not be used as indicator .Use methyl violet as indicator.
e. Breather is mounted approximately 1200 mm above rail top level.
f. Manufacturer shall provide flexible connection pipes to be used during
replacement of any silica gel breather

11.7 Pressure Relief Device

Minimum two number of pressure relief devices shall be provided at suitable

locations on the tank cover. These shall have opening diameter of at least 100 mm
for rapid release of any pressure that may be generated in the tank and which may
result in damage to equipment. The device shall maintain its oil tightness under
static oil pressure equal to the static operating head of oil plus 20kPa. The device
shall operate and attain its full opening in not more than 2.5 milli second , when
subject to an internal pressure impulse equal to static operating head of oil plus 50
kPa. Each device shall be provided with one set of potential free contacts (suitable
for 2.5sq.mm control cable), for trip.
It shall be capable of withstanding full internal vacuum at mean sea level. It shall be
mounted directly on the tank. Discharge of pressure relief device shall be properly
taken through pipes and directed away from the transformer/other equipment and
this shall be prevented from spraying on the tank. The terminal box/boxes of PRD
shall conform to degree of protection as per IP 55

11.7 BUCHHOLZ RELAY

One double float, reed type Buchholz relay shall be provided in the connecting pipe
between the oil conservator and the Transformer. Any gas evolved in the
Transformer shall be collected in this relay. The relay shall be provided with a test
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cock suitable for a flexible pipe connection for checking its operation and taking
gas sample. A copper tube shall be connected from the gas collector to a valve
located about 1200 mm above ground level to facilitate sampling while the
Transformer in service. Each device shall be provided with two potential free
contacts (suitable for 2.5sq.mm control cable), one for alarm and other for trip on
gas accumulation and on sudden rise of pressure.

The Buchholz relay shall not operate during starting/ stopping of the transformer
under any oil temperature conditions. The pipe or relay aperture baffles shall not
be used to decrease the sensitivity of the relay. The relay shall not mal-operate for
through fault conditions or be influenced by the magnetic fields around the
transformer during the external fault conditions. Pressurized water ingress test for
Terminal Box (routine tests) shall be conducted on Buchholz relay.

11.8 OIL TEMPERATURE INDICATOR (OTI)

All transformers shall be provided with a dial type thermometer of around 150 mm
diameter for top oil temperature indication. It shall have adjustable, potential free
alarm and trip contacts (suitable for 2.5sq.mm control cable). A temperature
sensing element suitably located in a pocket on top oil shall be provided. This shall
be connected to the OTI by means of capillary tubing. Temperature indicator dials
shall have linear gradations to clearly read at least every 2 dig C. Accuracy of OTI
shall be 2.0 dig C or better for a temperature up to 120 dig C.

The setting of alarm and tripping contacts shall be adjustable at site. For alarm &
trip settings the Pre-Commissioning shall be as per approved test Procedures and
formats submitted. The temperature indicators shall be with micro switch instead of
mercury switches

In addition to the above, the following accessories shall be provided for

remote indication of oil temperature:

a) Temperature transducer with PT 100 sensor

RTD shall be provided with Pt100 temperature sensor having nominal

resistance of 100 ohms at zero degree centigrade. The Pt100 temperature
sensor shall have three wire ungrounded system. The calibration shall be as per IEC
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60751-2 or equivalent. The Pt100 sensor may be placed in the pocket containing
temperature sensing element. RTD shall provide dual output 4-20mA for remote
OTI and SCADA system individually. Suitable convertor for RS 485 output shall
be provided in the RTCC panel for future use. The transducer shall be installed in
the Individual Marshalling Box. Any special cable required for shielding purpose,
for connection between Pt100 temperature sensor and transducer, shall be in the
scope of contractor /Manufacturer.

b) Remote oil temperature indicator

It shall be suitable for flush mounting on remote control panel/ digital RTCC panel
and shall operate on 4-20mA input available from the above transducer. Any special
cable required for shielding purpose, for connection among Individual Marshalling
Box, Common Marshalling Box/Cooler control cabinet and remote OTI control
circuit, shall be in the scope of manufacturer/Contractor.

11.9 WINDING TEMPERATURE INDICATOR (WTI)

All Transformers shall be provided with devices for measuring the hot spot
temperature of each winding (HVand LV) with dial type thermometer of 150 mm
diameter for winding temperature indication and shall have adjustable potential
free alarm and trip contacts (suitable for 2.5sq.mm control cable) besides the
two set of contacts required for control of cooling equipment . WTI shall have
Temperature sensing element, Image coil and Auxiliary CTs, if required to match
the image coil, shall be mounted in the cooler control cabinet. Temperature indicator
dials shall have linear gradations to clearly read at least every 2 dig C. Accuracy of
WTI shall be 2.0 dig C or better for a temperature upto 150 dig C. The
temperature indicators shall be with micro switch instead of mercury switch.

The temperature indicators (OTI & WTI) shall be so mounted that the dials are
about 1200 mm from ground level. Glazed door of suitable size shall be provided
for convenience of reading.

In addition to the above, the following accessories shall be provided for

remote indication of oil temperature:

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a) Temperature transducer with PT 100 sensor for each winding

RTD shall be provided with Pt100 temperature sensor having nominal

resistance of 100 ohms at zero degree centigrade. The Pt100 temperature
sensor shall have three wire ungrounded system. The calibration shall be as per
IEC 60751-2 or equivalent. The Pt100 sensor may be placed in the pocket
containing temperature sensing element. RTD shall include image coil,
Auxiliary CTs, if required to match the image coil, for WTI system and shall
provide dual output 4-20mA for remote WTI and SCADA system
individually. Suitable convertor for RS 485 /optical output shall be provided in
the RTCC panel for future use. The transducer, Auxiliary CT shall be installed
in the Individual Marshalling Box. Any special cable required for shielding
purpose, for connection between Pt100 temperature sensor and transducer, shall
be in the scope of Manufacturer. /contractor

b) Remote winding temperature indicator (RWTI)

It shall be suitable for flush mounting on transformer control panel/ digital

RTCC panel and shall operate on 4-20mA input available from the above
transducer. Any special cable required for shielding purpose, for connection
among Individual Marshalling Box / Cooler control cabinet, Common
Marshalling Box and remote WTI control circuit, shall be in the scope of
Contractor.

Separate individual RWTI shall be provided for display of temperature of the

two windings (HVand LV as applicable).

11.10 EARTHING TERMINALS

11.10.1 Two (2) earthing pads (each complete with two (2) nos. holes, M16 bolts, plain and
spring washers) suitable for connection to 75 x 12 mm galvanized steel grounding
flat shall be provided at position close to earth of the two (2) diagonally opposite
bottom corners of the tank.

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11.10.2 Two earthing terminals suitable for connection to 75 x 12 mm galvanized steel flat
shall also be provided on each cooler, marshalling box, Cooler Control Cabinet and
any other equipment mounted separately.

11.10.3 Equipotential flexible copper link of suitable size at least 4 Nos. for Tank mounted
turret with tank and tank with cover shall be provided. For other components
like - pipes, conservator support etc. Connected to tank shall also be provided with
equipotential flexible copper link. The size of the flexible shall be suitable for
carrying the earth fault current. The size of earthing copper link shall be declared in
the OGA drawing for approval.

11.11 CORE

11.11.1. The core shall be constructed from high grade, non-ageing, cold rolled, super grain
oriented silicon steel laminations (HI-B or better grade).

11.11.2 The design of the magnetic circuit shall be such as to avoid static
discharges, development of short circuit paths within itself or to the earthed
clamping structure and production of flux component at right angles to the plane of
laminations which may cause local heating.

11.11.3. The temperature of any part of the core or its support structure in contact with oil
shall not exceed 120 dig C under normal operating condition and 130 dig C under
10% over voltage and maximum ambient air temperature conditions of 50 dig C.
Adequate temperature margin shall be provided to maintain the long life
expectancy for this material.

11.11.4 Core and winding shall be capable of withstanding the shock during
transport, installation and service. Adequate provision shall be made to prevent
movement of core and winding relative to tank during these conditions.

11.11.5 All steel sections used for supporting the core shall be thoroughly sand / shot blasted
after cutting, drilling and welding.

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11.11.6 Each core lamination shall be insulated with a material that will not deteriorate due
to pressure and hot oil.

11.11.7 The supporting frame work of the core shall be so designed as to avoid presence of
pockets which would prevent complete emptying of tank through drain valve or
cause trapping of air during oil filling.

11.13.8. Adequate lifting lugs will be provided to enable the core and windings to be lifted.

11.11.8 The core shall be earthed to the core clamping structure at one point only, through a
removable external link of minimum size of 80 sq. mm copper suitably located and
protected to facilitate testing after installation of the transformer. The removable
links shall have adequate section to carry ground fault current. Separate
identification name plate/labels shall be provided for the ‘Core’ and ‘Core clamp’
on the tank cover.

11.11.9 In case core laminations are divided into sections by insulating barriers or cooling
ducts parallel to the plane of the lamination, tinned copper bridging strips shall be
inserted to maintain electrical continuity between sections.

11.12 WINDINGS

11.12.1 The Manufacturer shall ensure that windings of all transformers are made in dust
proof and conditioned atmosphere only.

11.12.2 The conductors shall be of electrolytic grade copper free from scales and burrs.

11.12.3 The insulation of transformer windings and connections shall be free from
insulating compounds which are liable to soften, ooze out, shrink or collapse and
shall be non- catalytic and chemically inactive in transformer oil during service.

11.12.4 Coil assembly and insulating spacers shall be so arranged as to ensure free circulation
of oil and to reduce the hot spot of the winding.

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11.12.5 The coils would be made up, shaped and braced to provide for expansion
and contraction due to temperature changes.

11.12.6 The conductor shall be transposed at sufficient intervals in order to minimize eddy
currents and to equalize the distribution of currents and temperature along the
winding.

11.12.7 The windings shall be designed to withstand the dielectric tests specified. The type
of winding used shall be of time tested. An analysis shall be made of the transient
voltage distribution in the windings, and the clearances used to withstand the
various voltages. Margins shall be used in recognition of manufacturing tolerances
and considering the fact that the system will not always be in the new factory
condition.

11.12.8 The barrier insulation including spacers shall be made from high- density
pre- compressed pressboard (1.1 gm./cc minimum for load bearing and 1 to
1.3 gm./cc minimum for non-load bearing) to minimize dimensional changes.

11.12.9 The conductor insulation shall be made from high-density (at least 0.75 gm. /cc)
paper having high mechanical strength. The characteristics for the paper will be
reviewed at the time of design review.

11.12.10 Wherever required, electrostatic shield, made from material that will withstand
the mechanical forces, will be used to shield the high voltage windings from the
magnetic circuit.

11.12.11 All winding insulation shall be processed to ensure that there will be no detrimental
shrinkage after assembly. All windings shall be pre-sized before being clamped.

11.12.12 Windings shall be provided with clamping arrangements which will distribute
the clamping forces evenly over the ends of the winding.

11.12.13 The bracing of the windings and connections shall be such that these parts shall
safely withstand the cumulative effects of stresses which may occur during

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handling, transportation, installation and service including line-to–line and line-to–

ground faults.

11.12.14 Current carrying connections

The mating faces of bolted connections shall be appropriately finished and prepared
for achieving good long lasting, electrically stable and effective contacts. All lugs
for crimping shall be of the correct size for the conductors. Connections shall be
carefully designed to limit hot spots due to circulating eddy currents.

11.13 WINDING TERMINATIONS

11.13.1 Winding termination interfaces with bushings shall be designed to allow for
repeatable and safe connection under site conditions to ensure the integrity of the
transformer in service.

11.13.2 The winding end termination, insulation system and transport fixings shall be
so designed that the integrity of the insulation system generally remains intact
during repeated work in this area.

11.13.3 Allowances shall be made on the winding ends for accommodating tolerances on the
axial dimensions of the set of bushings and also for the fact that bushings may have
to be rotated to get oil level inspection gauges to face in a direction for ease of
inspection from ground level.

11.13.4 In particular, rotation or straining of insulated connections shall be avoided during

the fastening of conductor pads (or other methods) on the winding ends onto
the termination surfaces of the bushing.

11.13.5 Suitable inspection hole and access facilities into the tank in the bushing oil-end
area shall be provided to minimize the possibility of error in connections, thus
avoid faults during the installation of all the bushings.

11.14 PAINT SYSTEM AND PROCEDURES

The typical painting details for transformer main tank, pipes, conservator tank,
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radiators, control cabinets/ marshalling box / conservator etc. shall be as given in

Annexure – D. The proposed paint system shall generally be identical or better than
the system outlined under annexure-D. The quality of paint should be such that its
color does not fade during drying process and shall be able to withstand temperature
up to 120 dig C.

12.0 INSULATING OIL

The oil for first filling together with 10% extra shall be supplied with each
transformer. The oil shall comply with uninhibited oil in all respects with
Annexure- B of the specification. Particular attention shall be paid to deliver the oil
free from moisture having uniform quality throughout. The quantity of oil for first
filling & 10% extra of transformer shall be stated in the tender.

12.1 The manufacturer of transformer shall furnish test certificates of the insulating oil
supplied against their acceptance norms, prior to dispatch.
Subsequently oil samples shall be drawn

i) At manufacturer’s works before and after heat run test, the following shall be
tested at CPRI/ERDA/in manufacturer’s LAB in the presence of KSEBL.
a) BDV in kVrms
b) Moisture content
c) Dissolved Gas Analysis – samples for DGA shall be taken from sampling
device within 24 hrs. prior to commencement of heat run test and immediately
after this test. The acceptance norms shall be as per IS: 10593 (based on IEC-
60599)

Transportation of Oil

The insulating oil for the transformer shall be delivered at site with prior
information to the KSEBL.

Insulating oil shall be delivered to the site in non-returnable oil drums. The drums
shall be suitable for storing the oil for long period

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13 BUSHINGS

13.1 Bushing shall have high factor of safety against leakage to ground and shall be so
located as to provide adequate electrical clearances between bushing and grounded
parts. Bushings of identical voltage rating shall be interchangeable. All bushings
shall be equipped with suitable terminals of approved type and size and shall be
suitable for bimetallic connection, if necessary. The insulation class of the high
voltage neutral bushing shall be properly coordinated with the insulation class of the
neutral of the high voltage winding.

All main windings and neutral leads shall be brought out to outdoor through
bushings which shall be so located that the full flashover strength will be utilized
and phase to phase and phase to earth clearance shall be more than minimum value
specified below. Location and arrangement of bushing shall follow Indian
Standards.
Each bushing shall be so coordinated with the transformer insulation that flashovers
will occur outside the tank.
All porcelain used in the bushings shall be made of the wet process, be
homogeneous and free from cavities or other flaws. The glazing shall be uniform in
color and free from blisters, burns, and other defects. Upper portion of Bushing
made of Porcelain & lower portion made of Epoxy/porcelain is also acceptable.

Bushings for 245 KV and 72.5kV voltage class shall be Oil Filled Condenser type
and shall be hermetically sealed. HV Neutral bushing shall be of 36 KV class for
220 KV class transformers. All OIP bushing shall have provision of measurement of
capacitance and tan-delta without dismantling of the bushing. Rating plate of
bushing shall be provided near each type of bushing with terminal marking and
physical position as per IS: 2026.

The electrical and mechanical characteristic of bushings shall conform to IS: 2099
and IS: 3347. The characteristic of the oil used in the bushing shall be the same as
that of the oil in the transformer.

Main terminals shall be solder less and “Terminal Connectors” shall be as per cl.
No. 15.5 of this technical specification. The spacing between the bushings must be
adequate to prevent flashover between phases under all conditions of operation.

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All bushings shall be suitable for heavily polluted atmosphere and minimum
creepage distance shall be taken as 25 mm per KV.

Where Bushing mounted Current Transformers are used, the bushing/CTs shall be
removable without disturbing the current transformers/Bushings.

The voltage and current rating of the bushings shall be as follows:

Highest System Voltage (kV) Rated Current in Amp.

245kV 400 A
72.5kV 1250A
36kV (Neutral) 1000 A

14 TERMINATIONS

14.1.1 220kV Terminations

The 220kV terminations shall be made through 245kV class, 400Amp. OIP
condenser bushing of appropriate without arcing horns???. Porcelain used in
bushing manufacture shall be homogenous, free from lamination, cavities and
other flaws or imperfections that might affect the mechanical or dielectric
quality and shall be thoroughly vitrified, tough and impervious to moisture
Bushings shall be provided with TEST TAP rated for 2kV.

14.1.2 66 kV Terminations

The 66kV terminations shall be made through 72.5kV class 1250A. OIP condenser
bushing of appropriate without arcing horns. Bushings shall be provided with TEST
TAP rated for 2kV

14.1.3 Neutral Termination

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The neutral point shall be brought out through an Oil/Air solid porcelain bushing of
suitable rating. And support insulators shall be provided on the tank wall for secure
connection of ground to the neutral bushing .Minimum three number of support
insulator shall be provided .which shall be clearly shown in the outline GA drawing.

14.5 Terminal Connections

14.5.1 General
i) The bushing shall be equipped with suitable terminals for connector as specified
herein.

ii) Each terminal (including the neutral) shall be distinctly marked on both the
primary and secondary sides in accordance with the diagram of connection plate
supplied with the transformers.

iii) Universal type bi-metallic, rigid connector for bushing stud shall be provided.

iv) Clamp and connector shall be made from Cold forged Aluminum Alloy Plate i.e.
Extruded Aluminum Clamp and Connector shall be processed through Cold forging
for 220KV, 72.5kV & 36KV Bushings.

v) The Nuts & Bolts associated with equipment of connector pieces shall be MS
Hot dip galvanized. Quality of Nuts & bolts shall conform to relevant IS of latest
edition.

vi) Minimum thickness at any point of current carrying part of any clamp &
connector shall not be less than 12mm. The terminal connector drawing shall be
submitted for approval.

i) The distance from outermost whole edge to nearest edge of any clamp &
connector shall not be less than 12mm.

14.5.2 HV Terminal

The HV Terminal connectors (TC) shall be suitable to connect between transformer

HV bushing and ACSR Kundah conductor/ AL pipe bus as per approved terminal
connector drawing for the site .Proper bimetallic (ALCO) shall be provided. Shall
have proper bolts to get proper connection and shall be easily removable on
requirement. The contact area between bushing & TC and TC & conductor shall be
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suitable for carrying 120% the rated current continuously and the short time fault
currents as per standards.

14.5.3 LV Terminal

The LV Terminal connectors (TC) shall be suitable to connect between transformer

LV bushing and single ACSR Moose conductor /AL pipe bus as per approved
terminal connector drawing for the site. Proper bimetallic (ALCO) shall be
provided. Shall have proper bolts to get proper connection and shall be easily
removable on requirement. The contact area between bushing & TC and TC &
conductor shall be suitable for carrying 120% of the rated current continuously and
short time fault currents as per standards.

14.5.4 The Neutral Terminal.

The Neutral Terminal Connector shall be suitable to connect between transformer

Neutral bushing and ACSR KUNDAH/ earthing GI strip. Proper bimetallic (ALCO)
sheet shall be provided at copper/AL interface; shall have proper bolts to get proper
connection and shall be easily removable on requirement. The contact area between
bushing & TC and TC & conductor shall be suitable for carrying the unbalanced
/fault current as per standards.

15 Cooling Equipment and its Control

15.1. Cooling Equipment for Radiator Bank

15.1.1 The cooler shall be designed using separately mounted radiator banks mounted
external to the Transformer main body. Design of cooling system shall satisfy the
performance requirements.

15.1.2 The radiator shall be of sheet steel in accordance with IS 513 and of minimum
thickness 1.2 mm.
15.1.3 Cooling equipment for the Transformer shall conform to the requirement stipulated
below:

a). The cooler shall be designed using 2x50% radiator banks

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Each radiator bank shall have its own cooling fans, shut off valves at the top and
bottom & blanking plate on each radiator, lifting lugs, top and bottom oil filtering
valves, air release plug at the top, a drain plug and sampling valve and thermometer
pocket fitted with captive screw cap on the inlet and outlet and two grounding
terminals for termination, of two (2) Nos. 75x12 mm galvanized steel flats.
.

b). The cooling fan shall be so mounted that they do not impose any adverse loading on
radiator tubes. Cooling fans shall not be directly mounted on radiator bank which may
cause undue vibration. These shall be located so as to prevent ingress of rain water. Each
fan shall be suitably protected by galvanised wire guard. The no. & capacity of cooler fans
associated with each radiator bank shall be such that outage of any fan does not reduce the
continuous rating of the transformer. In case the standby fans are separately identified &
are not in continuous operation, they shall be arranged to automatically come into
operation on tripping of working fan.
c). Cooling fan motor shall be suitable for operation on 415 ±10% V, three phase, 50 Hz +3%
- 5% power supply & shall conform to IS: 325. Each cooling fan motors shall be provided
with starter with thermal overload & short circuit protection. The motor winding insulation
shall be conventional class B type. Motor shall have enclosure with degree of protection
equivalent to IP 55 as per IS: 4691. The temperature rise of the motor shall be limited to 70
deg. C above ambient of 50 deg. by winding resistance method & shall comply with
IS: 325.

d). Fault indicating device: An alarm contact shall be furnished to

indicate the unintended stoppage of a fan. The contractor shall also indicate if any
additional alarm & indication lamp is required to be provided in Central control room.

Following lamp indications shall be provided in M. Box: or RTCC ??

(1.) Cooler supply failure ( main)
(2.) Cooler supply changeover
(3.) Cooler supply failure (standby)
(4.) Control supply failure
(5.) Common thermal overload trip
(6.) Cooling fan failure for each bank

One potential free initiating contact for all the above conditions independently to the
terminal blocks of M. Box exclusively for

15.1.4 Each radiator bank shall be detachable and shall be provided with flanged inlet and

outlet branches. Expansion joint shall be provided on top and bottom cooler pipe

connection

15.1.4 The cooler & its accessories shall preferably be hot dip galvanised or corrosion resistant
paint should be applied to it.

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15.1.5 The cooler pipes, support structure and its accessories shall be hot dip galvanized or
corrosion resistant painted. Painting should be applied to external surface of the
radiators, which are invariably hot dip galvanized.

15.1.6 Air release device and Drain valves shall be provided in order that each section of
pipe work can be drained independently.
15.2 Cooling Equipment Control unit
a) Automatic operation control fans shall be provided (with temp. change) from contacts of
winding temp. Indicator. The Contractor shall recommend the setting of WTI for
automatic changeover of cooler control from ONAN to ONAF. The setting shall be such
that hunting i.e. frequent start-up operation for small temp. differential do not occur.
b) Suitable manual control facility for cooler fans shall be provided
a) Selector switches and push buttons shall also be provided in the Marshalling Box to
disconnect the automatic control and start/stop the fans manually.

a. Each fan and pump motors shall be provided with a 3 pole electrically
operated contactors with control gear for motor operation by hand and
automatically through WTI contacts.
b. All connections shall be so arranged as to allow either individual or
collective operation for cooling fans.
c. The stand by fan motor shall automatically start if any one of the fans in that
group fails. Also it shall be possible to run the Standby fan in manual mode.
d. Necessary single phasing preventer, motor protection relays etc. shall be
provided.
e. Separate 3 phase MCB/ fuses shall be provided for each fan circuit.
f. All contactors, protective devices, MCBs etc. shall be properly labeled.
a. Selector switch for ON, OFF, AUTO/Manual shall be provided. in the
cooler control cabinet to disconnect the automatic control and start/stop of
the fans manually
g. Test push buttons are provided for checking of the working of motors
individually.

15.2.1 The cooler control cabinet / Marshalling box shall have all necessary devices meant
for cooler control and local temperature indicators. All the contacts of various
protective devices mounted on the transformer and all the secondary terminals of
the bushing CTs shall also be wired up to the terminal board in the cooler control
cabinet/ Marshalling box. All CT secondary terminals in the cooler control cabinet

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shall have provision for shorting to avoid CT open circuit while it is not in use. One
set potential free initiating contact shall also be wired independently to the terminal
blocks of cooler control cabinet.

15.2.2 All necessary terminations for remote control shall be wired up to the cooler
control cubicle/ Marshalling kiosk by the transformer manufacturer.

15.3 Auxiliary Power Supply for OLTC, Cooler Control and Power Circuit

15.3.1 415 volt, three phase 50Hz four (4) wire AC supply will be provided by KSEB Ltd.

15.3.2 For each circuit, suitably rated power contactors, MCBs/MCCBs as required for
entire auxiliary power supply distribution scheme including distribution to DM
boxes etc. (as applicable), shall be provided by manufacturer in cooler control
cabinet.

15.3.3 Auxiliary power supply distribution scheme shall be submitted for approval. Supply
and laying of Power, Control and special cables from marshalling box to all
accessories is in the scope of the contractor/manufacturer.

16 VALVES

16.1 All valves up to and including 100 mm shall be of gun metal.

Larger valves except radiator shut off valves may be of gun metal or may have
cast iron bodies with gun metal fittings. They shall be of full way type with
internal screw and shall open when turned counter clock wise when facing the hand
wheel. All hardware used shall be hot dip galvanized / stainless steel.

16.2 Suitable means shall be provided for locking the valves in the open and close positions
which can be operated with special tools only.

16.3 Each valve shall be provided with the indicator to show clearly the position
(Open/close) of the valve.

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16.4 All valves flanges shall have machined faces.

16.5 All valves in oil line shall be suitable for continuous operation with transformer
oil at 115 deg C.

16.6 The oil sampling point for main tank shall have two identical valves put in series. Oil
sampling valve shall have provision to fix rubber hose of 10 mm size to facilitate
oil sampling.

16.7 Valves or other suitable means shall be provided to fix various on line
condition monitoring systems to facilitate continuous monitoring. The location
& size of the same shall be finalized during detail design review/engineering.

16.8 FLOW SENSITIVE CONSERVATOR ISOLATION VALVE

a) In order to restrict the supply of oil in case of a fire in transformer, flow sensitive
valve shall be provided to isolate the main conservator oil from the main tank .

a) A valve which shall be flow sensitive and shut off when the flow in the pipe is
more than the flow expected in the permissible normal operating conditions. This
valve shall be located in the piping between the conservator and the buchholz
relay and shall not affect the flow of oil from and to the conservator in normal
conditions.

b) When the flow from conservator to main tank is more than the normal operating
conditions, the valve shall shut off by itself and will have to be reset manually. It
shall be provided with valve open/close position indicator along with alarm
contact indication in control room during closing operation of valve. This valve
shall be provided with locking arrangement for normal position and oil filling /
filtration position.

a) A suitable platform / ladder shall be provided to approach the valve for manual
reset.

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All valves shall be painted with a shade (preferably red or yellow distinct and
different from of main tank surface and as per the painting system and procedure
specified.

17.0 Cabling
· Separate cables shall be used for AC & DC.

· At least one (1) core shall be kept as spare in each copper control cable of 4C, 5C
or 7C size whereas minimum no. of spare cores shall be two (2) for control
cables of 10 core or higher size.

· Copper wires used for manufacturing the cables shall be true circular in shape
before stranding and shall be uniformly good quality, free from defects.

· The fillers and inner sheath shall be of non-hygroscopic, and outer sheath shall
be suitable for the operating temperature of the equipment.

· For control cables only round wire armoring shall be used.

· All the cables shall conform to fire resistance test as per IS: 1554 (Part - I).

· The normal current rating of all PVC insulated cables shall be as per IS: 3961.

All interconnecting control and power cables between various parts of

Transformers like turret CT, Nuetral Bushing CTs, MBs, Buchholz, PRD, MOLG
etc. shall be routed through covered cable tray or GI conduit and shall be properly
dressed. All cables shall be armored type. Un-armored cables (if provided) in any
circuitry, shall be through GI conduit and no part shall be exposed. Cable
terminations shall be through stud type TB and ring type lugs.
Contractor/manufacturer shall provide type tested cables from approved sources.
Both ends of all the wires (control & power) shall be provided with proper ferrule
numbers for tracing and maintenance. Further, any special cables (if required) shall
also be considered included in the scope. All cable accessories such as glands, lugs,
cable ties, cable tags/ numbers etc. as required shall be considered included in the
scope of supply.

18.0 TAP CHANGING EQUIPMENT

The transformer shall be provided with On Load Tap changing equipment as

specified elsewhere. The OLTC offered shall be suitable for bi directional power
flow and shall comprise tap selectors and high speed transition diverter switch.

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18.1 ON Load Tap Changing (OLTC) Equipment

18.1.1 Main OLTC Gear Mechanism

18.1.2 The transformer shall be provided with an on load tap changing Mechanism. The
tap changer shall be suitable for bidirectional power flow. The OLTC shall be
comprising tap selectors and diverter switch of high speed transition. This shall
be designed suitable for remote operation from the remote tap changer control
(RTCC) panel in the control room in addition to being capable of local manual as
well as local electrical operation.

The tappings shall be controlled by a high speed resistor transition type gear in
which tap change is carried out virtually under ‘no volt’ ‘no ampere’ condition and
the selector switches do not make and break any current, main current is never
interrupted and a resistor is provided to limit the arcing at diverter contacts to a
minimum. In particulars, the tap change gear shall be suitable for delivering the full
output plus permissible overload when operating at the lowest voltage tap on the HV
side.

The value of the transition resistor shall be indicated on the rating plate of the OLTC
with continuous current rating with reference to design ambient temperature
specified.

18.1.3 OLTC shall be motor operated suitable for local as well as remote operation. The
diverter switch or arcing switch shall be designed so as to ensure that its operation
once commenced shall be completed independently of the control relays or
switches, failure of auxiliary supplies etc. To meet any contingency which may
result in incomplete operation of the diverter switch, adequate means shall be
provided to safeguard the transformer and its ancillary equipment. The current
diverting contacts shall be housed in a separate oil chamber not communicating
with the oil in main tank of the transformer. The contacts shall be accessible
for inspection without lowering oil level in the main tank and the contacts shall be
replaceable.

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18.1.4 Necessary safeguards shall be provided to avoid harmful arcing at the current
diverting contacts in the event of operation of the OLTC gear under overload
conditions of the transformer.

18.1.5 The OLTC oil chamber shall have oil filling and drain valve, oil sampling valve, relief
vent and level glass. Oil sampling valve of minimum size, accessible from ground,
shall be provided to take sample of oil from the OLTC chamber. It shall also be
fitted with an oil surge relay which shall be connected between OLTC oil
chamber and OLTC conservator tank.

18.2 Local OLTC Control Cabinet (Drive Mechanism Box)

The transformer unit shall have OLTC gear with following features:

18.2.1 OLTC shall be suitable for manually handle operated and electrically motor
operated.
For local manual operation from Local OLTC Control cabinet (Drive Mechanism
Box), an external handle shall be provided.

18.2.2 OLTC’s Local control cabinet shall be mounted on the tank in accessible position.
The cranking device/ handle for manual operation for OLTC gear shall be
removable and suitable for operation by a man standing at ground level. The
mechanism shall be complete with the following:

Mechanical tap position indicator which shall be clearly visible from near the
transformer. A mechanical operation counter of at least five digits shall be fitted to
indicate the number of operations completed and shall have no provision for
resetting. Mechanical stops to prevent over-cranking of the mechanism beyond the
extreme tap positions.
The manual control considered as back up to the motor operated on load tap
changer control shall be interlocked with the motor to block motor start-up
during manual operation.
The manual operating mechanism shall be labeled to show the direction of
operation for raising the voltage and vice-versa.

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An electrical interlock to cut-off a counter impulse for reverse step change

being initiated during a progressing tap change and until the mechanism comes to
rest and resets circuits for a fresh position.

18.2.3 For electrical operation from local as well as remote, motor operated mechanism
shall be provided. It shall not be possible to operate the electric drive when the
manual operating gear is inserted. It shall not be possible for any two controls to be
in operation at the same time. Thermal device or other means shall be provided to
protect the motor and control circuit.

18.2.4 The Local OLTC Drive Mechanism Box shall house all necessary devices meant for
OLTC control and indication. It shall be complete with the followings:

i. A circuit breaker/contactor with thermal overload devices for controlling the

AC Auxiliary supply to the OLTC motor
ii. Emergency Push Button to stop OLTC operation
iii. Cubicle light with door switch provided with anti-condensation metal clad
heaters to prevent condensation of moisture
iv. Padlocking arrangement for hinged door of cabinet
v. All contactors relay coils and other parts shall be protected against corrosion,
deterioration due to condensation, fungi etc.
vi. The cabinet shall be tested at least IP 55 protection class.
vii. Control circuit transformer 415/55-0-55 V, adequate capacity
viii.Local remote selector switch 1 pole, 2 way, 6A, pistol grip
ix. Retaining switch raise / lower
x. Handle interlock switch
xi. Raise / lower switch 1 pole, 2way, 6A, pistol grip
xii. Lower limit switch
xiii.Raise limit switch
xiv. Tap changer motor, 415 V AC, 3 phase, adequate rating
xv. Motor protection relay with single phasing preventer
xvi. Motor control contactors raise / lower
xvii. Stepping relay
xviii. Out of step switch
xix. Tap position indicator

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xx. Operation counter

xxi. Tap change incomplete scheme with timer
xxii Manual operation device

18.2.5 All relays and operating devices shall operate correctly at any voltage within the
limits specified in this specification In case auxiliary power supply requirement for
OLTC DM Box is different than station auxiliary AC supply, then all necessary
converters shall be provided by the manufacturer.

18.2.6 Operating mechanism for on load tap changer shall be designed to go through one
step of tap change per command only, until the control switch is returned to the off
position between successive operations / repeat commands.

18.2.7 Limit switches shall be provided to prevent over running of the mechanism and shall
be directly connected in the control circuit of the operating motor provided
that a mechanical de-clutching mechanism is incorporated. In addition, a
mechanical stop shall be provided to prevent over-running of the mechanism under
any condition. An interlock to cut-out electrical control when it tends to operate the
gear beyond either of the extreme tap positions.

18.2.8 OLTC local control cabinet shall be provided with tap position indication for
the transformer. Drive Mechanism shall be equipped with a fixed resistor network
capable of providing discrete voltage steps / provide 4-20mA transducer
outputs for tap position indication in driving Mechanism and input to
RTCC/SCADA system. Suitable convertor for RS 485 /optical output shall be
provided in the RTCC panel for future use.

18.2.9 'Local-remote' selector switch shall be provided in the local OLTC control cabinet. In
Local mode, all electrical commands from remote (RTCC, SCADA etc.) shall be
cut-off/blocked. Electrical operations to change tap positions shall be possible by
using raise/lower push buttons under local mode from DM Box. In remote mode
electrical commands from RTCC/SCADA etc. shall be executed. The remote-local
selector switch shall be having at-least two spare contacts per position.

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18.2.10 The following minimum contacts shall be available in DM Box, which shall be wired
to Digital RTCC panel:

i. INCOMPLETE STEP for loss of auxiliary power.

ii. OLTC motor overload protection operated
iii. Supply to DM Motor failed
iv. OLTC IN PROGRESS
v. Phase sequence protection
vi. Local / Remote Selector switch
position
vii.OLTC upper/lower limits
reached.

18.2.11 All relays, switches, fuses etc. shall be mounted in the OLTC local control cabinet and
shall be clearly marked / labelled for the purpose of identification.

18.2.12 A permanently legible lubrication chart if required shall be fitted within the OLTC
local control cabinet.

18.3 RTCC Panel

The contractor/manufacturer shall supply one indoor cubicle for the transformer
(RTCC panel) for installation in the control room for the remote operation of the tap
change from control room and from remote (viz. Load dispatch center through
SCADA) having the following dimension
Width 900mm
Depth 800mm
Height 2200+100mm

The RTCC panel shall be made of CRCA sheet steel of thickness minimum 2.5 mm
for load as well as non-load bearing member.

The RTCC panel shall be provided with suitable size Min. 3 mm thick detachable
gland plate.

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The following control switches/ push buttons shall be provided in the RTCC panel.

Push button for ‘RAISE”

Push button for “LOWER”
“EMERGENCY STOP” button to stop Tap Change operation.
“Control Supply ON/OFF” switch.
“OFF/MASTER/FOLLOWER/INDEPENDENT” Mode Selector Switch.

The RTCC panel shall be provided with an annunciation window having an

annunciation Relay system having TEST, ACCEPT & RESET facilities. The relay
shall be suitable for TRIP and NON-TRIP alarms. In the event of any contact
initiates, the corresponding window shall glo w and an audible alarm shall be
operated. The TRIP window shall have Black text in Red background and Non-Trip
alarm window shall have black text in white background.
There shall be minimum two nos. each of TRIP & NON TRIP windows as
SPARES.

The relay shall be suitable for the following TRIP and NON-TRIP alarms.

· WTI alarm and trip

· OTI alarm and trip
· Bucholz relay alarm and trip for main tank
· OSR trip.
· MOG low level alarm for main tank and OLTC
· PRD main tank trip
· PRD OLTC Trip
· Sudden pressure relay trip
· Main fan in GR-1 fail
· Main fan in GR-2 fail
· Drive Motor Auto trip
· Out of step alarm

Following bunch of LED indications shall be provided on the RTCC panel.

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· Supply ON- Green

· Tap Change in Progress- Amber
· OLTC control supply On- Green
· DC Supply ON- Green
· TC Upper limit reached- Yellow
· TC Lower limit reached- Red
· TC in LOCAL mode- Red
· TC in REMOTE mode- Blue

Further the RTCC panel shall be provided with

·Remote Oil & winding temperature indicators
·Remote tap position indicators etc.

Following signals / controls shall be available for connecting to remote from RTCC
through SCADA

· TAP positions
· Winding and Oil temperatures
· Tap changer LOW and RAISE controls.
· And all protection alarm and trip signals from transformer to RTCC panel for
extending to elsewhere (Load dispatch Centre) through SCADA.

4 to 20mA signal for SCADA of tap positions for connecting from RTCC

Following shall be provided in the RTCC panel.

1) Cubicle lamp with door switch and separate fuse / MCB

2) Approved space heaters controlled by thermostat and separate fuse / MCB
3) Incoming fuse switch / MCB for the incoming supply
4) A table showing voltages on each tap position engraved in stainless steel plate
shall be fixed on the front of the panel by rivet.
5) Stainless steel door handle with lock & additional facility for padlock
6) Earthing strip inside the panel for connecting to the substation grounding.
7) Single phase power plug industrial type 15/5 Amp. With MCB.
8) All hinged parts (doors etc.) shall be properly grounded.

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The Size of the panel(width) shall be as specified

18.4 Master / Follower/ Independent/ off mode

Master Position: If the selector switch is in master position, it shall be possible to

control the OLTC units of other parallel operating transformers in the follower
mode by operation from the master unit.

Follower Position: If the selector switch is in Follower position, control of OLTC

shall be possible only from panel where master mode is selected.

Independent Position: In independent position of selector switch, control of

OLTC shall be possible only from the panel where independent mode is selected.
Suitable interlock arrangement shall be provided to avoid unwanted/inconsistent
operation of OLTC of the transformer is it required ?????

19.0 CONSTRUCTIONAL FEATURES OF COOLER CONTROL CABINET/

INDIVIDUAL MARSHALLING BOX/ AND RTCC PANEL

19.1 The transformer unit shall be provided with local Drive Mechanism Box,
cooler control cabinet /individual marshalling box and RTCC panel.

19.2 The Cooler control cabinet/Marshalling Box, RTCC panel etc. shall be made of
CRCA sheet of minimum thickness of 2.5mm and shall be painted suitably as per
Annexure –D.

19.3 The degree of protection shall be IP: 55 for outdoor and IP: 51 for indoor in accordance
with IS: 13947/IEC: 60947.

19.4 All doors, removable covers and plates shall be with gasket all around with
suitably profiled. All gasket surfaces shall be smooth straight and reinforced if
necessary to minimize distortion to make a tight seal. For Control cubicle /
Marshalling Boxes etc. which are outdoor type, all the sealing gaskets shall be of
EPDM rubber or any better approved quality, whereas for all indoor control

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cabinets / RTCC panel, the sealing gaskets shall be of neoprene rubber or any better
approved quality. The gaskets shall be tested in accordance with approved quality
plan, IS: 1149 and IS: 3400.

19.5 Ventilating Louvers, if provided, shall have screen and filters. The screen shall be
fine wire mesh of brass. All the control cabinets shall be provided with suitable
lifting arrangement. Thermostat and hygrostat controlled space heater and cubicle
lighting with ON-OFF/door switch shall be provided in each panel.
The welding of the panel shall be continuous on joints. Welding at regular intervals
on joints and filling of gaps with use of Mseal is not accepted. All cables shall be
bottom entry and access from rear side.
19.6. The size of all cabinets shall be suitable for fixing all required accessories. All
accessories shall be easily accessible inspection and maintenance. All cabinets
except RTCC shall be tank/Local mounted. The RTCC panel shall be suitable for
mounting indoor.

RTCC panel height shall be 2.2m +100mm +15 mm anti vibration pad 800 mm
depth color IS 631 light grey interior white Powder coating 80 -100 micron (this is
tentative and the width of the panel will be finalized during design review). The
switches shall not be below 750 mm of the CL

20.0 Fittings & accessories

The following fittings & accessories shall be provided with the transformer covered
in this specification. The fittings listed below are not exhaustive and other fittings
which are required for satisfactory operation of the transformer are deemed to
be included.

a. Conservator for main tank with air cell, isolating valves, drain valve, magnetic
oil level gauge with low & high level alarm contacts, prismatic oil level gauges
and dehydrating breather

b. Conservator for OLTC with drain valve, oil surge Relay, filling hole with cap,
prismatic oil level gauge and dehydrating breather

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c. Minimum 2 Numbers pressure relief devices

d. Buchholz relay double float, reed type with isolating valves on both sides,
bleeding pipe with pet cock at the end to collect gases and alarm / trip contacts.

e. Air release plugs

a. Inspection openings/manholes and covers

f. Bushing with metal parts and gaskets to suit the termination

arrangement
g. Winding & Oil temperature indicators for local and remote mounting
a. Cover lifting eyes, transformer lifting lugs, jacking pads, towing holes and core
and winding lifting lugs

b. Protected type mercury or alcohol in glass thermometer or magnetic or micro-

switch type dial type temperature indicator.

h. Bottom and top filter valves with threaded male adaptors, bottom sampling
valve and drain valve

i. Rating and diagram plates (in English) on transformers and auxiliary apparatus

j. Valve schedule plate

k. On load tap changing gear, OLTC DM Box, Cooler control cabinet, and RTCC
Panel (indoor type) as applicable

l. Cooling equipment

m. Bushing current transformers for winding temperature imaging and protection

circuit.

n. Oil flow indicators

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o. Drain valves/plugs shall be provided in order that each section of pipe work can
be drained independently

p. Terminal marking plates

q. Ladder to climb up to the Transformer tank cover/conservators with
suitable locking arrangement to prevent climbing during charged condition

r. Suitable Platform for buchholz relay, MOLG shall be provided, in case these are
not accessible from transformer top.

s. Haulage lugs

t. Flow sensitive conservator isolation valve.

u. Flanged bi-directional wheels

21. Bushing Current Transformer

Bushing CTs shall be used for HV& LV winding temperature imaging on V phase.

21.1 Current transformers shall comply with IS 2705/ IEC 61869-Part-1 & part 2.
21.2 It shall be possible to remove the turret mounted current transformers from
the Transformer tank without removing the tank cover. Necessary precautions
shall be taken to minimize eddy currents and local heat generated in the turret.
21.3 HV & LV side Nuetral Bushings CTs of required ratings as per technical requirement

shall be provided for protection purpose

21.4 Current transformer secondary leads shall be brought out to a weather proof terminal
box near each bushing.
22 General warranty

The manufacturer shall among other things guarantee the

following:

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i) Quality and strength of materials used.

ii) The contractor/manufacturer shall give guarantee for satisfactory working of

the complete transformer for 12/84 months from the date of commissioning of
equipment or 18/90 months from the date of receipt of transformer at site,
whichever is earlier.

Guarantee period will be reckoned from the date of receipt of 100 % accessories and
not from the date of receipt of main tank only.

Defects any noticed during the guarantee period due to faulty design/
workmanship, inferior raw materials or non-adherence to the relevant standards
shall be made good by way of replacement/repair on all free of cost to KSEB Ltd

23 Hand Tools

One set of hand tools of reputed make packed in a carry bag/box broadly
comprising of double ended spanners (open jaws, cranked ring, tubular with
Tommy bar each of sizes 9mm to 42mm, one set each), adjustable wrenches (8 &12
inch one set), gasket punches (of different sizes used - one set), pliers (flat nose,
round nose & side cutting one of each type), hammer with handle (one ), files with
handle (two), knife with handle (one), adjustable hacksaw (one), and cold chisel
(one), Hole punching tools for punching holes on gaskets (of all required sizes for
the offered transformer) etc. shall be supplied.

24 Centre of Gravity

The center of gravity of the assembled transformer shall be low and as near the
vertical center line as possible.
The transformer shall be stable with or without oil. If the center of gravity is
eccentric relative to track either with or without oil, its location shall be shown on
the outline drawing.

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25 Inspection and Testing

The manufacturer should have a well-established Quality Assurance System in

place and the QAP should be submitted for review and approval of KSEB Limited
within 30 days from the date of purchase order. The manufacturer shall carry out
a comprehensive inspection and testing program during manufacture of the
equipment as per the approved QAP. The inspection envisaged by the KSEBL is
given below. This is however not intended to form a comprehensive program as it
is Contractor/manufacturer's responsibility to draw up and carry out such a program
in the form of detailed quality plan duly approved by KSEBL for necessary
implementation.

25.1 Inspection

25.1.1 Tank and Conservator

a) Check for flatness
b) Welder's qualification and welding procedure
c) Inspection of major weld preparation
d) Crack detection of major strength weld seams by dye penetration test
e) Measurement of film thickness of:
i Oil insoluble varnish
ii Zinc chromate paint
iii Finished coat
f) Check correct dimensions between wheels, demonstrate turning of wheels
through 90 degree and further dimensional check.
g) Check for physical properties of materials for lifting lugs, jacking pads, etc. All
load bearing welds including lifting lug welds shall be subjected to Non Destructive
Testing.
h) Leakage test of the conservator and main tank
i) Certification of all test results
j) Test for proper and effective shielding of tank

25.1.2 Core

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a. Sample testing of core materials for checking specific loss, bend properties,
magnetization characteristics and thickness
b. Check on the quality of varnish if used on the stampings:

i) Measurement of thickness and hardness of varnish on stampings

ii) Solvent resistance test to check that varnish does not react in hot oil
iii) Check overall quality of varnish by sampling to ensure uniform shining
color, no bare spots, no over burnt varnish layer and no bubbles on varnished
surface
c. Check on the amount of burrs
d. Bow check on stampings
e. Check for the overlapping of stampings. Corners of the sheet are to be part.
f. Visual and dimensional check during assembly stage
g. Check for inter-laminar insulation between core sectors before and after
pressing
h. Visual and dimensional checks for straightness and roundness of core,
thickness of limbs and suitability of clamps
i. High voltage test (2 kV for one minute) between core and Yoke clamps, Yoke
clamps to tank and Core to Tank
J Certification of all test results

25.1.3 Insulation Material

a. Sample check for physical properties of materials

b. Check for dielectric strength
c. Visual and dimensional checks
d. Check for the reaction of hot oil on insulating materials
e. Dimension stability test at high temperature for insulating material
f. Tracking resistance test on insulating material
g. Certification of all test results

25.1.4 Winding
a. Sample check on winding conductor for mechanical properties and
electrical conductivity
b. Visual and dimensional checks on conductor for scratches, dent marks etc.

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c. Sample check on insulating paper for pH value, bursting strength and

electric strength
d. Check for the reaction of hot oil on insulating paper
e. Check for the bonding of the insulating paper with conductor
f. Check and ensure that physical condition of all materials taken for windings is
satisfactory and free of dust
g. Check for absence of short circuit between parallel strands
h. Check for brazed joints wherever applicable
i. Measurement of voltage ratio to be carried out when core/yoke is
completely restacked and all connections are ready
j. Conductor enamel test for checking of cracks, leakage and pin holes
k. Conductor flexibility test
l. Heat shrink test for enameled wire. Certification of all test results.

25.1.5 Checks before Drying Process

a. Check condition of insulation on the conductor and between the windings.

b. Check insulation distance between high voltage connections, cables and earth
and other live parts
c. Check insulating distances between low voltage connections and earth and other
parts
d. Insulation of core shall be tested at 2 kV/minute between core and Yoke clamps,
Yoke clamps to tank and Core to Tank
e. Check for proper cleanliness and absence of dust etc.
f. Certification of all test results

25.1.6 Checks during Drying Process

a. Measurement and recording of temperature, vacuum and drying time during

drying process
b. Check for completeness of drying by periodic monitoring of
dryness
c. Certification of all test results

25.1.7 Assembled Transformer

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a. Check completed transformer against approved outline drawings, provision for

all fittings, finish level etc.
b. Jacking test of Transformer in oil-filled condition (excluding separately
mounted cooler bank)
c. Dye penetration test shall be carried out after the jacking
test

25.1.8. Bought Out Items

The maker of all major bought out items shall be subject to KSEBL's approval for the
following components:

a) Buchholz Relay
b) Axles and wheels
c) Winding temperature indicators for local and remote mounting
d) Oil temperature indicators
e) Bushings
f) Bushing current transformers
g) Cooler control cabinet/ Individual Marshalling box and common marshalling
box as applicable
h) Cooling equipment
i) Oil pumps
j) Fans/Air Blowers
k) Tap change gear
l) Pressure relief device.
m) Sudden pressure relay

The above list is not exhaustive and the manufacturer shall also include other
bought-out items in this program.

25.2 Factory Tests

The manufacturer shall be fully equipped to perform all the required tests as
specified. Manufacturer shall confirm the capabilities of the proposed

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manufacturing plant in this regard when submitting the bid. Any limitations shall
be clearly stated in.

The contractor/manufacturer shall bear all additional costs related to tests which are
not possible to carry out at his own works.

Type tests report of the same design and ratings shall be submitted for review .

The contractor/manufacturer shall submit an Inspection and test plan (ITP) for
approval. A typical test plan is indicated in “Annexure-E”.

All tests shall be done in line with IS 2026/IEC-60076 and the test procedures as
mentioned in “Annexure-E”. Complete test report shall be submitted to KSEBL
after proper scrutiny and signing on each page by the testing engineer of the
manufacturer.

25.3 Type Tests on fittings:

The following fittings shall conform to type tests as per relevant IS/IEC and the type
test reports shall be furnished by the contractor/manufacturer along with the
drawings of equipment/ fittings.

· OLTC
· Buchholz relay
· Cooler Control cabinet, OLTC DM box
· Pressure Relief device Test
· The terminal box / boxes of PRD should conform to degree of protection of
IS 13947/Equivalent IEC standard.
· Magnetic Oil Level gauge & Terminal Box.
· Air Cell (Flexible air separator) - Oil side coating, Air side under Coating,
Air side outer coating and coated fabric as per IS: 3400/ BS: 903/ IS: 7019
· OTI & WTI
· Cooling fan and motor assembly
· Bushings
· Sudden pressure relay
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25.4 Pre-Shipment Checks at Manufacturer's Works

25.4.1 Check for inter-changeability of components of similar transformers for mounting

dimensions.

25.4.2. Check for proper packing and preservation of accessories like radiators,
bushings, dehydrating breather, rollers, buchholz relay, fans, control cubicle,
connecting pipes, conservator etc.

Each transformer when prepared for shipment shall be fitted with a shock indicator
or recorder, which shall remain in situ until the transformer is delivered to Site. In
the event that the transformer is found to have been subjected to excessive shock in
transit, such examination as is necessary shall be made in the presence of KSEBL.

Where practicable, transformers shall be shipped with oil filled to cover core and
windings but when shipped under pressure of gas shall be fitted for the duration of
delivery to Site and for such time thereafter as is necessary, with a gauge and gas
cylinder.

25.4.3. Check for proper provision for bracing to arrest the movement of core and winding
assembly inside the tank.

25.4.4. Gas tightness test to confirm tightness and record of dew point of gas inside the
tank. Derivation of leakage rate and ensure the adequate reserve gas capacity.

25.5 Inspection and Testing at Site

The Contractor shall provide a detailed inspection and testing program for field
activities covering areas right from the receipt of material stage up to
commissioning stage. An indicative program of inspection as envisaged by the
KSEBL is given below. However, it is contractor's responsibility to draw up and
carry out such a program duly approved by the KSEBL. The program chart
including site inspection /testing shall be submitted for approval from KSEBL.

1. Receipt and Storage Checks

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25.6.1. Check and record condition of each package, visible parts of the transformer etc. for any
Damage.
1. Check and record the gas pressure in the transformer tank as well as in the gas cylinder.

1. Visual check for wedging of core and coils before filling up with oil and also check
conditions of core and winding in general.

1. Check and record reading of impact recorder at receipt and verify the allowable limits
agreed during engineering.

2. Installation Checks

1. Inspection and performance testing of accessories like tap changers, cooling fans,
etc.

2. Check the direction of rotation of fans and pumps and Check the bearing
lubrication.

3. Check whole assembly for tightness, general appearance etc.

4. Oil leakage test

5. Capacitance and tan delta measurement of bushing before fixing/connecting to the

winding, contractor shall furnish these values for site reference.

6. Leakage check on bushing before erection.

7. Measure and record the dew point of gas in the main tank before assembly.

8. Commissioning Checks

1. Check the color of silica gel in silica gel breather.

2. Check the oil level in the breather housing, conservator tanks, cooling system,
condenser bushing etc.

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3. Check the bushing for conformity of connection to the lines etc.,

4. Check for correct operation of all protection devices and alarms/trip :

i. Buchholz relay
i. Excessive winding temperature
i. Excessive oil temperature
i. Low oil flow
i. Low oil level indication
ii. Fan and pump failure protection
iii. Sudden pressure relay

5. Check for the adequate protection on the electric circuit supplying the accessories.

6. Check resistance of all windings on all steps of the tap changer. Insulation
resistance measurement for the following:
i) Control wiring
ii) Cooling system motor and control
iii) Main windings
iv) Tap changer motor and control

7. Check for cleanliness of the transformer and the surroundings

8. vector group test

9. Ratio test on all taps

10. Magnetizing current test

11. Capacitance and Tan delta measurement of winding and bushing

1. Frequency response analysis (FRA). FRA equipment shall be arranged by the

contractor.

2. DGA of oil just before commissioning and after 24 hours energisation at site.

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3. Gradually put the transformer on load, check and measure increase in temperature
in relation to the load and check the operation with respect to temperature rise and
noise level etc.

4. Continuously observe the transformer operation at no load for at least 24hours.

1. Contractor shall prepare a comprehensive commissioning report including all

commissioning test results as per Pre-Commissioning Procedures and forward to
KSEBL for future record.

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Annexure – A1
Standard Technical Particulars / Parameters - Requirements
(220/66kV, 63 MVA 3-Phase Transformer)

Cl.N Description U TECHNICALPARAMETERS

o. nit
1 Rated Capacity

1.1 HV MV 63
A
1.2 LV MV 63
A
2 Voltage ratio k 220/66
V
3 Single/Three Phase Design Three

4 Applicable Standard IS 2026/IEC60076

5 Frequency H 50
z
6 Cooling& Percentage Rating at different ONAN/ONAF : 75%/100%
Cooling

7 Type of Transformer Outdoor Type Two winding Power

Transformer
8 Flux density at rated voltage & Freqency 1 .72 Tesla

9 Voltage variation on supply side + / - 10%

10 Frequency variation on supply side + / - 5%

- 20% or + 10% combined variation of

11 Transient condition. voltage and frequency
12 Radio interference Voltage Maximum 250 μV.

13 HV-LV Impedance at 75DegC at % impedance at principal tap at rated

Principal Tap % voltage, frequency at 63 MVA Base
shall be 12.5/ 14.23%, with IS
tolerance
1 Type of insulating media Immersed in mineral Oil
4

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1 Losses
5
Maximum no load loss at rated
1 No load losses in kW condition allowed without any
5. positive tolerance shall be
1 33/22.5kW
Maximum load loss at rated
1 Load loss at principal tap condition @ 75⁰C and principal tap
5. allowed without any positive
2 tolerance shall be 185 250/115kW
at 63 MVA Base
Maximum guaranteed auxiliary
1 Auxiliary losses losses at rated voltage and frequency
5. of aux. supply shall be 12 2.5/4.5
3 kW.

As per CBIP manual section-AA

1 Loss Capitalization formula (Publication No.317, 2013)
6
Capitalized value of No load loss per
1 kW (in Indian Rupees) 429,704/-
6.
1
Capitalized value of load loss per 2,57823/-
1 kW (in Indian Rupees)
6.
2
Capitalized value of auxiliary load 1,71882/-
1 loss per kW (in Indian Rupees)
6.
3
17 Service OUTDOOR

18 Duty CONTINUOUS

19 Overload Capacity As per IS 6600/IEC60076-7, IEC 354

20 Guaranteed Temperature rise limit as per

heat run.
2 Top oil measured by thermometer Deg. 45/50
0 C
.
1
2 Average winding temperature measured Deg.
0 by Thermometer C 50/55

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. method
2
23 Design air Clearances in mm. Phase to Earth Phase to Phase

Highest System voltage of 245kV mm. 1800 2000

Highest System voltage of 72.5kV mm. 660 700

Highest System voltage of 36kV mm. 320 350

24 Windings

2 System Fault level

4.
1
HV k 50
A
LV k 31.5/25/
A 31.7

2 Lightning Impulse withstand Voltage

4.
2
HV k 1050
V
p
LV k 325
V
p
Neutral k 95
V
p
2 One Minute Power Frequency
4. withstand
3 Voltage
HV kVr 460
ms

LV kVr 140
ms
Neutral kVr 38
ms

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25 Neutral Grounding Solidly grounded

26 Insulation

HV G
R
A
D
E
D
LV G
R
A
D
E
D
28 Tan delta of winding % <0.5
%
29 Vector Group (3–ph.)
(unless specified differently elsewhere) YNynO

30 Tap Changer OLTC. Shall be suitable for bi-

directional power flow.
30.1 Tap Range &No. of steps +5% to -7.5% of HV variation in the
step of 1.25/2.5%,
30.2 Location of Tap changer On the HV winding.

30.3 Design Constant flux voltage variation

Type as per IS 2026
30.4 Tap control Full capacity-on load tap changer
Suitable for group/independent,
remote/local electrical and local
manual operation and bi-
directional power flow

31 Bushings

31.1 Rated voltage

HV k 245
V
LV k 72.5
V
Neutral k 36
V

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31.2 Rated current(Min.)

HV A 400/1250

LV A 1250

Neutral A 1000

31.3 Lightning Impulse withstand Voltage

HV k 1050
V
p
LV k 350/325
V
p
Neutral k 95
V
p
31.4 One Minute Power Frequency withstand
Voltage

HV kVr 460/2756
ms

LV kVr 140
ms
Neutral kVr 38
ms
31.5 Bushing termination application type

HV OH line

LV OH line

Neutral GI Flat

31.5.1 Bushing type

HV OIP
condens
er oil-
air /RIP

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LV OIP
conden
ser oil-
air/RIP
Neutral Plain
Porcel
ain
Oil-air
31.6 Tan delta of bushing

HV % <0.5
%
LV % <0.5
%
Neutral % N.A

31.7
Max Partial discharge level at Um

HV p 10
C
LV p 10
C
MaxPartialdischargelevelat1.5Um/√3 p 100
C
31.8 Nuetral Bushing CTs

HV LV
Ratio & Class 300/1A PS Class 600/1A
No.of Cores 2 Cores

Vk 250 V
Im at Vk Less than or equal to 30 mA at Vk

Max Noise level at rated voltage and at Shall not exceed limits as per NEMA
32 Principal tap on full load and all dB TR1 with all accessories running,
cooling active measured as per standard.

33 Auxiliary supply to OLTC, oil pumps 3 Phase, 415V ± 10%

and cooler fans
34 Auxiliary DC supply for alarm and 110V DC
tripping (volt) (Available DC system
Voltage)

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35 Width of rail gauge Rail guage available (1690 mm

between rails)

Notes:

1. For parallel operation with existing transformer, the impedance, OLTC connection &
range and the winding configuration (if necessary) is to be matched. Is it required ???

2. No external or internal Transformers / Reactors are to be used to achieve the

Specified HV/LV impedances.

3. Tan delta of Winding & Bushing shall be measured at ambient temperature.

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Annexure-B
Specification for Transformer Insulating Oil.
(IS 335)
TRANSFORMER OIL:

Sl. Characteristics. Requirement Methods of Test.

No.

1. Appearance The oil shall be clear A representative sample of

and transparent and free oil shall be examined in a
from suspended matter 100 mm thick layer at
or sediment. ambient temperature.

2. Density at 20oC Max. 0.89 g/cm3 IS.1448,ISO 3675/12185

3. Kinematic Viscosity at 27oC 27 CST IS.1448

Max.

4. Interfacial tension at 27oC 0.04 N/m IS.6104,ISO 6295

Min.

5. Flash point (Penske Marten – 140oC(Min.) IS.1448,ISO2719

closed cup)

6. Pour point -6(Max.) IS.1448,IEC 60296, ISO

3016

7. Neutralization value (total 0.03 mg KOH/g IS.335 Appx.A. IEC62021-

acidity) Max. 1

8. Corrosive sulphur (in terms of Non-corrosive IS.335 Appx.B.

classification of copper strip) DIN51353,
BS2000 PART373

9. Electric strength (break down

voltage) Min.

a) New untreated oil 30KV (rms) (if the IS.6792

above value is not IEC 60814
attained, the oil shall be
treated.

b)After treatment 60KV(rms) IS.6792. IEC 60814

10. Dielectric dissipation factor 0.002 IS.6262

(tan delta) at 90oC Max. IEC60247/61620

11 Specific resistance (resistivity)

a) At 90°CMin. 35X1012 ohm-cm IS.6103

b)at 27°C Min. 1500x1012 ohm-cm

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12 Oxidation stability IEC 61125 part C

a) Neutralization value after 0.40 mg/KOH/g

oxidation (Max.)

b) Total sludge after 0.10 percent by weight.

Oxidation Max.

13. Presence of oxidation The oil shall not contain IS.335 Appendix .D
inhibitor. anti-oxidant inhibitors.

14 Water contents Max. 50 ppm IS.2362.IEC 60814

15 Ageing characteristics After

96 hrs. with catalyst (copper)

a) Resistivity As per ASTM –D 1934.

i) 27°C 12
2.5x10 ohm cm.

ii) 90°C 0.2x1012 ohm cm.

b) Tan delta at 90°C 0.2 (Max.)

c) Total acidity 0.05 mg/KOH/gm.

(Max.)

d) Total Sludge content % 0.05% (Max.)

by mass

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Design Details Annexure- C

Sr.No Description
.
1. Core and Magnetic Design
2. Over-fluxing characteristics upto 1.7 Um
3. Inrush-current characteristics while charging from HV&LV respectively.
4. Winding and tapping design
5. Short-circuit withstand capability including thermal stress for 2Sec.
6. Thermal design including review of localized potentially hot area.
7. Cooling design
8. Overload capability
9. Eddy current losses
1 Seismic design, as applicable
0
.
1 Insulation co-ordination
1
.
1 Tank and accessories
2
.
1 Bushings
3
.
1 Tap changers
4
.
1 Protective devices
5
.
1 Fans, pumps and radiators
6
.
1 Sensors and protective devices–its location, fitment, securing and level of redundancy
7
.
1 Oil and oil preservation system
8
.

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1 Corrosion protection
9
.
2 Electrical and physical Interfaces with substation
0
.
2 Earthing(Internal & External)
1
.
2 Processing and assembly
2
.
2 Testing capabilities &Detailed test procedure.
3
.
2 Inspection and test plan
4
.
2 Transport and storage
5
.
2 Sensitivity of design to specified parameters
6
.
2 Acoustic Noise
7
.
2 Spares, inter-changeability and standardization
8
.
2 Maintainability
9
.
3 PRD and SPR(number& locations)
0
.
3 Conservator capacity calculation
1
.
3 Winding Clamping arrangement details with provisions for taking it“in or out of tank”
2
.
3 Conductor insulation paper details
3
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.
3 The design of all current connections
4
.
3 Location& size of the Valves
5
.

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Annexure – D

Painting Procedure

Painting Surf P Inter Finish Total C

ace r medi coat dry o
ate
prepar i unde film l
ation m rcoat thick- o
e ness r
r (DFT) s
h
c a
o d
a e
t
Main tank, Shot Blast Epoxy Epoxy Aliphatic Minimu Shade
pipes, cleaningAS base high polyuret m no.631
conserv a2 Zinc build hane 155 µ m of IS 5
ator ½* primer Micace e(PU) or
tank, oil (30- ous (Minimu equivale
storage 40 µ m ) iron m nt
tank& oxide 50 µ m)
DM (HBMI
Box etc. O) (75
(externa µm )
l
surfaces
)
Main tank, Shot Blast Hot oil -- -- Minimu Shad
pipes(abo Cleaning proof, m e
ve ASa2 low 30 µ m no.63
80NB), ½* viscosit 1 of
conserva y IS 5
tor tank, varnish or
oil or Hot equiv
storage oil alent
tank resistan
&DM t, non-
Box etc. corrosi
(Internal ve
surfaces) Paint
Radiator Chemical/ Epoxy Epoxy PU paint Minimu Shade
(exter Shot Blast base base (Minimu m no.631
nal cleaning Zinc Zinc m 100 µ m of IS 5
surfa ASa2 primer primer(3 50 µ m) or
ces) ½* (30- 0- equivale
40 µ m ) 40 µ m ) nt

Manufacturer may also offer Radiators with hot dip

galvanized in place of painting with minimum

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thickness of 40 µm(min)
Radiator Chemical Hot -- -- --
and cleanin oil
Pipes up g, if proo
to require f,
80NB d low
(Inter
visco
nal
surfa sity
ces) varni
sh or
Hot
oil
resist
ant,
non-
corro
sive
Paint
Seven tank Zinc -- EPOXY Minimum
paint 80 µ m/for powder
RTCC processe chro With coated minimum
Panel/indo s mate PU top 100 µ m
or panels perIS:36 prim coat or
18 POWD
er
&IS:6005 ER
(two coated
coats
)

Note: (*) indicates ASA 2 ½ as per ISO 8501 Part-1.

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Annexure –E
TEST PLAN

N Test
o.
1 Measurement of winding resistance Routine
.
2 Voltage ratio measurement Routine
.
3 Vector group test Routine
.
4 No-load loss and excitation current measurement Routine
.
5 Magnetic balance test(for three phase Transformer only) Routine
.
6 Impedance and load loss measurement Routine
.
7 Measurement of insulation resistance & Polarization Index Routine
.
8 Measurement of insulation power factor and capacitance between Routine
. winding and earth and Bushings
9 Chopped wave lightning impulse test for the line terminals (LIC) Special
. test
1 Full wave lightning impulse test for the line terminals (LI) Ro
0 u
. t
i
n
e
1 Induced voltage withstand test (IVW) with PD Ro
2 u
. t
i
n
e
1 Applied voltage test (AV) Routine
3
.
1 On-load tap changer test (Ten complete cycle before LV test) Routine
4
.
1 Gas-in-oil analysis Routine

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5
.
1 Core assembly dielectric and earthing continuity test Routine
6
.
1 Oil leakage test on transformer Routine
7
.
1 Appearance, construction and dimension check Routine
8
.
1 Measurement of no load current & Short circuit Impedance with Routine
9 415V,50Hz AC.
.
2 High voltage withstand test on auxiliary equipment and wiring after Routine
0 Assembly
.
2 Tank vacuum test type
1
.
2 Tank pressure test type
2
.
2 Lightning impulse test for the neutral terminals (LIN) Type
3
.
2 Temperature rise test Type
4
.
2 Measurement of Zero seq. reactance Type
5
.
2 Measurement of harmonic level in no-load current Type
6
.
2 Measurement of acoustic noise level Type
7
.
2 Dynamic Short circuit withstand test Type
8
.
2 DGA tests before and after conducting the Temperature Rise Test Type
9
.
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3 Pressure Relief Device Test Type

0
.
3 SFRA test before and after dielectric test Routi
1 ne
.
3 The pressure Relief Device of each size shall be subjected to Routi
2 increase in oil/ air pressure test. ne

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BIDDING SCHEDULE
(To be filled in and signed by the Manufacturer) SCHEDULE ‘A’

SCHEDULE OF GUARANTEED TECHNICAL PARTICULARS FOR 220/66 kV, 63

MVA THREE PHASE TRANSFORMER

No. Particulars Offered

A General Data of Manufacturer

1 Name of Manufacturer

2 Country of Origin

3 Business Type of Company (e.g.

Manufacturer/ Contractor etc.)
B General Data of the Transformer

1 Conforming Applicable Standards

(including Bushing &other)
2 Conceptual Design of Transformer
(E.g. Outdoor /oil immersed /core type
/Indoor /etc.)
Type of Operation of the Transformer
3 (e.g. Interconnection -Autotransformer/
Distribution/ Generator step-up/ Step
down)

4 Rated Frequency (in Hz)

6 Rated MVA Capacity Of the Transformer

·HV
·LV
7 Rated No-load Voltage of the Transformer
·HV
·LV
8 No Load Current in percent of Full Load
current at rated KV &rated frequency at
Normal Tap
9 Vector Group

10 Type of Cooling

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11 Method of Neutral Grounding

12 Rated No load Voltages of windings in kV

·HV Winding
·LV Winding

13 Normal ratio of transformation

14 Rated Current in Ampere.

·HV Winding
·LV Winding
15 Overload capacity

16 Width of Track gauge (in mm)

C Thermal Data

1 Temperature rise of top oil (in °C)

measured by thermometer with ONAN/
ONAF cooling

2 Temperature rise of winding measured by

resistance : With ONAN/ ONAF cooling,
in °C
3 Limit of hot spot temperature in ° C for
which the transformer is designed
4 Temperature gradient between Oil
&Winding.
5 Limit for hot spot temperature
For which transformer is designed.
D Impedance Data

1 Percentage Impedance (HV-LV)at rated

current and frequency at 75 °C(with
tolerance)
·At maximum tap
·At Normal tap
·At Lowest tap

Percentage reactance (HV-LV) at 75 °C

·At maximum tap
·At Normal tap
·At Lowest tap

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3 Resistance of windings in ohm at 75 °C HV LV

·At maximum tap
·At Normal tap
·At Lowest tap
4 Zero Sequence Impedance(HV-LV) at 75
°C at 100% rating
a. At maximum tap
b. At Normal tap
c. At Lowest tap
E Guaranteed Loss

Guaranteed maximum no load loss (KW)

1 on principal tap at rated voltage and
Frequency
No load loss at rated voltage and
2 frequency at highest tap (max.)
Guaranteed maximum load loss at rated
3 current at rated voltage, rated frequency
and 75°C average winding temperature,
kW (excluding aux. losses).
At principal tap
For ONAF cooling
At maximum tap
For ONAF cooling
At minimum tap
For ONAF cooling
4 Maximum Auxiliary Loss (KW)

5 Total losses at normal ratio, rated output,

rated voltage, rated frequency and
maximum attainable temperature at site
including auxiliary losses.
6 Time for which the transformer can run at
full load without exceeding the max.
permissible temperature at reference
temperature when power supply to fans is
cut off (in minutes)
7 Exciting current and power factor

F Efficiency &Regulation

1 Efficiency (in percent) at unity power

factor at 75°C

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At 110% Load

At 100% Load

2 Efficiency (in percent) at 0.85 power

factor (Lag) at 75°C
At 110% Load

At 100% Load

At 75% Load

At 50% Load

At 25% Load

3 Maximum Efficiency %

4 % Load and power factor

at which Max efficiency occurs
5 Regulation at Unity Power factor

6 Regulation at 0.8 lagging Power factor

G Radiators

1 Overall dimensions l x b x h, mm

2 Total weight with oil, Kg

3 Total weight without oil

4 Vacuum withstand capacity, Tor

5 Number of radiator banks

6 Mounting of radiators in each bank

7 Number of radiators in each bank

8 Type &size of individual

radiator valve

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9 Total radiating surface, sq. M

10 Thickness of radiator tubes, mm

1 Oil drain plug and air release

1 plug provided on each radiator (Yes/No)

1 Schematic flow diagram of the cooling

2 system furnished (Yes/No)

H Cooling System

Cooling Fans

1 Make and type

1.1 No. of fans in each group excluding

standby fans
1.2 No. of connected units in each bank

1.3 No. of standby units in each bank

1.4 Rated power input, watts

1.5 Capacity ( cum/minute)

1.6 Rated voltage,

1.7 Locked rotor current,

1.8 Efficiency of motor at full load, %

1.9 Temp.rise of motor at full load, °C

1.10 Temperature range over which the control

is adjustable, °C
1.11 Whether fans suitable for continuous
operation
1.12 Period of continuous working at full load
without fan for ONAN/ONAF

1.13 Continuous MVA rating without fan for

ONAN/ONAF

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1.14 Estimated time constant in hours for

1. Natural cooling (ONAN)
2. Forced air cooling ONAF

I Core

1 Type of core construction

2 Type of core joints

3 Net core area in sq. meter

4 Core material & grade of sheet HIB or

better
5 Thickness of lamination mm

6 Insulation of core lamination, mm

7 Specific loss of core material (Watts/Kg)

at 1.72 Tesla
8 Insulation between core laminations

9 Details of oil duct

10 Whether in the plane and at right angle to

the plane of winding
11 Across the plane of laminations

12 Design flux density of the core at rated

voltage &frequency at principal tap, Tesla

13.1 1. Core

13.2 2. Yoke

14 Maximum flux density allowed

in the core at extreme over excitation /
over fluxing , Tesla
14.1 Power factor of Magnetizing current at
normal ratio and frequency
14.2 85 % of rated voltage

14.3 100 % of rated voltage

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14.4 105 % of rated voltage

14.5 110 % of rated voltage

15 Over Excitation withstand time (sec) at

110% / 125% /140%
16 Materials of core clamping plate

17 Thickness of core clamping plate

18 Insulation of core clamping plate

19 Describe Location/ method of core

grounding
20 Details of oil ducts in core

21 Guaranteed No load current at 90% /100%

/ 110% rated voltage &frequency(Amp )

22 HV

22.1 LV

22.2 Noise level (in dB) when energized at

normal voltage and normal frequency at
no load.
J Winding

1 No. of windings

Type of Winding ( e.g. Helical / Disc/

layer /pancake)
HV
2
LV
Arrangement of main windings &
3 Geometrical sequence

Winding material
4 HV
LV
5 Maximum current density allowed, Amp
per mm2
HV

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LV
6 Whether windings are
Interleaved (HV/LV)
Whether HV windings are
7 Preshrunk (HV/LV)

Whether electro-static shields are provided

8 to obtain uniform voltage distribution in
the windings
Gauge/area of cross section
9 of conductor, mm2
HV
LV
10 Maximum current density achieved in
winding Amps/ mm2
·HV
·LV
11 Insulating material used for:
HV turn
LV turn
LV to core
Between HV &LV

12 Insulation material thickness in mm used

for:
HV turn
LV turn
Between HV &LV
13 Type of coil axial support
·HV winding
·LV winding
14 Type of coil radial support
·HV winding
·LV winding

15 Weight of support insulators including

insulation cylinders

16 Maximum allowable torque on coil

clamping bolts
17 Inter-turn insulation

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18 Extent of extreme end turns reinforcement

19 Extent of end turns reinforcement

20 Extent of turns adjacent to tapping

L Minimum design clearance , mm

1 HV to earth in air

2 HV to earth in oil

3 LV to earth in air

4 LV to earth in oil

7 Between HV &LV in Air

8 Between HV &LV in Oil

13 Top winding &Yoke

14 Bottom winding &Yoke

M Insulating Oil

1 Governing standard

2 Type of oil

3 Spec. resistance (ohms-cm) at 27°C /90° C

4 Tan delta

5 Water content , ppm

6 Dielectric strength (BDV), kV

7 Characteristics of oil after ageing test

8 Sludge content

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9 Neutralization number

10 Quantity of oil in Ltrs.

11 In the transformer tank

12 In each radiator

13 Total quantity

14 10% excess oil furnished? (Yes/No) &

Quantity in Ltrs.
N Conservator

1 Details of oil preservation

equipment offered
2 Oil preservation system provided
(Yes/No)
3 Total volume of conservator (Ltr)

4 Volume between highest

and lowest visible oil levels (Ltr)
5 Details of Air cell
·Make
·Type
·Material
·Capacity
O Bushing Particulars

1 Manufacturer
HV
LV
Neutral
2 Type of bushings (
HV (oil-air type or oil-oil type )
LV (oil-air type or oil-oil type )
Neutral

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3 Reference Standard
HV
LV
Neutral

4 Rated Voltage in kV HV LV Neutral

5 Rated Current in Amp.

6 Lightning impulse voltage (1.20/50µSec.)

in kVp
7 Switching impulse voltage in kV

8 Power Frequency Withstand Voltage

(Dry)
9 Power Frequency Withstand Voltage
(Wet)
9.1 Wet Flash over voltage, kV

9.2 Dry Flash over voltage, kV

10 Partial discharge level

11 Creepage distance in mm

12 Creepage distance (protected)

13 Whether test tap is provided? If so, power

frequency withstand test
voltage of test tap,
14 Quantity of oil used in bushing
&specification of oil used.
15 Weight of assembled bushing, Kg

16 Minimum clearance height

for removal of bushings, mm
17 Cantilever strength

18 Terminal connections HV LV Nuetral

P-1 Details of bushing CT

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1 Purpose

2 Installed on which phase bushing

HV/LV
3
No. of bushing CTs installed
4 Type

5 Make

6 Reference standard

7 CT ratio

8 Burden, VA

9 Class of accuracy

P-2 Details of Nuetral bushing CT HV Nuetral LV Nuetral

1 Purpose

2 Installed on which bushing

HV/LV
3 No. of bushing CTs installed

4 Type

5 Make

6 Reference standard

7 CT ratio & No. of Cores

8 Burden, VA

9 Class of accuracy

10 Vk

11 Im at Vk

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Q On Load Tap Changer

1 Make

2 Type

3 Total Tap Range

( + ) percent to ( - ) percent of Voltage
4 Percent of Voltage per tap step

5 No. of steps

6 Time (in second) for total tap change

7 Diverter selector switch

transient time, cycles
8 Power flow-uni directional/
bidirectional/restricted bi directional
9 Rated voltage to earth, kV

10 Rated currents, Amp

11 Control – Manual/Local
electrical/ Remote electrical
12 Is suitable for Parallel operation

13 Protective devices

14 Auxiliary supply details

15 Value of maximum short

circuit current, kA
16 Maximum impulse withstand test voltage
with 1.2/50μS, full wave between switch
assembly and ground, kV peak
17 Maximum Power frequency test voltage
between switch assembly and earth, kV
rms
18 Maximum impulse withstand test voltage
with 1.2/50μs, across the tapping range,
kV peak

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19 Approx. overall dimensions of the tap

changer (in case of separate tank type),
mm
20 Approx. overall weight, (in case of
separate tank type), Kg
21 Approx. mass of oil ((in case of separate
tank type),Kg
22 Particulars of the OLTC control panel for
installation in the control room (RTCC
panel)
23 Driving Mechanism box

24 Make and Type

25 Details of apparatus proposed

R Details of protective devices

1 Pressure release device

1.1 Make &Type

1.2 Minimum pressure the

Device is set to rupture.
1.3 Rain hood provided or not

1.4 Number of PRD

2 Bucholz relay of main tank

2.1 Type &make

2.2 No. of contacts

3 Oil Surge relay

3.1 Type &make

3.2 No. of contacts

4 OTI

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4.1 Make &Type

4.2 No. of contacts

4.3 Setting range

5 WTI

5.1 Make &Type

5.2 No. of contacts

5.3 Setting range

6 Oil Level gauge

6.1 Type &make

6.2 No. of contacts

S Lifting Jacks

1 No. of jacks in one set

2 Type and make

3 Capacity (tons)

4 Pitch, mm

5 Lift, mm

6 Height in closed position, mm

7 Mean dia. Of thread, mm

T Alarm and trip contact ratings of

protective devices
1 Rated/making/ breaking
currents , Amp &voltage for
1.1 PRD for main tank and OLTC tank

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1.2 Bucholz relay

1.3 OTI

1.4 WTI

1.5 Magnetic oil level gauge

Fittings accessories for the transformer

U are furnished as per different clauses in
the specification (separate sheet giving
details, make and bill of materials to be
attached)
V Painting: as per annexure –D for the
transformer, radiator, marshalling box,
etc. (Yes/No)
W Details of Tank

1 Material

2 Approximate thickness of sheet

3 Sides, mm

4 Bottom, mm

5 Cover (Top), mm

6 Radiators, mm

7 Pressure mm of Hg

8 Vacuum recommended for

Hot oil Circulation
9 Vacuum to be maintained during oil filling
in transformer tank
10 Vacuum to which the tank can be
subjected without distortion as per
specification
11 Confirmation of tank designed and tested
for vacuum pressure (Ref: CBIP manual )
(Yes/No)

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12 Is the tank lid slopped?

13 Inspection cover provided(Yes/No)

14 Location of inspection cover (Yes/No)

15 Min. dimensions of inspection cover

(provide list of all inspection cover with
dimension), mm x mm
16 No. of bi-directional wheels provided

17 Track gauge required for the wheels in

transverse axis
18 Track gauge required for the wheels in
longitudinal axis
20 Minimum clearance height for lifting core
and winding from tank, mm
21 Minimum clearance height
for lifting tank cover, mm
22 Over all transformer dimensions

22.1 Length , mm

22.2 Breadth , mm

22.3 Height , mm

23 Transformer tank dimensions

23.1 Length , mm

23.2 Breadth , mm

23.3 Height , mm

24 Marshalling box dimensions

24.1 Length , mm

24.2 Breadth , mm

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24.3 Height , mm

25 Weight data

25.1 Core, Kg

25.2 Frame parts, Kg

25.3 Core and frame, Kg

25.4 Weight of core clamp kg

25.5 Weight of winding kg

HV
LV
25.6 Total winding Kg

25.7 Core and frame winding, Kg

25.8 Tank, Kg

25.9 Tank lid, Kg

25.1 Empty conservator tank, Kg

0
25.1 Each radiator empty , Kg
1
25.1 Total weight of all radiator empty , Kg
2
25.1 Weight of oil in tank , Kg
3
25.1 Weight of oil in each conservator, Kg Main OLTC
4
25.1 Weight of oil in each radiators, Kg
5
25.1 Total weight of oil in radiator, Kg
6
25.1 OLTC gear including oil , Kg
7

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25.1 Total transport weight of

8 the transformer , Kg

25.1 Total transport weight of the transformer

9 with OLTC and all accessories, Kg

26 Volume data

26.1 Volume of oil in main tank, liters

26.2 Volume of oil between highest and lowest

levels of main conservator, liters
26.3 Volume of oil between highest and lowest
levels of OLTC conservator, liters
26.4 Volume of oil in each radiator, liters

26.5 Total volume of oil in radiators, liters

26.6 Volume of oil in OLTC, liters

26.7 Transformer total oil volume , liters

27 Shipping data

27.1 Weight of heaviest package, kg

27.2 Dimensions of the largest

package (L xB x H) mm
X Tests

1 All in process tests confirmed as per

Cl.25.2 &Annexure-E (Yes /No)
2 All types tests confirmed as per Cl. 25.2
and Annexures E (Yes /No)
3 All routine tests confirmed as per 25.2and
Annexures E (Yes /No)
3 All special tests confirmed as per
Annexure E and Cl. 25.2 (Yes /No)
Y Others

1 Transformer will be transported

with oil/gas/dry air

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2 Quality Assurance Plan:

3 An outline of quality assurance plan used

by the manufacturer attached
4 General warranty for the transformer as
per specification
5 Test procedure attached

Z Important design parameters

1 Maximum no load loss at rated

condition allowed without any
positive tolerance (kW).

2 Maximum load loss at rated condition

@ 75°C and principal tap allowed
without any positive tolerance (kW).

3 Grade of core sheet, Hi-B or better

4 Type of winding for HV/LV

5 Design value of flux density

6 Design value of current density

7 Weight of HV winding

8 Weight of LV winding

10 Weight of support insulators including

insulation cylinders
11 Weight of core(kg)

12 Weight of core clamp

13 Per turn voltage

14 Conductor cross section

LV/HV
15 Winding stack height(mm)

16 Confirm that the weight of copper in

winding and CRGO in core during
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detailed design and manufacturing and

supply of the transformer is not less
than the values mentioned above.
17 Transformer tank dimensions(mm)
(lxbxh)

18 Weight of tank (kg)

19 Total volume of oil in tank (Liters)

20 Weight of core, winding and frame(kg)

21 Overall dimensions of the

transformer(mm)(lxbxh)

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SCHEDULE ‘B’
SCHEDULE OF GUARANTEED TECHNICAL PARTICULARS
ON LOAD TAPCHANGING GEAR (To be filled by the Manufacturer)

Sl. No ITEM Offered

Make
1
Type designation
2
Suitable for auto/manual Operation (Yes / No)
3
Rated voltage (KV)
4
Rated current (Amps)
5
Step voltage(Volts)
6
7 Number of steps

8 Rated voltage of drive motor (V)

9 List of routine tests to be carried out

Location of the tap switch with respect to the

10 terminals of the tapped winding

Drawing or pamphlet-number of the technical and

11 descriptive particulars of the OLTC, enclosed with the
Bid.
12 Is suitable for bi directional power
flow? Yes/ No

Drawing number of the complete control schematic

13 drawing enclosed with the Bid, along with a write-up
of the scheme provided. (YES/NO)
Separate conservator and oil surge relay provided
14 ( YES/ NO)
Local outdoor cabinet general arrangement drawing
15 number (enclosed with the Bid).

Remote indoor control cabinet arrangement drawing

16 number (enclosed with the Bid.)

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17 Quantity foil in the OLTC chamber (Ltrs)

18 Capacity of OLTC conservator tank in Cu.mtr.

SCHEDULE ‘C’ (To be filled in and signed by the Manufacturer)

SCHEDULE OF GUARANTEED TECHNICAL PARTICULARS
CONTROL CABINETS

No. Item MK Box Cooler Control RTCC

1 Manufacturer's name and
Country
2 Indoor/outdoor application

3 Design ambient air

temperature(C0)
4 Thickness of sheet steel for
outdoor &indoor panels(mm)
5 Degree of protection
provided (as per IS:13947or
equivalent)
6 Bill of material for various
equipment giving make, type,
ratings etc. enclosed(YES/NO)

7 Colour of finish paint

·Outside

·Inside

8 Temperature rise at rated

current over specified ambient
temp. of 50°C
9 Continuous current rating
(Amp)
10 Three second current rating
(KA) (short time)
11 Control wiring

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(a) Material of conductor for

various circuits
(b) ii)Size of conductor For various
circuits in mm2
(c) iii)Conductor –Solid/ Stranded

Terminal Blocks

12 i) Make

ii) Current rating

13 Power terminals(Amp)

14 Other terminals(Amp)

15
All tests as specified in
Section-D(ii)
DATASHEETA1Specificationf
or the control panel will be
carried out (Yes/ No.)

Space heater rating(Watts)

16

Manufacturer’s Name

Name

Designation

Date

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