Specification for 11/0.

433 kV Oil Filled, Ground Mounted, Distribution Transformers EP-MS-P4/S4-015

EP-MS-P4/S4-015

Specification for
11/0.433 kV Oil Filled,
Ground Mounted, Distribution
Transformers

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Specification for 11/0.433 kV Oil Filled, Ground Mounted, Distribution Transformers EP-MS-P4/S4-015

Document Control
Department Document Type Document Title
EP-MS-P4/S4-015
Material Specification for
EP Specification 11/0.433 kV Oil Filled, Ground
Standards Mounted, Distribution
Transformers
Issue Approval
Prepared By Approved By

Consultant M/s. Ewbank Preece Limited Head of Design & Development

Member of the Mott Mac Donald Group,UK

Materials Standards & Specification Engineer Manager, EN Planning Dept.

Signature: Signature:

Issue Record
Issue No. Date Reason for re-issuing Document

0.0 30.04.2003 First issue of Materials Specification Standards

22.12.2008 Review of Materials Specification Standards

1.0
2.0 19.04.2010 Review of Materials Specification Standards

3.0 13.06.2011 Review of Materials Specification Standards

4.0
5.0

Key Words : Specification for 11/0.433 kV Oil Filled, Ground Mounted,

Distribution Transformers.
Review Frequency : Every 3 years

When this document is approved for publishing on the intranet, a copy of its Document Control page should be sent to the
QA section who is custodian of KM quality management system.

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Specification for 11/0.433 kV Oil Filled, Ground Mounted, Distribution Transformers EP-MS-P4/S4-015

Main Sub Description Page

Clause Clause No
1.0 SCOPE 5
2.0 REFERENCES 5
3.0 COMPLIANCE WITH STANDARDS 6
4.0 ENVIRONMENTAL CONDITIONS 6
5.0 STANDARD TRANSFORMER OPERATING CONDITIONS 7
6.0 PRINCIPAL CHARACTERISTICS 7
6.1 General Design Requirements 7
6.2 Rated Power 7
6.3 Rated Voltage/KVA Rating/% Impedance 8
6.4 Tapping Range 8
6.5 Tapping Methods & Tap changer 8
6.6 Windings 9
6.7 Losses 9
6.8 Impedance 9
6.9 Insulation Levels 9
6.10 Flux Density 10
7.0 RATING AND CONNECTION PLATES – MARKING OF TERMINALS 10
7.1 Rating and Connection Plates 10
7.2 Marking of Terminals 10
8.0 OIL 10
9.0 GENERAL CONSTRUCTION AND FITTINGS
9.1 Tank and Tank Covers 11
9.2 Magnetic Core Assembly 12
9.3 Windings 13
9.4 Gaskets 13
9.5 Fittings & Accessories 13-17
9.6 Radiators 17
9.7 Provision for Cable Box Connections 17
9.8 Nuts, Bolts & Washers 17
10.0 CLEANING AND PAINTING WORK 18
11.0 CABLE BOXES & BUSHINGS
11.1 General 18
11.2 Construction of Cable Boxes 19
11.3 Retrofitting LV Fuse Box (Bolt-on Feeder Pillar) 19
12.0 TESTING, INSPECTION, DELIVERY, TRAINING, DOCUMENTS 20

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13.0 TESTS
13.A Routine Tests 21
13.B Type Tests 21
13.C Special Tests 22
13.D Tests on Painting Work 22
14.0 TENDER INFORMATION
14.A Technical Details & Documents 22
14.B Drawings 23
14.C Deviations from Technical Specifications 23/24
15.0 WARRANTY, REPLACEMENTS, AND FAILURE ANALYSIS 24
16.0 RESTRICTIONS ON OUTSOURCING 24
APPENDIX-A HV CABLE BOX DETAILS 25
APPENDIX-B LV CABLE BOX DETAILS FOR 500/800/1000 KVA 26
APPENDIX-C LV CABLE BOX DETAILS FOR 1250/1600 KVA 27
TABLE-B1 28
TABLE-B2 28
TABLE-B3 28
DRAWING STD-EQP-63 RATING PLATE & CONNECTION DIAGRAM 29
DRAWING STD-EQP-67 LIMITING DIMENSIONS 30
DRAWING STD-EQP-64 EARTHING TERMINAL & LIFTING LUGS 31
DRAWING STD-EQP-68 11KV CABLE BOX 32
DRAWING STD-EQP-155 LV CABLE BOX 33

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Specification for 11/0.433 kV Oil Filled, Ground Mounted, Distribution Transformers EP-MS-P4/S4-015

1.0 SCOPE

1) This Specification details about requirements for design, manufacture, testing,

transport, and delivery of transformers of the hermetically sealed, oil filled type, for
use on the 11KV distribution network in the State of Qatar.

2) It applies to transformers in the range 500kVA to 1600kVA for continuous service

at 50 Hz. It applies to three phase two winding oil immersed naturally cooled
(ONAN type) transformers suitable for indoor or outdoor service connected by
bushings into cable boxes, to transform energy from 11kV (nominal) to low voltage.

3) 11kV System
The 11kV system is a three phase three wire 50 Hz system with the star point
earthed at in-feed substations such that the maximum earth fault current is limited to
4500 Amps. The system maximum fault current is 25kA (rms) symmetrical.

4) Low Voltage System

The output of the transformers, at centre tap, with 11kV applied is 433/250V. This
is to provide consumers with a nominal supply voltage of 415/240V (three phase 4
wire 50Hz.), after permitted system voltage drops.
The star point is solidly earthed. Transformers are to be suitable for parallel
operation.

2.0 REFERENCES

This Specification makes reference to the following Standards:

IEC 60296/ BS 148 Insulating Oil for Transformers and Switchgear.

IEC 60076 Power Transformers
IEC 60076-7 Loading Guide for Oil Immersed Power Transformers
IEC 60502 Power cables with extruded insulation.
IEC 60529 Degrees of Protection Provided by Enclosures.
IEC 60076-10 Method of Measurement of Transformer and Reactor Sound Levels.
IEC 60404-8-7: 2008 Specification for CRGO Electrical steel strips & sheets
Specification for Colours for Identification, Coding, and Special
BS 381C 1996
Purposes.
BS EN ISO 1461 Hot Dip Galvanized Coatings on Iron and Steel Articles.
BS 2562 1979 Specifications for Cable Boxes for Transformers and Reactors.
BS EN ISO 2063 & Sprayed Metal Coatings.
BS 2569-2
ISO 4759/1 ISO Metric Precision Hexagonal Bolts, Screws and Nuts.
ISO 272/885/888/4759/1 ISO Metric Black Hexagonal Bolts, Screws and Nuts.
Preparation of Steel Substrates before application of paints and related
ISO 8501 Pt# 1 to 4.
products.-Visual assessment of surface cleanliness.

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Specification for 11/0.433 kV Oil Filled, Ground Mounted, Distribution Transformers EP-MS-P4/S4-015

Preparation of Steel Substrates before application of paints and related

ISO 8502 Pt# 1to 12 -
products.-Tests for assessment of surface cleanliness
Preparation of Steel Substrates before application of paints and related
ISO 8503 Pt# 1 to 5 products – Surface roughness characteristics of blast – cleaned steel
substrates.
Preparation of Steel Substrates before application of paints and related
ISO 8504 Pt# 1 to 3
products – Surface preparation methods.
ISO 12944-1 PT #1 to8 Paints & Varnishes – Corrosion Protection
Protection against Iron & Steel Structures – Zinc and Aluminum Coating
ISO 14713
– Guidelines.
Specifications for Unfilled Enclosures for the Dry Termination of HV
BS 6435 1993 Cables for Transformers and Reactors.[Note: Even though this standard
become obsolete, it is retained till we identify equivalent standard]

3.0 COMPLIANCE WITH STANDARDS

The transformers shall generally comply with the requirements of IEC 60076 except
where otherwise covered by this Specification. Cable boxes referred to shall comply
with BS 2562 1993 and the Oil shall comply with IEC 60296/BS148.

4.0 ENVIRONMENTAL CONDITIONS

The following conditions prevail generally throughout the State of Qatar.

1) Altitude - low lying, generally close to sea level, no point exceeding 100m above
sea level.

2) Maximum air temperature 50°C (46°C typical).

3) Minimum air temperature 0°C (10°C typical).

4) Mean maximum Summer air temperature - 45°C typical.

5) Mean maximum exposed sunlight temperature - 75°C.

6) Solar radiation - peak 1030 W/sq.m.

7) Humidity - 100% humidity is common throughout the year, and may occur at air
temperatures in excess of 30°C or more.

8) Rainfall - very low on average. The winter season may bring infrequent very heavy
rainfall, and lightning storms.

9) General atmospheric conditions may be described as a hot atmosphere containing

very fine, highly penetrating dust particles.

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Specification for 11/0.433 kV Oil Filled, Ground Mounted, Distribution Transformers EP-MS-P4/S4-015

5.0 STANDARD TRANSFORMER OPERATING CONDITIONS:

a) Average Continuous Ambient

Temperature…………………………………………… 35°C
b) Maximum Top Oil Temperature Rise, above ambient for Continuous Rated
Load…… 45°C
c) Maximum Average Winding Rise, above ambient for Continuous Rated
Load………. 50°C
d) Maximum Hot Spot Temperature for continuous Rated
Load………………………... 98°C
e) Oil Temperature shall not exceed 105°C under any conditions.
f) Hot Spot Temperature shall not exceed 118°C under any conditions.

6.0 PRINCIPAL CHARACTERISTICS

6.1 General Design Requirements

1) The transformers shall be hermetically sealed, oil-immersed type, in which pressure

excursions are absorbed by, a) inert gas (preferably by nitrogen gas) cushion placed
above the oil surface in a sealed-tank system with detachable panel type radiators, or b)
the elastic movement of permanently sealed corrugated tank fins. They shall be
completely filled with oil.
[Note: The required option from the above alternatives (a ) & (b) shall be
confirmed by KM at the time of initiating purchase tender, through Bill of
Quantity document]

2) The transformers shall be of three phase, two winding, oil-immersed, naturally cooled
(ONAN type), and suitable for indoor and outdoor service, connected by bushings into
cable boxes, to transform energy from 11KV (nominal) to low voltage.
[Note: Forced cooling system with cooling fans (ONFN) is not acceptable]

3) The transformers shall be designed for operation at ambient temperature up to 50 o C,

without application of any de-rating factor.

4) The maximum permissible temperature rise, under full load conditions, of top oil shall
not exceed 45o K, and that of winding shall be limited to 50 o K.

5) The transformer shall be capable for continuous operation at full load at any tap
position with-in their specified temperature rise limits and environmental and
operating conditions specified above.

6) The transformer shall be capable of withstanding short circuit at least for 2 sec.

6.2 Rated Power

1) The standard rated powers shall comply with Table 1 below and be suitable for the
application of IEC 60076-7 - Loading Guide for Oil Immersed Power
Transformers.

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2) The assigned rated power shall be identical for both windings. The rated power
refers to continuous loading. This is a reference value for guarantees and tests
concerning load losses and temperature rises.

6.3 Rated Voltage/KVA Rating/% Impedance

The standard no-load voltage ratio shall comply with Table 1.

TABLE 1

Voltage Ratio kVA Rating % Impedance

500 4.75
800 5.16
11,000/433-250
1000 5.45
1250 6.00
1600 6.00

Notes:
1) The above no-load secondary voltages are chosen so as to facilitate provision of
the following national low voltages, subject to permitted voltage drops.

Three Phase - 415/240V, 4 wire

Single Phase - 240V, 2 wire

2) The above rated primary voltage of 11,000V relates to highest voltage for
equipment of 12kV.

3) The rated power shall be available even when the low voltage fuse-gear (BOFP)
is mounted directly on transformers and also when high voltage switchgear is
mounted directly on unit substation transformers.

4) The column headed '% Impedance' refers to impedance voltage corrected to

75oC expressed as a percentage of normal voltage.

6.4 Tapping Range

Tapings shall be provided on the higher voltage winding, for a variation of the no-
load Primary voltage (specified in Table 1) of ± 2.5% and ± 5%.

6.5 Tapping Methods & Tap Changer

1) The tap changer design & its performance shall generally conform to IEC
60214-1.

2) Tap changing shall be carried out with the transformer off circuit, by means of
an externally operated self-positioning tapping switch, which shall be mounted
on one end of the transformer tank. . The moving contacts shall be spring
loaded, self-aligning roller type. The tap changer selector switch shall be easily
accessible to the operator from convenient height from floor/ground.

3) Switch position No. 1 shall correspond to the maximum plus tapping. Provision
shall be made for locking of the tapping switch handle at any position, such
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means incorporating a hole for accommodating a padlock having a 5mm

diameter shackle. The switch shall be retained in a safe position if a padlock
with a 5mm diameter shackle is used.

4) The tap-changer assembly shall be of a robust construction and shall be capable

of carrying the same current as the windings when under conditions of short
circuit. Current ratings of contacts used in tap changers shall not be less than 63
amps for 1000KVA, 1250KVA & 1600KVA transformers, and not less than 30
amps for 500KVA, 800KVA transformers.

5) Numerical digits need to be used as indication of the tap positions, shall be

embossed or engraved permanently on the knob.

6) Tap changer shall be of high quality product; type tested according to the
requirements of IEC 60214-1, and shall be sourced from internationally reputed
manufacturers only.

6.6 Windings

1) Windings shall be oil immersed and made of high conductivity electrolytic

copper. Insulating material of high quality shall be used. 11kV and low voltage
windings shall be separate.
2) The windings shall be connected Delta Star in accordance with Vector Group
reference Dyn11 of IEC 60076.
3) Electrical insulation shall conform to the requirements mentioned under
TABLE-2. Thermal insulation requirements shall be not less than those
specified under Class-A (105oC), IEC 60085

6.7 Losses

The losses shall be measured in accordance with IEC 60076, at the reference
temperature of 75oC. They shall not exceed the maximum values as defined below
[Note: the tolerance limits specified in IEC 60076-1 shall not be applicable. The
manufacturers need to take sufficient care while designing & manufacturing, so that
the below specified maximum limits are not exceeded]
Transformer Size Load Dependent Losses
No Load Losses/ Watts
KVA max load Watts
500 610 7200
800 890 9000
1000 1000 10,600
1250 1150 11,700
1600 1360 15,300
6.8 Impedances
The guaranteed values of impedance, measured at the principal tap and corrected to
a reference temperature of 75°C, shall be as shown in Table 1 and shall be subject to
the tolerances specified ( ± 10% ) in IEC 60076.

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6.9 Insulation Levels

Complete transformers, arranged for service, shall be capable of withstanding
impulse voltages on the higher voltage windings, as shown in Table 2.

TABLE 2

Highest Voltage Nominal System Rated Lightning 50 Hz

Withstand Voltage Impulse Withstand Withstand
For Equipment kV Voltage kV (peak) Voltage kV
Um (r.m.s) kV rms
1.1 0.433/0.25 -- 3
12 11 75 28

6.10 Flux Density

The flux density at any point in the magnetic circuit, when the transformer is
connected at normal tap (3) and operating at normal voltage and frequency, shall be
not exceed 1.6 Tesla. .

7.0 RATING AND CONNECTION PLATES - MARKING OF TERMINALS

7.1 Rating and Connection Diagram Plates

1) Transformers shall be fitted with a rating plate in accordance with Drawing

No. EP-MS-P4/S 4-015 Fig.1 (STD-EQP-63), and the data thereon shall be
completed for each transformer. A connection plate in accordance with EP-MS-
P4/S4-015 Fig.1(STD-EQP-63) shall also be fixed to show the winding
connections and tapping in tabulated form.

2) Rating and Connection diagram plates shall be of durable, made from non-
corrodible material and shall be securely fixed to suitable supports welded to the
tank without forming as water traps.

3) Manufacturing date shall contain both month & year of manufacturing.

4) Both the manufacturing date (i.e month/year) and delivery date should be shown
on the rating plate of each transformer, and the time difference between these
two dates should not be more than 6-months.

5) Rating plate should also show details of the KM tender No/Purchase order No

7.2 Marking of Terminals

1) Terminals shall be identified by characters of a type, which cannot be

obliterated, marked on plates of durable and non-corrodible metal securely fixed
to the tank.

2) Phase colours shall not be used. Phase Markings shall be in compliance with
Drawing No. EP-MS-P4/S4-015 Fig.1(STD-EQP-63)

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8.0 OIL

Mineral oil shall meet the requirements of BS 148/IEC 60296.

9.0 GENERAL CONSTRUCTION AND FITTINGS

9.1 Tank and Tank Covers
For Radiator Type Design

1) The tank shall be of welded steel, and designed and constructed so that there is no
bulging/ deformation of the sidewalls when the transformer is transported full of oil or
lifted using the specified lifting fittings. The formation of side walls to be made by
means of bending single steel sheet on three edges, and restrict the welding to only one
edge, to prevent number of welded joints.

2) The welding work need to be carried-out through automated or robotic welding

process to ensure consistency in quality of welding.

3) The thickness of the sidewalls of the tank shall not be less than 5mm. The top and
bottom of the tank shall not be less than 4.5 mm thick. Radiators wall thickness shall
be 1.2mm (minimum)

4) The bolts/studs used for fixing radiator flanges or any instruments on the tank sides,
shall be fixed through ‘stud welding’ process. Welding of these studs from inside tank
walls is not acceptable.

5) Nitrogen gas volume and oil volume in the tank are so designed that, occurrence of
negative gas pressure inside the tank, above 200C of oil temperature, shall be
prevented. [Note: Negative pressure inside tank may allow outside air into the tank and
restrict free flow of oil when sampling device is opened]. At the same time the gas
pressure inside tank, at maximum permissible oil temperature, shall not cause false
tripping of PRV. A chart or graph showing the relation between the oil temperature
and the gas pressure, embossed/engraved on a non-corrosive metallic plate and
permanently fixed on each transformer.

For Corrugated Tank Type Design

6) The walls of flexible corrugated fins shall be made of CRCA steel sheets of 1.5mm
(maximum tolerance limits of ±0.1mm) thickness. All fins shall be free of any uneven
and/or sharp edges.

7) The corrugated tank walls shall be capable of providing sufficient cooling of

transformer, and also entirely compensate for the changes in the oil volume during
operation.[Note: Rigid type corrugated walls are not acceptable]. There shall not be
any changes in oil pressure inside the tank, during operation, as the same are expected
to be entirely absorbed by the elastic action (contraction and expansion) of corrugated
fin walls.

8) The side walls of transformers accommodating the LV and HV cable boxes shall not
be less than 5mm thick, and the top and bottom shall not be less than 4.5mm thick.

9) The welding work need to be carried-out through automated or robotic welding

process to ensure consistency in quality of welding.

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Parameters Common for Both Types of Tank Designs

10) The under-base of transformers shall be in the form of skids, fitted with removable
type bi-directional wheels. The design & construction of wheels shall be such that, it
should be possible to set their orientation, in installed condition, to either of the
direction when required, for easy maneuvering. Further, these wheels arrangement
shall have built-in braking mechanism having braking pads on both sides of wheels to
have firm grip, or alternatively use ‘anti-vibration’ pads made of polycarbonate, having
capability of carrying load of transformer, below the wheels. These pads shall serve as
wheel blocking device, as well as dampen the intensity of vibrations and avoid
resonance. The skid shall be provided with 42 mm diameter holes on axle at each end,
clear of the jacking position. Provision shall be made on the skid-frame-work to park
the removed wheel assemblies when not in use, in bolted condition.

11) All the bolts used in the transformers for mounting/fixing tank cover, Cable box
mounting flanges, bushings, radiators, etc, shall have consistency in its size & length,
and the fixing shall be such that, at least 2 or 3 threads of the bolt shall come out of nut
outer face.

12) All the nuts & bolts used for fixing cable boxes, and HV & LV bushing Clamps, shall
be accessible from outside the tank (through inside cable boxes) for easy opening or
tightening. They should be accessible without opening the top tank cover.

13) For transformers of 1000KVA and less, the clearance between inner edges of
corrugated wall panels or radiator fins, on LV cable box side, shall be at least 670mm,
to facilitate retrofitting of ‘bolt-on’ Feeder pillar in place of LV cable box.

14) All welds are required to be tested for oil tightness. Oil pressure test to be conducted
on each transformer, at least at a pressure of not less than 0.3bar for a period of 16
hours to verify effectiveness of all welded joints and gaskets against oil leaks. The test
results are to be included in the routine test reports being submitted.

15) Overall maximum dimensions of transformers with radiators and corrugated fins shall
be in accordance with Drawing EP-MS-P4/S4-015 Fig. 2(STD-EQP-67).

9.2 Magnetic Core Assembly

1) The magnetic core shall be made of high permeability, low loss, non-aging, grain
oriented, cold- rolled silicon steel laminations. Each lamination shall be insulated with
high quality coating without burrs.
2) High grade CRGO steel laminations, having ‘specific watt loss’ of not more than 0.95
w/kg at 1.7T and 50Hz, shall be used. It shall conform to IEC 60404-8-7:2008. Details
of actual grade used, name of manufacturer, country of origin, product catalogue need
to be submitted along with tender offer, or technical submittal for approval against
external projects.
3) All limbs and yokes shall be designed for keeping noise levels, no load losses, and hot
spot temperature in core as low as possible.
4) Core and its clamping plates shall form in to rigid unit structure, to withstand all
stresses caused by S/C conditions, shipment, transportation, and installation.

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5) Ensure to secure uniformly distributed mechanical pressure over all laminations, to

limit noise & vibrations to minimum level.

6) Complete core assembly shall be provided with suitable lifting eyes to facilitate its
removal from the tank.

9.3 Windings
1) The insulation materials, and connections shall be free from any insulation
compounds or materials prone to softening, shrinking, or collapse during
service. They should not disintegrate, carbonize, or become brittle under hot oil,
or full load conditions.

2) Use best technology & design to have low inter-turn stresses, and withstanding
capabilities to stresses under S/C. Coils must be capable of withstanding
movement and distortion caused by all operating conditions. Adequate barriers
need to be provided between windings and core, and between HV and LV
windings.

3) All leads & connecting bars from winding to terminal boxes/ bushings must be
rigidly supported. Any stresses on coils and connections must be avoided.

9.4 Gaskets

1) All Gaskets (nitrile rubber bonded cork sheets and nitrile rubber seals or o-
rings) shall be heat and oil resistant, and do not contain any joints or openings.
They shall be of one piece construction only. Joints in the gaskets are not
allowed. The rubber bonded cork shall be of 5mm uncompressed thickness
unless otherwise stated.
2) Nitrile rubber seals or O-Rings (used for flange connections, bushings,
instruments connections, etc,) shall be laid in grooves or groove equivalent
retainers on both sides of tank walls.
3) Hemp materials, or gaskets of neoprene and /or such material which can be
easily damaged by over-pressing are not acceptable.

9.5 Fittings & Accessories

The following fittings & Accessories are to be fitted on each transformer:

1) Drain Valve and Sampling Device

Transformer shall be equipped with drain and filler valves. The nominal size of
drain valve shall be 1 inch. Good quality, non-corrosive, gate valve type, hand
wheel operated valves to be used for this purpose. There shall be separate
outlets for oil draining and sampling on the same device. The sampling outlet
shall be smaller in size and at right angle direction to the main drain outlet. The
valve handles should have locking arrangement. This device shall facilitate
filling, draining, sampling, and venting of oil. The location of the drain valve
cum sampling device shall be so selected that it is easily accessible, and its
operation shall not be hindered by any other component (ex: cable connections)
installed on transformer.

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2) Earthing Terminal
Two stainless steel (SS316) earthing flags as shown in Drawing EP-MS-P4/S4-
015 Fig.3 (STD-EQP-64) shall be provided. One each on opposite sides of tank
body, shall be provided. They shall be positioned vertically below the cable
boxes with the centre line 200 ± 5mm above the underside of the skid base.
There shall not be any sharp edges on the earthing flags

3) Jacking Lugs
Four Jacking lugs (i.e. one at each corner of the tank) at 400 + 5mm above
ground level are to be provided. There shall be clear access of 200 mm to
engage a jack with the lug. Access to the jacking lugs should not have any
obstruction. It should not obstruct the fixing of Bolt-on-Feeder Pillar.

4) Skids with removable type wheels

Skids shall be fitted and shall be provided with four 42mm diameter axle holes.
It is important to note that the orientation of the skid base shall be on the
longitudinal side of the transformer (length-wise), but not on width-wise. The
skids shall be fitted with wheels as explained under clause # 9.1.9

5) Lifting Fittings
Lifting Fittings as shown in Drawing EP-MS-P4/S4-015 Fig.3 (STD-EQP-64)
shall be provided suitable for lifting the transformer with crane and chains, as
specified in Section 8.1. These shall not be located on the top of the transformer.

6) Oil Level Gauge

This will provide indication of the real (actual) oil levels over the full range of
normal temperature excursions. The oil levels shall need to be visible through
either prismatic or thick transparent unbreakable glass/plastic with required
protection against mechanical damage. It will be calibrated to show the normal
oil level at 200C, 35°C, and 950C. Indirect ways of oil level indication (like
through magnetic or other indirect indicating types) are not acceptable.
Markings for the maximum and minimum oil levels should be clearly marked
on the instrument. [Note: Instruments with colour code indications are not
acceptable]

7) Sealed Filler Boss

The design shall be such that water cannot collect in the vicinity of the boss.

8) Oil Temperature Gauge (Thermometer) with alarm & Trip contacts.

a) A dial type thermometer to indicate the temperature of the oil at the top of
the tank needs to be provided. It’s scale shall be graduated in degrees
Centigrade and cover the range of 20°C to 120°C with increment marks at
not more than 5°C intervals.

b) The dial shall be fitted with pointers to indicate the present oil temperature,
and its maximum value. The maximum temperature pointer, alarm & trip
contacts, shall be manually re-settable type from the front. Two auxiliary
switches, each containing (2NO contacts) and rated @ 10A, 240VAC, shall
be provided for Alarm & Trip signals. The contact terminals shall be
suitable for terminating 4C x 2.5 sq.mm stranded copper conductor cable.
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c) Cable entry hole on the thermometer shall be fitted with suitable conduit
fitting (not cable gland) conforming to at least IP 65, and capable of
accommodating 4Cx2.5sq.mm, CU/PVC/SWA cable along with flexible
conduit.
d) A permanent wiring, to be made to the junction box mounted on side walls
of transformer tank, through rain tight conduit & conduit fittings.
Cable/conduit entry to the thermometer alarm contacts shall be from bottom.

e) The oil temperature gauge alarm & trip values shall be pre-set at 95oC and
1050C respectively, by default.

f) The Standard thermometer size as described below shall be used.

Nominal dial size: Approx 100mm

Sensing element type Bimetallic, stem type
Bezel & Casing material: Stainless steel (SS-316)
Dial & Pointer: Black pointer on white dial
Maximum Pointer Red Pointer
Measuring Range: 20-140oC.
Connection type: Radial bottom
Stem size & material: 120mm(L)x12mm(D), stainless steel.
Process Connection: G½ inch male nut, stainless steel fitting.
Thermometer pocket(thermo-well): Welded to tank, W/matching
thread.
O-Ring suitable size of O ring shall be used.

9) Additional Thermometer Pocket

An additional thermometer pocket (thermo-well without thermometer) of same
size shall be fitted in the tank, for the purpose of routine testing & measuring
with portable instruments. The thermo-well opening shall be closed with
matching cap/plug.

10) Pressure Relief Valve

The device shall be with a fixed pressure setting assigned by the manufacturer to
permit pressure relief when the transformer is subject to abnormal operating
conditions or an internal fault. It shall be fitted with a prominent indicator,
which shall remain in place after an operation of the device.
The pressure relief valve shall also be fitted with re-settable auxiliary switch
containing 2NO (two normally open contacts) and rated @ 10A, 240VAC and
conforming to IP65. Operation of the switches shall coincide with operation of
the pressure relief valve. The limit switch containing these auxiliary switches
shall be totally concealed below the PRV outer cover, to protect it from the
external environment and rain. The conduit fitting, conforming to at least IP 65,
at the cable entry of PRV terminal box, shall be capable of accommodating
4Cx2.5sq.mm, CU/PVC/SWA cable along with flexible conduit.
A permanent wiring from the limit-switch to be made, with the cable, to the
junction box mounted on side walls of transformer tank, through rain tight
conduit & conduit fittings. Cable/conduit entry to the limit-switch shall be from
the bottom.

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11) Junction Box (for control wiring)

A suitable junction box (control box) made of sheet steel body with protective
coatingg and painting, shall be fixed on suitable side wall of tank. It shall be
fitted with suitably rated terminal strip, cable gland/conduit fittings, front hinged
door and gaskets, etc. The location of the junction box is such that it facilities
easy access to its connections. The box shall not hinder functions of any
transformer operations or other components. IP rating of the box shall not be
less than IP65.

Two inlet and two outlet electrical cable entry holes shall be provided to the box
through rain-tight conduit fittings. All cable/conduit entries shall be from
bottom only. Inlet connections shall be wired from thermometer alarm contacts,
and PRV limit switch through flexible conduits. Outgoing terminal connections
shall be left free, to make connections during installation. All outgoing and
incoming cable entry holes shall be fitted with conduit fittings (IP65) capable of
accommodating 4Cx2.5sq.mm, CU/PVC/SWA cable along with flexible
conduit. All un-used entry holes shall be closed individually with suitable
caps/plugs. A permanent label showing terminal wiring diagram, terminal
markings, functions of all terminal connections, shall be fixed inside the front
door of the junction box. The front door shall have provision for fixing KM
standard pad-lock having 5mm shackle..

12) Pressure Gauge with Isolating Valve (Applicable for Radiator type
Transformers)
A pressure gauge capable of measuring negative and positive pressures of
nitrogen gas inside the tank, over the atmospheric pressure, shall be fitted on the
inlet oil pipe line of each transformer. The pressure gauge shall be along with an
isolating valve as a combination, capable of isolating the gauge in normal
conditions, and measure gas pressure only when required. Suitable manifold, if
required, to be used at the Oil inlet valve, to accommodate this ‘pressure gauge
+ isolating valve’ combination.

Suitable gaskets/seals/O-rings, shall be used at all joints of the fittings to ensure

no gas leaks during their service life. There should not be any joints or openings
in the gaskets used.

The gauge nominal diameter shall not be less than 100mm. The bezel & casing
of the gauge, isolating valve, and their fittings shall be made of stainless steel
(SS316). The dial of the gauge shall have linier graduations of measuring range,
in black letters on white back-ground, with centre zero reading, covering both
negative and positive pressures. Further, maximum & minimum values of
pressure to be maintained inside transformer tank, shall be marked in RED
colour on the dial. All these readings shall be clearly visible through front non-
breakable transparent glass

An additional pressure gauge (‘Master gauge’) is to be supplied, free of cost, as

an accessory, for every 100 transformers supplied.

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13) Connection Diagram Plate(s)

A connection plate shall be provided which gives full details of the tap position,
as specified in Section 6.1.

14) Pressure-VS-Temp chart/graph plate: A permanent chart or graph showing the

relation between the gas pressure-vs-top oil temperature inside the tank,
between the operating temperature range of +200C to +950C at with incremental
intervals of 20C. The chart or graph shall be indelibly printed or engraved on
non-corrosive metallic plate and permanently fixed on the transformer body.
PRV setting pressure shall also be clearly mentioned on this plate.

15) Accessories to be supplied as spares (free of cost)

a) One additional nitrogen pressure gauge, as mentioned in clause # 9.5.12 is to
be supplied, for every 100 transformers (Radiator type) supplied.
b) One nitrogen gas filling kit, consists of gas cylinder, pressure regulative
valves, pressure gauges, hose pipes, hose fittings, and trolley, to be supplied
for every 250 transformers Radiator type) supplied.
c) One additional ‘thermometer with alarm contacts’ shall be supplied for
every 100 transformers supplied.
d) One additional set of complete gaskets, as used in transformers, shall be
supplied for every 50 transformers, of each type (radiator/corrugated) and
KVA rating, supplied. Each piece of gasket in the kit shall be clearly
identified with labels containing details of its function, manufacturer part
number, name of manufacturer, country of origin.

e) 10 pieces of Transparent viewing window glasses shall be supplied free of

cost for every 100 Transformers supplied.

9.6 Radiators
Radiators shall be of the panel type, detachable, connected to the Transformer main
tank through flanges.

9.7 Provisions for Cable Box Connections

Facings and internal connections shall be provided for mounting HV and LV
bushing assemblies and cable boxes, as detailed in Appendices A, B and C.

Fixing studs shall be provided on transformer facings positioned to match the cable
boxes detailed in the Appendices.

9.8 Nuts, Bolts & Washers

All nuts, bolts and washers used for fixing/mounting cables boxes, box covers, tank
cover, bushings, oil-level gauges, etc., shall be non-corrosive alloy steel or stainless
steel. Both spring & flat washers need to be provided with every bolt fitted on the
transformer.

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10.0 CLEANING AND PAINTING WORK

1) The definitive guideline document is BS EN ISO 12944 Parts #1 to 8, & BS EN

ISO 14713.

2) The atmospheric corrosive category of local environmental conditional is

considered to be close to C5-M (as per ISO 12944-2), and it is imperative for the
manufacturer to provide a painting system suitable for this classification.

3) It is the responsibility of the manufacturer to select suitable paint system, in

accordance with above referred standards withstanding the specified local climatic
& environmental conditions, and to give a service life of at least 15+ years.

4) The selection of surface preparation processes, protective paint systems, execution

and supervision of paint work shall be made in accordance with the requirements
specified above.
5) The exact Specification & procedure of surface preparation and painting system
followed by the manufacturer shall be submitted at time of tender. The
manufacturer shall clearly justify the selected paint system meeting above
mentioned requirements (Refer tables of BS EN ISO 12944 and BS EN ISO 14713)

6) The final coat on the exterior shall be Dark Admiralty Grey, Colour conforming to
632 of BS 381C, or a near equivalent.

7) The manufacturer should possess required testing equipment in their laboratory to

test the paint work in accordance with BS EN ISO 12944-6. These test reports
should be submitted along with each consignment of delivery.

8) KM Engineers shall have the option of witnessing the tests on painting work, before
delivery of each consignment.

11.0 CABLE BOXES & BUSHINGS

11.1 General

1) The attached Appendices cover high voltage and low voltage cable boxes for
distribution transformers having ratings from 500kVA to 1600kVA.

2) They apply to cable boxes in which the conductors of cables terminate within
the box and are connected to terminals fixed therein.

3) The cable boxes shall be of the dry type and suitable for using heat shrink
terminations.

4) The cable boxes shall be suitable for operating both indoors and outdoors under
the service conditions stated in IEC 60076, and those stated in this Specification

5) Cable entry shall be from below

6) Cable boxes shall be in accordance with the relevant Drawings nos. EP-MS-
P4/S4-015 Figs 4(STD-EQP-68) and 5(STD-EQP-155) and generally comply
with the requirements of BS 2562 and, where applicable BS 6435.

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7) High Voltage and low voltage cable boxes shall be mounted on opposite sides of
the transformer.

8) Heights of Center lines of the HV & LV bushings from transformer skid base
shall be in accordance with Drawing EP-MS-P4/S4-015 Fig 2 (STD-EQP-67).

9) The low voltage cable boxes shall be suitable to terminate XLPE insulated
cables and paper/lead single core cables.

10) HV bushings are to be mounted in such a way that their mounting brackets &
bolts are accessible from outside the transformer tank through HV cable
box.[Note: Even though in drawing# Fig.4, these brackets are shown inside the
transformer tank, in actual supply they should be outside the tank]

11) Cable boxes shall be ventilated to permit free access of air, whilst preventing
inflow of rain or draining water. The ventilation shall be such as to prevent the
entry of vermin.

12) Lengths of all phase and neutral bus-bars, in the LV mono-block bushing
assembly, shall be of equal lengths. [Note: Some manufacturers offering shorter
length for neutral bus-bar, which is not acceptable]

11.2 Construction of Cable Box

1) The construction shall be such that the accumulation of water is avoided and the
box is effectively sealed against weather and insects.

2) Breathing holes, 12mm diameter covered with an internally fitted wire gauge
shall be provided. The degree of protection shall be to IP41 of IEC 60529.

3) The minimum size of any fixing stud or bolt for securing a front cover plate
shall be M10 mild steel.

4) Gaskets, where applicable shall be of synthetic rubber-bonded cork and shall not
be less than 5mm thick.

5) HV & LV Cable Box cover plates shall be provided with handles for easy
handling.

6) Each cable box front cover shall be equipped with inspection window of 3 in. x
5 in. size, covered with unbreakable polycarbonate transparent sheet of at least
4mm thickness. This window assembly shall have at least IP44 degree of
protection. The inspection window is located in such a place that, inside
bushings are clearly visible without opening the cable box cover plate.

11.3 Retrofitting LV Fuse Cabinets

1) For Transformers up to and including 1000kVA, the user may remove the LV
cable box and replace it by a bolt on fuse cabinet.

2) The format of the fuse cabinet(Feeder Pillar) is as follows:

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• Maximum external width of the cabinet - 610 mm.

• From the center line of the bushing, To the top of the cabinet - 460 mm
• From the center line of the bushing, To the bottom of the cabinet -1270
mm.
• Feeder pillar depth from face of transformer to feeder pillar front - 650
mm.
• Door hinge on the left hand side and can swing through 180 degrees.

3) This will influence the design of this face of the transformer in the following
respect:
a) From the vertical centre line of the LV bushing assembly there shall be a
clear, unobstructed clearance of 320 mm either (each) side between the
LV side radiators/corrugated panels.
b) The height of the center line of LV bushing assembly will be such that
the bottom of feeder pillar cabinet shall not be below the base of the
transformer, and shall not touch the ground.
c) The two ‘supporting bolts’ at rear bottom of the Feeder Pillar, shall
properly mate with a solid surface on the tank or base of the transformer.
d) There shall not be any obstruction on the body of transformer for proper
fixing of Bolt-on-Feeder Pillar

12.0 TESTING, INSPECTION, DELIVERY, TRAINING & DOCUMENTS

1) Before commencing the production/manufacturing of bulk quantities, against

KM tenders, the manufacturer is obliged to produce two samples of
transformers (of each rating) and inform Kahramaa for inspection and
witnessing factory acceptance tests, including routine tests. KM retains the
option of inspecting these proto-type samples either at KM workshop or at
factory.

2) The manufacturer is obliged to inform Kahramaa, at least 20 days before, about

subsequent dispatch of every lot, against KM purchase orders, and obtain
clearance. KM Engineers have the option of inspecting & witnessing all factory
acceptance tests, including routine tests, at manufacturer’s factory premises for
each lot.

3) Acceptance by KM Engineer(s)/Representative(s) of any transformer(s) shall not

relieve the manufacturer from any of their responsibilities, guarantees, or from
any other obligations.

4) All Type tests & Special Tests are to be carried out on specimen transformer
essentially of same design and ratings, as being offered, in an internationally
reputed independent laboratory where the manufacturers does not have any
association or influence.

5) Each transformer shall be subjected to all routine tests at factory before delivery.
One transformer in each lot will be subjected to prescribed tests on paint work.
Further, each transformer shall be subjected to inspection on receiving them at
DOHA to verify its healthiness and its conformity with the guaranteed design
data.

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6) The tests should be performed in accordance with the latest issue of relevant
IEC standards

7) Bidder is obliged to submit, detailed test procedure for approval prior to tests.

8) Three sets (copies) of routine test reports to be prepared. One set to be attached
with the transformer body in strong water-proof envelope. Second copy to be
sent along with delivery note. Third copy to be sent to the end-user department.

9) Each delivery note shall include the details of ‘serial number’ and
‘month/year’ of manufacture of each transformer.

10) Both the manufacturing date (i.e month/year) and delivery date should be shown
on the rating plate of each transformer, and the time difference between these
two dates should not be more than 6-months.

11) The manufacturer needs to organize training workshops for KM technical staff,
to familiarize with installation, operation & Maintenance, trouble shooting
guidelines.

12) The manufacturer need to submit 6 copies of:

a) Operation & Maintenance Manuals,
b) Installation Instructions,
c) Trouble shooting manual,
d) Details of condition monitoring parameters, its required data values,
frequency of monitoring of each parameter, etc.
e) Technical data-sheets and product catalogues of all accessories mounted on
the transformers [i.e, Magnetic core material, PRV assembly, Tap-changer
assembly, thermometer assembly, drain valve cum sampling device, LV
bushing assembly, HV bushings, pressure gauge & isolating valve assembly,
oil-level gauge, all gaskets, etc]
13.0 TESTS

A. ROUTINE TESTS

1) Measurement of Winding resistance

2) Measurement of Voltage ratio and check of phase displacement.
3) Measurement of Short-circuit impedance and load loss.
4) Measurement of no-load loss and current.
5) Separate source AC withstand voltage test
6) Short duration induced AC withstand voltage test
7) Main tank Oil pressure test at 0.3 bar for 16 hrs on each transformer.
8) Oil Breakdown voltage test (BDV) and oil acidity test.

B. TYPE TESTS
1) Temperature rise test
2) Dielectric Type tests (LI)
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C. SPECIAL TESTS
1) Dielectric Special tests
2) Determination of capacitances windings-to-earth, and between windings
3) Short-circuit withstand test
4) Determination of Sound levels (report should be submitted for each lot of
delivery)
5) Measurement of insulation resistance to earth of the windings, and/ or
measurement of dissipation factor (tan delta) of the insulation system
capacitances.

D. TESTS ON PAINTING WORK

1) Measurement of thickness of protective coating (ISO 2808)
2) Specular gloss factor at 60 deg (ISO 2813): 90±5%
3) Falling weight test (ISO 6272): 1kg/50cm
4) Cross cut test (ISO 2409): classification: 0
5) Cupping test (ISO 1520): 08mm
6) Bending test – Cylindrical mandrel test (ISO 1519): 3.0mm
7) Salt spray (fog) test (ISO 7253): 1000hrs

14.0 TENDER INFORMATION

The following technical & other documents need to be submitted along with technical
offers:

A: TECHNICAL DETAILS & DOCUMENTS

1) Technical data-sheets, containing all technical details including, ratings,

parameters, vector group, connections symbols, losses, max. flux density,
cooling, tank details, winding details, oil details, temperature rise limits, %
impedance values, insulation levels, efficiency, regulation, etc, of the
transformer

2) All technical details, parameters, data-sheets belong to each of the accessories

fitted to the transformer, including tap-changer, thermometer, PRV, HV & LV
bushings, Oil level indicator, gas pressure gauge with isolating valve, drain
valve with sampling device, etc.

3) All Type tests & Special test certificates of the transformer

4) Type test certificates of tap-changer

5) Type test certificates of HV & LV bushings

6) Specific Product catalogues of the transformer, tap-changer, magnetic core
material, Oil-level indicator, PRV, Thermometer, HV & LV Bushings, various
gaskets used, gas pressure gauge, etc.

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7) Details of Painting system applied to the transformer

8) Detailed Operation & maintenance manuals of transformer.

9) Valid proof of documents showing the sourcing of tap-changer, magnetic core

laminations, HV & LV bushings from internationally reputed manufacturers.

10) Valid ISO 9001 certification of the Transformer manufacturer

11) Compliance/deviation statement against each clause of this specification

document.

12) Two sets of Complete drawings, as stated below

13) Complete sales history of the proposed product, indicating details of the
Transformer rating, Client name, Year of supply, quantity supplied etc. The list
should highlight the supplies made to clients in GCC countries.

B: DRAWINGS

The following drawings shall need to be submitted along with technical offers:

1) General layout arrangement of transformer: Shall indicate all components, all

major dimensions, bill of materials, weight of core and winding assembly,
weight of tank & fittings, total weight including oil, oil quantity, thickness of
tank walls, overall dimensions of the transformer, base and cover dimensions,
thickness of radiator walls, gap between radiators panels, center of gravity
position.
2) Detailed dimensional drawing of HV Cable box
3) Detailed dimensional drawing of LV Cable box
4) Detailed dimensional drawing of HV bushings
5) Detailed dimensional drawing of LV bushing assembly
6) Rating plate details & Connection diagram
7) Detailed dimensional drawing of thermometer.
8) Detailed dimensional drawing of Oil-level indicator
9) Detailed dimensional drawing of PRV
10) Detailed dimensional drawing of Tap-changer
11) Detailed dimensional drawing of Oil-drain Valve with sampling device
12) Detailed dimensional drawing of pressure gauge & isolating valve

Note: Each drawing size should be at least in A4 size, drawn as per standard ISO
format containing all the standards views (plan, front elevation, side elevation, and
sectional views, where-ever necessary). Simple sketches are not acceptable. Details
in the drawings should be clearly legible & properly documented. The list of
drawings to be submitted is as mentioned below

C: DEVIATIONS FROM THE TECHNICAL SPECIFICATION

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The bidders are required to attach a separate deviation list to their Technical Offer
and include it in the Technical Package if the offered equipments do not meet the
requirements of any clause of the Specification.
Offers without any deviation list attached to the Technical Offer and included in
the Technical Package shall mean that the offer meets the requirements of the
Specifications on all the clauses.
Offers with deviations listed out shall mean that the offer meets the requirements of
the Specification on all the other clauses not included in the deviation list.

15.0 WARRANTY, REPLACEMENTS & FAILURE ANALYSIS

The manufacturer shall provide warranty for at least 3 years from the date of delivery,
or 2 years from the date of installation, whichever is earlier, for each transformer
supplied, against any design, manufacture, and material defects.
Any transformer failed during service, with in the warranty period, need to be replaced
with new transformer. The faulty transformer(s) need (s) to be fault-analyzed with
reputed independent agencies and fault-analysis reports to be submitted.
Further, it is the responsibility of the manufacturer to arrange for investigation of any
abnormalities/defects observed during transformer service period, even if it is out of
warranty period.

16.0 RESTRICTIONS ON OUT-SOURCING

1) Out sourcing of any of main components (like tank body, radiators, corrugations,
paint work, magnetic core assembly, winding coils etc) related to transformers, need
to be declared in the beginning it- self, before the transformer is pre-qualified or
short listed for tenders. In such case, the transformer manufacturer is responsible for
quality of these main components and paint work, and need to produce all
documentary evidences as to how they control quality of these components.

2) If any changes proposed by the manufacturer at later stage (after pre-qualification or

short-listing in tenders) in sourcing of these main components or accessories, shall
need to be informed to and obtain KM approval before the changes are made. Non-
compliance of this condition may lead to rejection of goods.

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APPENDIX A
CABLE BOXES

High Voltage Cable Boxes for all Sizes of Transformers

General

The high voltage cable box shall be in accordance with the requirements of Drawing
No. EP-MS-P4/S4-015 Fig 4 (STD-EQP-68), and generally be in accordance with BS
2562:1979, and where applicable, BS 6435.

It shall be air filled and suitable for using heat-shrink terminations with cable entry
from below.

The high voltage bushing arrangement shall be of the porcelain type of rating 250
Amps, in accordance with Fig 3 of BS 2562:1979.

A brass wiping gland shall be provided in accordance with Fig 32 of BS 2562:1979

suitable for terminating 3 core 70-120 sq.mm XLPE insulated PVC sheathed steel wire
armoured cable to IEC 60502. The cable gland shall not be insulated from the cable
box. 70mm2 compression type lugs are required for each bushing.

An armour clamp shall be provided.

The cable box shall be designed for cables entering vertically from below, and to permit
ease of access for jointing and connecting the cable it shall be so constructed that the
cable can be introduced into the box without threading, with the cores cut to length and
the gland and plate located on the cable sheath. For this purpose, the bottom plate, with
gland, shall be detachable.

Breathing holes covered with wire gauze shall be made in the cable box as shown, the
degree or protection being IP41 of IEC 60529. The same shall apply to a hole situated
on the bottom plate of the box, the purpose of which is to drain condensate.

The transformer tank wall shall have a flange facing "E" in accordance with Fig 24 of
BS 2562:1979.

The minimum clearances of insulated connections shall be as follows:

Between Phases -- 45mm

Between Phases and earth -- 32mm

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APPENDIX B

Low Voltage Cable Terminations and Cable Box for Transformers in the range
500/800/1000kVA

The low voltage Cable Box shall be in general accordance with BS 2562:1979 and, in
particular Fig 30 (unfilled boxes) and Fig 16 (cast resin bushings). The arrangement,
and dimensional requirements of the attached Drawing EP-MS-P4/S4-015 Fig. 5
(STD-EQP-155) are mandatory.

The box shall be open backed and air insulated, and suitable for terminating single core
cables entering from below. The bottom plate to be removable and plate holes diameter
for glands to be minimum 70mm each.

The cables will be single core, stranded compacted copper, up to 630 sq. mm, XLPE
insulated, PVC inner sheath, and copper wire armoured, PVC oversheath to IEC 60502.
There shall be two cables per phase. Terminations will be by heat shrink techniques.

Termination shall be by the use of brass plumbing glands with armour clamp in
accordance with BS 2562.

The cable box shall be of Shell Type 114, as defined in Table 11 of BS 2562 (except as
may be modified by Drawing EP-MS-P4/S4-015 Fig. 5) and the flange facing letter
shall be to Type F.

Three 12mm diameter breathing holes covered with fine wire gauze shall be made
equidistant along the stepped underside of the box. The degree of protection shall be
IP41 of IEC 60529. The same shall apply to a hole situated on the bottom plate of the
box, the purpose of which is to drain condensate.

The minimum clearances of live metal in air shall be:

Between Phases -- 26mm

Between Phase and earth -- 20mm

The low voltage bushing shall be of the cast resin assembly type for use up to 1.1kV, as
shown in Fig 16 of BS 2562 : 1979. The busbars shall be of high conductivity copper.

Lengths of all phase and neutral bus-bars, in the LV mono-block bushing assembly,
shall be of equal lengths. [Note: Some manufacturers offering shorter length for neutral
bus-bar, which is not acceptable]

The cable cores shall be connected to the bushing using 4 hole compression lugs as per
the cable size shown in Table B3.

Drawings shall be submitted for approval at tender stage.

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APPENDIX C

Low Voltage Cable Terminations and Cable Box for 1250/1600 kVA
Transformers

The low voltage Cable Box shall be in general accordance with BS 2562:1979. The
arrangement, and dimensional requirements of the attached Drawing EP-MS-P4/S4-015
Fig 5(STD-EQP-155) are mandatory.

The box shall be open backed and air insulated, and suitable for terminating single core
cables, entering from below. The bottom plate to be removable and plate holes diameter
for glands to be minimum 70mm each.

The cables will be single core, stranded compacted copper, up to 800 sq. mm, XLPE
insulated , PVC inner sheath, and copper wire armoured, PVC oversheath to IEC
60502. There shall be two cables per phase. Terminations will be by heat shrink
techniques.

Termination shall be by the use of brass plumbing glands with armour clamp in
accordance with BS 2562.

The cable box shall use Type F, of BS 2562, except as may be modified by Drawing
EP-MS-P4/S4-015 Fig 5 (STD-EQP-155)

Three 12mm diameter breathing holes covered with fine wire gauze shall be made
equidistant along the stepped underside of the box. The degree of protection shall be
IP41 of IEC 60529. The same shall apply to a hole situated on the bottom plate of the
box, the purpose of which is to drain condensate.

The minimum clearances of live metal in air shall be:

Between Phases -- 26mm

Between Phase and earth -- 20mm

The low voltage bushing shall be of the monoblock epoxy resin type of 2500 Amps
rating in accordance with Fig 16 of BS 2562. The busbars shall be of high
conductivity copper and copper area shall be 63mm x 20mm..

Lengths of all phase and neutral bus-bars, in the LV mono-block bushing assembly,
shall be of equal lengths. [Note: Some manufacturers offering shorter length for neutral
bus-bar, which is not acceptable]

The cable cores shall be connected to the bushing using 4 hole compression lugs as per
the cable size shown in Table B3.

Drawings shall be submitted for approval at tender stage.

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Table B1

S.No. Description HV Box LV Box

1. Rated Voltage 12kV 1.1kV
2. No. of Poles 3 4
3. No. of Glands 1 7
i) 1c/300 to 630 up to 1250 kVA
4. Size of Cables 3/70 - 120 sq.mm to 1250 kVA.
ii) c/630 to 800 for 1600kVA.
5. Bushing Assembly 250A Porcelain Cast resin.
XLPE SWA PVC
XLPE copper wire armoured PVC
with stranded
sheath compacted circular copper
6. Type of Cable compacted circular
conductor to IEC 60502.
copper conductor to
IEC 60502
Dry type, using heat Dry type, using heat shrink
7. Type of Box
shrink terminations. terminations.
8. Cable entry From Below From Below
9. Flange Facing letter E F
10. Shell Number 20 37

Clearances
The minimum air clearances in the cable boxes shall be as follows:

Table B2

Voltage Live metal to earth Phase/Phase Distance to earth over

(Taut string distance)mm mm surface of bushing mm
433 20 26 26
11kV 32 45 75

Table B3

Transformer Rating No. of Cables Size of Cables

kVA sq.mm

500 7 300
800 7 300
1000 7 630
1250 7 630
1600 7 800

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Specification for 11/0.433 kV Oil Filled, Ground Mounted, Distribution Transformers EP-MS-P4/S4-015

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Specification for 11/0.433 kV Oil Filled, Ground Mounted, Distribution Transformers EP-MS-P4/S4-015

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Specification for 11/0.433 kV Oil Filled, Ground Mounted, Distribution Transformers EP-MS-P4/S4-015

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Specification for 11/0.433 kV Oil Filled, Ground Mounted, Distribution Transformers EP-MS-P4/S4-015

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Specification for 11/0.433 kV Oil Filled, Ground Mounted, Distribution Transformers EP-MS-P4/S4-015

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