Invitation of Comments Solar Park Transformer-1

Chapter-1
TECHNICAL SPECIFICATIONS OF POWER TRANSFORMERS FOR

SOLAR PARK POOLING STATION
1.0 GENERAL
1.1 This chapter covers specification for design, engineering, manufacture,

testing, delivery at site including all materials, accessories, unloading,
handling, proper storage at site, erection, testing and commissioning of
the Power Transformer for solar park pooling station.
1.2 For transportation, erection, testing and commissioning and condition

monitoring & life cycle management, the document “Standard
Specifications and Technical Parameters for Transformers and Reactors
(66 kV & above Voltage Class)” issued by CEA may be referred.
1.3 The design and workmanship shall be in accordance with the best
engineering practices to ensure satisfactory performance throughout
the service life.
1.4 Any material and equipment not specifically stated in this specification
but which are necessary for satisfactory operation of the equipment
shall be deemed to be included unless specifically excluded and shall
be supplied without any extra cost.
1.5 Components having identical rating shall be interchangeable.
2.0 STANDARD RATINGS OF TRANSFORMER
Standard ratings of transformer for Solar Park pooling stations shall be

as given below:
Sr. No. MVA Line Voltage Phase No. of

Rating Rating Secondary
windings
1. 315 MVA 400/33 kV Three Phase Two
2. 250 MVA 400/33 kV Three Phase Two
Chapter-1:Technical Specification for Power Transformers for Solar parks Page 1

3. 160 MVA 400/33 kV Three Phase One

*230/33 kV
*230/33 kV
*230/33 kV
*110/33 kV
*110/33 kV
*110/33 kV
11. 31.5 132/33 kV Three Phase One
MVA *110/33 kV
*For Tamil Nadu and Karnataka, as applicable
Note: The transformers of 400/33kV, 160MVA & 125MVA rating

should be avoided as practice of using such low MVA rating
transformers are not desirable at 400kV level.
It is desirable that Transformers of above ratings are only procured by

utilities to have standard ratings across the country. The transformers
of other ratings should be procured only under special circumstances,
for example to match with the rating of existing transformer for parallel
operation.
3.0 SPECIFIC TECHNICAL REQUIREMENTS
The technical parameters of these transformers are detailed in

Annexure-A: Specific Technical Requirements.
4.0 GUARANTEED AND OTHER TECHNICAL PARTICULARS

The manufacturer shall furnish all the Guaranteed and other technical
particulars for the offered transformer as called for in Annexure–C:
Guaranteed and Other Technical Particulars. The particulars
furnished by the manufacturer in this Annexure shall make basis for
the design review. Any other particulars considered necessary may
also be given in addition to those listed in that Annexure.
5.0 PERFORMANCE
5.1 Transformers shall be capable of operating under natural cooled

condition up to the specified load. The forced cooling equipment,
wherever specified, shall come into operation by pre-set contacts of
winding temperature indicator and the transformer shall operate in
forced cooling mode initially as ONAF (as specified) up to specified load
and then as ODAF (or OFAF)
5.2 In case of ONAN/ONAF cooling and ONAN/ONAF/ODAF (or OFAF)

cooling, the cooling system shall be so designed that the
transformer shall be able to operate at full load for at least ten (10)
minutes in the event of total failure of power supply to cooling fans
and oil pumps without the calculated winding hot spot
temperature exceeding 140 deg C. If the Transformer is fitted with
two cooler banks, each capable of dissipating 50 per cent of the
loss at continuous maximum rating, it shall be capable of operating
for 20 minutes at full load /continuous maximum rating in the
event of failure of the oil circulating pump or fans/blowers
associated with one cooler bank without the calculated winding
hot spot temperature exceeding 140 deg C. The contractor shall
submit supporting calculations for the above and the same shall be
reviewed during design review.
5.3 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 are in operation.
5.4 The transformers shall be capable of operating continuously at the

rated MVA without danger, at any tapping with voltage variation of
10% corresponding to the voltage of that tapping.

5.5 The transformers shall be capable of being over loaded in accordance
with IEC 60076-7. There shall be no limitation imposed by bushings,
tap changers etc. or any other associated equipment.
5.6 The hotspot temperature in any location of the tank shall not
exceed 110 degree Celsius at rated MVA. This shall be measured
during temperature rise test at manufacturer’s works.
5.7 The maximum flux density in any part of the core and yoke at the
rated MVA, voltage and frequency shall be 1.7 T and under 10 %
continuous over-voltage condition it shall be 1.9 Tesla at all tap
positions.
5.8 The current density in any of the windings shall not exceed 3.5
A/sq.mm at all tap positions.
5.9 The transformer and all its accessories including bushing/built in CTs
etc. shall be designed to withstand the thermal and mechanical effects
of any external short circuit to earth and of short circuits at the
terminals of any winding without damage. The transformer shall be
designed to withstand the thermal stress due to short circuit for a
duration of 2 seconds and the same shall be verified during design
review.
5.10 The following short circuit level shall be considered for the HV & IV
System to which the transformers will be connected:
400kV system - 63 kA for 1 sec (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.
Zs = 0).
5.11 Transformer shall be capable of withstanding thermal and mechanical
stresses due to 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 with rated voltage
applied to HV and/or LV terminals of transformer. The short circuit
shall alternatively be considered to be applied to each of the HV, LV and
tertiary transformer terminals as applicable. The tertiary terminals (if
available) shall be considered not connected to system source. For short
circuit on the tertiary terminals (if available), the in-feed from both HV

& LV system shall be limited by the transformer self-impedance only
and the rated voltage of HV and LV terminals shall be considered.
5.12 Transformers shall withstand, without damage, heating due to the

combined voltage and frequency fluctuations which produce the
following over fluxing conditions:
110 % continuously
125 % for 1 minute
140 % for 5 seconds
Withstand time for 150% & 170% over fluxing condition shall be
indicated. Over fluxing characteristics up to 170 % shall be
submitted.
The air core reactance of HV winding of transformer shall not be

less than 20%. External or internal reactors shall not be used to
achieve the specified HV/LV or HV/LV1 and HV/LV2 (as applicable)
impedances.
5.13 Tertiary Windings (if applicable as per Annexure - A)
The tertiary winding shall be avoided for transformers designed with

three (3) limbed cores. The tertiary windings, if provided, for
transformers designed with five (5) limbed core shall be suitable for
transferred surge from primary side and shall not be loaded. If terminal
(s) of tertiary winding is brought out then it shall be insulated to avoid
any accidental short circuiting.
5.14 Radio Interference and Noise Level
The transformer shall be designed with particular attention to the

suppression of harmonic voltage, especially the third and fifth
harmonics so as to minimise interference with communication circuits.
The noise level of transformer, when energised at normal voltage and

frequency with fans and pumps running shall not exceed the values
specified at Annexure- A, when measured under standard conditions.
6.0 MAXIMUM LOSSES
The maximum permissible losses (No load loss, auxiliary loss and
load loss) at rated voltage/current (at 75 deg C) have been specified
in Annexure-A for various ratings of transformers covered under
this specification. Following penalties shall be levied on the
manufacturer/contractor (as the case may be) if losses measured
during routine test are found to be within +2% tolerance of the losses
specified in Annexure–A, beyond which the transformer/ shall be
liable for rejection. No benefit shall be given for supply of transformer,
with losses (measured during routine tests) less than the losses
specified in Annexure –A.
S. Differential of specified losses vs RATE

No Measured losses (in INR per KW)
1 No load Loss Rs. 10,00,000/KW
2 Load Losses Rs. 8,00,000/KW
3 Auxiliary Losses Rs. 8,00,000/KW
Note: For a fraction of a kW, the penalty shall be applied on pro rata
basis.
7.0 DYNAMIC SHORT CIRCUIT TEST REQUIREMENT AND VALIDITY
The transformer, the design of which is similar to the offered

transformer, should have been successfully tested for short circuit
withstand capability as per IS 2026 Part-5 in line with the requirement
of CEA (Technical Standards for Construction of Electrical Plants and
Electric Lines) Regulations. The criteria for similar transformer is
specified in Annexure-J. The relevant Test Report/certificate shall be
enclosed along with bid. Further, design review of offered transformer
shall be carried out based on the design of reference transformer, which
has already been subjected to Short circuit tests in lieu of repetition of
Short circuit tests. In case, manufacturer has not conducted short
circuit test earlier, the same shall be carried out on offered transformer.
A format (forms part of Annexure-J) filled with data of a typical sample

case has been prepared for reference and guidance of utility to compare
a Short Circuit tested transformer with the offered transformer in order
to verify the similarity criteria as per Annexure J.
8.0 TYPE TESTS REQUIREMENT AND VALIDITY
The offered transformer or the transformer, the design of which is

similar to the offered transformer, should have been successfully type
tested within last 5 years as on the last date of submission of bid.

Manufacturer may use same or different approved make of Bushings,
Tap changer and other accessories used in type tested or short circuit
tested unit in their transformer. Further, type test report of
transformer shall only be acceptable provided the offered
transformer has been manufactured from the same plant.
Central Electricity Authority’s “Guidelines for the validity period

of type tests conducted on major electrical equipment in power
transmission system” shall be followed for details regarding the
validity of type tests.
9.0 DESIGN REVIEW
9.1 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. Adequate safety margin w.r.t. thermal, mechanical,
dielectric and electrical stress etc. shall be maintained during design,
selection of raw material, manufacturing process etc. in order to
achieve long life of transformer with least maintenance.
9.2 Design reviews shall be conducted by the purchaser or by an appointed

consultant during the procurement process; however, the entire
responsibility of design shall be with the manufacturer. Purchaser may
also visit the manufacturers works to inspect design,
manufacturing and test facilities.
9.3 The design review shall be finalised before commencement of

manufacturing activity and shall be conducted generally following the
“CIGRE TB 529: Guidelines for conducting design reviews for power
transformers”. However, salient points on design review has been
specified in “Chapter-3: Design Review”.
9.4 The manufacturer shall provide all necessary information and

calculations to demonstrate that the transformer meets the
requirements of mechanical strength and inrush current.
9.5 The manufacturer will be required to demonstrate the use of

adequate safety margins for thermal, mechanical, dielectric and
vibration etc. in design 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 – I.

9.6 Each page of the design review document shall be duly signed by the
authorised representatives of manufacturer and purchaser and shall
be provided to the purchaser for record and reference before
commencement of manufacturing.
10.0 SERVICE CONDITION
The transformer shall be designed for the following service conditions

as specified by the utilities:
Sr. Description Parameters

No.
i) Site altitude
ii) Maximum ambient temperature
iii) Yearly weighted average cooling air
ambient temperature
iv) Monthly average cooling air
temperature of hottest month
v) Minimum cooling air temperature
vi) Wave shape of supply voltage
vii) Total Harmonic current
viii) Seismic zone and ground acceleration
(both in horizontal & vertical direction)
ix) Combined voltage and frequency
variation
x) Wind zone as per wind map provided in
National Building Code
xi) Maximum humidity
xii) Minimum humidity
x) Specific Creepage Distance of
insulation in air
In addition to the above, utilities may specify additional site

conditions separately in tender documents [example: restricted
ventilation (tunnels, enclosed area etc.), presence of fumes, vapours,
steams, dripping of waters, salt spray and corrosive environment,
excessive & abrasive dust, superimposed DC current in neutral of
the transformer, high frequency switching transients, frequent
energisation (>24 times a year), high solar radiation, frequent Short
Circuits etc.].
11.0 CONSTRUCTION DETAILS

The construction details and features of transformer shall be in
accordance with the requirement stated hereunder.
11.1 Tank & tank cover
11.1.1 The tank shall be of proven design of either Bell type with bolted/
welded joint or conventional (preferable) with bolted/welded top
cover. Bell type tank, if provided, shall have joint as close as
possible to the bottom of the tank.
11.1.2 The tank shall be designed in such a way that the transformer can
be rested on concrete plinth foundation directly or on roller
assembly.
11.1.3 Tank shall be fabricated from tested quality low carbon steel of
adequate thickness. Unless otherwise approved, metal plate, bar and
sections for fabrication shall comply with IS 2062.
11.1.4 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 and the base plate shall
have following minimum thickness.
Length of tank (m) Minimum plate thickness

(mm)
Flat bases
Over 2.5 m but less than 5m 20
Over 5 m but less than 7.5m 26
Over 7.5 m 32
11.1.5 Tank shall be capable of withstanding, without damage, severe strains

that may be induced under normal operating conditions or forces
encountered during lifting, jacking and pulling during shipping and
handling at site or factory. Tank, tank cover and associated structure
should be adequately designed to withstand, without damage or
permanent deflection / deformation, the forces arising out of normal oil
pressure, test pressures, vacuum, seismic conditions and short circuit
forces specified.
11.1.6 All seams and joints which are not required to be opened at site, shall
be factory welded, and shall be double welded [i.e. with a continuous
cord on both sides of the plate (inside and outside of the tank), bottom
& cover of the tank, turrets, flanges, etc.] to ensure adequate strength.

Butt welds on parts that are mechanically stressed or under
pressure must have full penetration. Welding shall conform to IS
9595. The requirement of post weld heat treatment of tank/stress
relieving shall be based on recommendation of IS 10801.
11.1.7 The welded joint shall be provided with flanges suitable for repeated
welding. The joint shall be provided with a suitable gasket to prevent
weld splatter inside the tank. Proper tank shielding shall be done to
prevent excessive temperature rise at the joint.
11.1.8 Tank stiffeners shall be provided for general rigidity and welded to the
tank continuously along its ends and sides (Intermittent welds will not
be accepted). These shall be designed to prevent retention of water.
Sharp edges on stiffeners should be avoided for better paint adhesion.
11.1.9 Tank MS plates of thickness >12 mm should undergo Ultrasonic

Test (UT) to check lamination defect, internal impurities in line with
ASTM 435 & ASTM 577.
11.1.10 After fabrication of tank and before painting, Non-destructive test

(dye penetration test) is mandatory on the load bearing members
such as base plate joints, jacking pads and lifting devices etc.
11.1.11 Suitable guides shall be provided for positioning the various parts
during assembly or dismantling. Adequate space shall be provided
between the covers & windings and the bottom of the tank for collection
of any sediment.
11.1.12 Tank should be provided with adequately sized inspection covers, either
in circular shape or in rectangular shape, preferably at diagonally
opposite sides of the tank to access the active part and one at each
end of the tank cover for easy access of the lower end of the
bushings, earthing connections and tap changers etc. for inspection.
Inspection covers shall be bolted type and shall not weigh more than
25 kgs. Handles shall be provided on the inspection cover to facilitate
its lifting.
11.1.13 The tank cover shall be provided with pockets for oil and winding
temperature indicators. The location of pockets (for OTI, WTI & RTDs
including two spare pockets) shall be in the position where oil reaches
maximum temperature. Further, it shall be possible to remove
bulbs/probes of OTI/WTI/RTD without lowering the oil in the tank. The
thermometer shall be fitted with a captive screw to prevent the ingress
of water.
Chapter-1:Technical Specification for Power Transformers for Solar parks Page

10
11.1.14 It should be possible to inspect Buchholz relay or Oil surge relay,
standing on tank cover or suitable arrangement shall be made to access
Buchholz relay safely.
11.1.15 The tank cover shall be designed to prevent retention of rain water
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.
11.1.16 Minimum four symmetrically placed lifting lugs of adequate size 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 lug shall not be less than 2.
Suitable haulage holes shall also be provided.
11.1.17 A minimum of four jacking pads (not fouling with rail, rollers or
other accessories) shall be provided in accessible position to enable
the transformer complete with oil to be raised or lowered using
hydraulic jacks. The location shall be such that it should not interfere
with loading & unloading from trailer.
11.1.18 Each jacking pad shall be designed with an adequate factor of

safety to support at least half of the total mass of the transformer
filled with oil in addition to maximum possible misalignment of
the jacking force to the centre of the working surface.
11.1.19 The tank shall be provided with suitable valves as specified in Clause
18: Valves and Clause 26: “Fittings and accessories” of this chapter.
Location of valves shall be finalized during design review.
11.1.20 The tank cover and bushing turret shall be fixed to the transformer
using copper links in such a way that good electrical contact is
maintained around the perimeter of the tank and turrets.
11.1.21 The transformer shall be provided with a suitable diameter pipe flange,
butterfly valve, bolted blanking plate and gasket at the highest point of
the transformer for maintaining vacuum in the tank.
11.1.22 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 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
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design for gas venting shall take into accounts the slopes of the plinth
(if any) on which the transformer is being mounted.
11.2 Gasket for tank & cover
All gasketed joints shall be designed, manufactured and assembled to

ensure long-term leak proof and maintenance free operation. All
gasketed joints shall preferably be O-ring and designed with
gasket-in-groove arrangement. If gasket/O-rings is compressible,
metallic stops/other suitable means shall be provided to prevent over-
compression. All bolted connections shall be fitted with weather proof,
hot oil resistant, resilient gasket in between for complete oil tightness.
All matching flanges of gasket sealing joints should be machined
(except curb joints). Gasket with intermediate stops are not acceptable.
To the extent possible, the seamless gasket should be used for openings
on tank/cover such as turrets, bushing, inspection covers etc. All tank
gaskets/O-rings used shall be of NBR (Acrylonitrile Butadiene
Rubber) suitable for temperature conditions expected to be
encountered during operation. The gasket material and additives
should be fully compatible with transformer insulating fluid/oil. The
gasket should not contain oil soluble sulphur compounds. The
properties of all the above gaskets/O-Rings shall comply with the
requirements of type-IV rubber of IS-11149. Gaskets and O-rings shall
be replaced every time whenever the joints are opened.
11.3 Foundation, Roller Assembly and Anti Earthquake Clamping

Device
Transformer shall be placed on foundation either directly or on

roller assembly.
11.3.1 For transformer to be placed directly on foundation, one set of rollers
shall be provided for movement within the yard. The rollers for
transformer are to be provided with flanged bi-directional wheels and
axles. This set 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.
11.3.2 The rail track gauge shall be 1676 mm.
11.3.3 To prevent movement during earthquake, suitable clamping devices

shall be provided for fixing the transformer to the foundation.

12
11.3.4 In case rail is not required for smaller rating transformers, arrangement
of unidirectional roller mounted on channel shall be provided and
channel shall be locked with the plinth suitably.
11.3.5 For foundation of separately mounted cooler bank of transformer, fixing
of cooler support shall be through Anchor Fastener with chemical
grouting and no pockets for bolting shall be provided.
11.3.6 For support of cooler pipes, Buchholz pipe (if required) and fire-fighting
pipe pylon supports, Pre-fabricated metallic support from pit shall be
provided which shall be further encased with concrete to prevent
rusting.
11.3.7 All control cubicles shall be mounted at least one meter above Finished
Ground Level (FGL) to take care of water logging during flooding.
Suitable arrangement (ladder and platform) shall be provided for safe
access to control cubicles.
11.4 Conservator
11.4.1 The conservator of main tank 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.
11.4.2 The conservator shall preferably be on the left side of the tank
while viewing from HV side.
11.4.3 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 100 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.
11.4.4 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.
11.4.5 The conservator shall be positioned so as not to obstruct any electrical

connection to transformer.
11.4.6 Contact of the oil with atmosphere is prohibited by using a flexible air
cell of nitrile rubber reinforced with nylon cloth. The temperature
13
of oil in the conservator is likely to raise up to 100 Deg C during
operation. As such air cell used shall be suitable for operating
continuously at this temperature.
11.4.7 The connection of air cell to the top of the conservator is by air proof
seal preventing entrance of air into the conservator. The main
conservator tank shall be stencilled 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. The transformer rating and
diagram plate shall bear a warning statement that the “Main
conservator is fitted with an air cell”.
11.4.8 The transformer manual shall give 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.
11.4.9 The conservator tank and piping shall be designed for complete
vacuum/ filling of the main tank and conservator tank. Provision
must be made for equalising the pressure in the conservator tank and
the air cell during vacuum/ filling operations to prevent rupturing of
the air cell.
11.4.10 The contractor 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.
11.4.11 OLTC shall have conventional type conservator (without aircell)

with magnetic oil level gauge with potential free oil level alarm
contact and prismatic oil level gauge.
11.4.12 Conservator Protection Relay (CPR)/Air cell puncture detection

relay shall be externally installed on the top of conservator to give
alarm in the event of lowering of oil in the conservator due to puncture
of air cell in service.
11.5 Piping works for conservator
11.5.1 Pipe work connections shall be of adequate size preferably short and
direct. Only radiused elbows shall be used.
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11.5.2 The feed pipe to the transformer tank shall enter the 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. This pipe shall rise towards the oil conservator,
through the Buchholz relay, at an angle of not less than 3 degrees.
The feed pipe diameter for the main conservator shall be not less than
80mm. The 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.
11.5.3 No metal corrugated bellow (Flexible metal system) should be used in

the feed pipe connecting main tank to conservator.
11.5.4 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.
11.5.5 Pipe work shall neither obstruct the removal of tap changers for
maintenance or the opening of inspection or manhole covers.
11.6 Dehydrating Silica Gel Filter Breather
Conservator of Main Tank and OLTC shall be fitted with dehydrating

silica gel filter breathers of adequate size. Connection shall be made to
a point in the oil conservator not less than 50 mm above the maximum
working oil level by means of a pipe with a minimum diameter of 25
mm. Breathers and 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) Silica gel is isolated from atmosphere by an oil seal.
c) Moisture absorption indicated by a change in colour of the
crystals.
d) Breather is mounted approximately 1200 mm above rail top level.
e) To minimise the ingress of moisture three breathers (of identical
size) for 220kV and above voltage class transformer/ and two
breathers (of identical size) for below 220kV class
transformer/ shall be connected in series for main tank

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conservator. Manufacturer shall provide flexible connection pipes
to be used during replacement of any silica gel breather.
f) To minimise the ingress of moisture, two breather in series of
identical size shall be connected to OLTC Conservator.
Manufacturer shall provide flexible connection pipes to be used
during replacement of any silica gel breather.
Note: Regenerative maintenance free breather may also be used if

desired by the utility.
11.7 Pressure Relief Device (PRD)
One PRD of 150 mm Diameter is required for every 30000 Litres

of oil. However, at least two numbers PRDs shall be provided. Its
mounting should be either in vertical or horizontal orientation,
preferably close to bushing turret or cover. PRD operating pressure
selected shall be verified during design review.
PRD shall be provided with special shroud to direct the hot oil in
case of fault condition. It shall be provided with an outlet pipe which
shall be taken right up to the soak pit of the transformer. The size
(Diameter) of shroud shall be such that it should not restrict rapid
release of any pressure that may be generated in the tank, which may
result in damage to equipment. Oil shroud should be kept away from
control cubicle and clear of any operating position to avoid injury to
personnel in the event of PRD operation.
The device shall maintain its oil tightness under static oil pressure
equal to the static operating head of oil plus 20 kPa.
It shall be capable of withstanding full internal vacuum at mean sea

level. It shall be mounted directly on the tank. Suitable canopy shall
be provided to prevent ingress of rain water. One set of potential free
contacts (with plug & socket type arrangement) per device shall be
provided for tripping. Following routine tests shall be conducted on
PRD:
a) Air pressure test

b) Liquid pressure test
c) Leakage test
d) Contact operation test
e) Dielectric test on contact terminals

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11.8 Sudden Pressure Relay/ Rapid Pressure Rise Relay (for 220kV and
above transformer/reactor)
One number of Sudden Pressure Relay/ Rapid Pressure Rise Relay

with alarm or trip contact (Terminal connection plug & socket type
arrangement) shall be provided on tank of transformer/reactor.
Operating features and size shall be reviewed during design review.
Suitable canopy shall be provided to prevent ingress of rain water.
Pressurised water ingress test for Terminal Box (routine tests) shall be
conducted on Sudden Pressure Relay/ Rapid Pressure Rise Relay.
11.9 Buchholz Relay
Double float, reed type Buchholz relay complying with IS:3637 shall
be connected through pipe between the oil conservator and the
transformer tank with minimum distance of five times pipe diameters
between them. Any gas evolved in the transformer shall be collected in
this relay. The relay shall be provided with a test 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. Suitable canopy shall be provided to
prevent ingress of rain water. It shall be provided with two potential
free contacts (Plug & socket type arrangement), one for alarm/trip
on gas accumulation and the other for tripping on sudden rise of
pressure.
The Buchholz relay shall not operate during starting/stopping of the

transformer oil circulation 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. Pressurised water
ingress test for Terminal Box (routine tests) shall be conducted on
Buchholz relay.
11.10 Oil Temperature Indicator (OTI)
The transformer shall be provided with a dial type thermometer of

about 150mm diameter for top oil temperature indication with
angular sweep of 270°. Range of temperature should be 0-150°C
with accuracy of ±1.5% (or better) of full scale deflection. The
instruments should be capable of withstanding high voltage of 2.5kV

17
AC rms, 50Hz for 1 minute. The terminal provided for auxiliary wiring
should be Press-fit type.
The thermometer shall have adjustable, potential free alarm and trip
contacts besides that required for control of cooling equipment (if any),
maximum reading pointer and resetting device, switch testing knob &
anti-vibration mounting grommets (for projection mounting). Type of
switch (NO/NC) shall be heavy duty micro switch of 5A at 240V AC/DC.
Adjustable range shall be 20-90% of full scale range. The instruments
case should be weather proof with epoxy coating at all sides.
Instruments should meet degree of protection of IP55 as per IS/IEC-
60529. A temperature sensing bulb located in a thermometer pocket
on tank cover should be provided to sense top oil. This shall be
connected to the OTI instrument by means of flexible stainless steel
armour to protect capillary tubing. Temperature indicator dials shall
have linear gradations to clearly read at least every 2 deg C. The setting
of alarm and tripping contacts shall be adjustable at site.
The OTI 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:
Temperature transducer with PT100 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 IS 2848 or equivalent. The PT100 sensor may
be placed in the pocket containing temperature sensing element. RTD
shall include image coil for OTI system and shall provide dual output
4-20mA for SCADA system. 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 manufacturer. 4-20mA signal shall
be wired to Digital RTCC panel/BCU for further transfer data to SCADA
through IS/IEC 61850 compliant communications.
11.11 Winding Temperature Indicator (WTI)
The transformer shall be provided with a dial type hot spot indicator of
about 150mm diameter for measuring the hot spot temperature of
each winding [HV, LV or LV1/LV2, Tertiary (if applicable)]. It shall have
angular sweep of 270o. Range of temperature should be 0-150°C
18
with accuracy of ±1.5% (or better) of full scale deflection. The
instruments should be capable of withstanding high voltage of 2.5kV
AC rms, 50Hz for 1 minute. The terminal provided for auxiliary wiring
should be Press-fit type.
The thermometer shall have adjustable, potential free alarm, trip

contacts besides that required for control of cooling equipment, if any.
Instrument should be provided with maximum reading pointer and
resetting device, switch testing knob & anti-vibration mounting
grommets (for projection mounting). Type of switch (NO/NC) shall be
heavy duty micro switch of 5A at 240V AC/DC. Adjustable range shall
be 20-90% of full scale range. The instruments case should be weather
proof and epoxy coating at all sides. Instruments should meet degree
of protection of IP55 as per IEC 60529. A temperature sensing bulb
located in a thermometer pocket on tank cover should be provided to
sense top oil. This shall be connected to the WTI instrument by means
of flexible stainless steel armour to protect capillary tubing. WTI shall
have image coil and auxiliary CTs, if required to match the image coil
mounted in local control box. The setting of alarm and tripping contacts
shall be adjustable at site.
The 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 winding temperature:
Temperature transducer with PT100 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 IS 2848 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. The transducer and
Auxiliary CT shall be installed in the Individual Marshaling Box. Any
special cable required for shielding purpose, for connection between
PT100 temperature sensor and transducer, shall be in the scope of
Contractor. 4-20mA signal shall be wired to Digital RTCC / BCU panel

19
for further transfer data to SCADA through IS/IEC 61850 compliant
communications.
11.12 Earthing Terminals
11.12.1 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 galvanised steel grounding flat shall be provided each at
position close to earth of the two (2) diagonally opposite bottom
corners of the tank.
11.12.2 Two earthing terminals suitable for connection to 75 x 12 mm

galvanised steel flat shall also be provided on each cooler,
individual/common marshalling box and any other equipment
mounted separately. For the tank-mounted equipment like online
drying/Online DGA/Optical Sensor Box etc., (if provided), double
earthing shall be provided through the tank for which provision shall
be made through tank and connected through two flexible insulated
copper link.
11.12.3 Equipotential flexible copper links of suitable size shall be provided

between turret & tank, between tank & cover or between Bell &
lower tank. Other components like - pipes, conservator support etc.
connected to tank may also be provided with equipotential flexible
copper link.
11.12.4 Each transformer unit should have provision for earthing and
connection to grounding mat when not in service.
11.13 Core
11.13.1 The core shall be constructed from non-ageing, cold rolled high
permeability grade or better grain oriented silicon steel
laminations. Indian transformer manufacturers shall use core
material as per above specification with BIS certification.
11.13.2 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. The
step-lap construction arrangement is preferred for better performance
in respect of noise, no-load current and no-load loss.

20
11.13.3 The hot spot temperature and surface temperatures in the core
shall be calculated for over voltage conditions specified in the
document and it shall not exceed 125 deg C and 120 deg C
respectively.
11.13.4 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.
11.13.5 All steel sections used for supporting the core shall be thoroughly
sand/ shot blasted after cutting, drilling and welding.
11.13.6 Each core lamination shall be insulated with a material that will not
deteriorate due to pressure and hot oil.
11.13.7 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 shall be provided to enable lifting of active part
(core & winding).
11.13.9 Core assembly shall be manufactured in such a way that lamination

shall remain flat and finally assembled core shall be free from
distortion.
11.13.10 Single point core earthing should be ensured to avoid circulating

current. Core earth should be brought separately on the top of the tank
to facilitate testing after installation on all transformers. 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’. Cross section of Core earthing connection shall
be of minimum size 80 sq.mm copper with exception of the connections
inserted between laminations which may be reduced to a cross-
sectional area of 20 sq. mm tinned copper where they are clamped
between the laminations.
11.13.11 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.
11.13.12 Insulation of core to clamp/frame shall be tested at 2.5 kV DC for

1 minute without breakdown after the transformer is filled with
21
liquid and insulation resistance should be at least 1 giga ohm for
new transformer.
11.14 Windings
11.14.1 The manufacturer shall ensure that windings of all transformers are
made in clean, dust proof (Cleanroom class ISO 9 or better as per ISO
14644-1), humidity controlled environment with positive
atmospheric pressure.
11.14.2 The conductors shall be of electrolytic grade copper free from scales
and burrs. Oxygen content shall be as per IS 12444.
Epoxy bonded Continuously Transposed Conductor (CTC) shall be

used in main winding for rated current of 400 A or more.
11.14.3 The conductor shall be transposed at sufficient intervals in order to

minimize eddy currents and to equalise the distribution of currents and
temperature along the winding.
11.14.4 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.
11.14.5 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.
11.14.6 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.
11.14.7 The coils would be made up, shaped and braced to provide for
expansion and contraction due to temperature changes.
11.14.8 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.

22
11.14.9 The barrier insulation including spacers shall be made from high-
density pre-compressed pressboard (1.15 gm/cc minimum for load
bearing and 0.95 gm/cc minimum for non-load bearing) to
minimize dimensional changes. Kraft insulating paper used on
conductor should have density of >0.75 g/cc.
11.14.10 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.
11.14.11 All insulating materials and structures shall be protected from

contamination and the effects of humidity during and after fabrication,
and after receipt, by storing them in a separate, climate-controlled area.
All blocks shall be installed such that the grain is oriented in the
horizontal direction, perpendicular to the winding compressive forces.
Aspect ratio of selected conductor shall be chosen suitably based on
manufacturer experience to result in stable winding under normal and
abnormal service condition after assembly.
11.14.12 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.
11.14.13 Winding paper moisture shall be less than 0.5%.
11.14.14 Windings shall be provided with clamping arrangements which will

distribute the clamping forces evenly over the ends of the winding.
11.14.15 Either brazing/crimping type of connections are permitted for

joints. It shall be time proven and safely withstand the cumulative
effect of stress which may occur during handling, transportation,
installation and service including line to line and line to ground faults
/Short circuits. Manufacturer shall have system which allows only
qualified personnel to make brazing or crimping joints.
11.15 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.
11.16 Winding terminations into bushings

23
11.16.1 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.
11.16.2 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.
11.16.3 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.
11.16.4 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.
11.16.5 Suitable inspection and access facilities into the tank in the bushing
oil-end area shall be provided to minimize the possibility of creating
faults during the installation of bushings.
12.0 PAINT SYSTEM AND PROCEDURES
The typical painting details for transformer main tank, pipes,

conservator tank, radiator, control cabinet/ marshalling box / oil
storage tank etc. shall be as given in Annexure–K. The proposed paint
system shall generally be similar or better than this. The quality of
paint should be such that its colour does not fade during drying
process and shall be able to withstand temperature up to 120 deg C.
The detailed painting procedure shall be finalized during award of the
contract.
13.0 INSULATING OIL
The insulating oil shall be unused inhibited (Type A, High Grade)

Transformer Oil conforming to IEC-60396-2020 & all parameters
specified at Annexure–L, while tested at oil supplier's premises. The
contractor shall furnish test certificates from the supplier against the
acceptance norms as mentioned at Annexure–L, prior to despatch of oil
from refinery to site. Under no circumstances, poor quality oil shall be
filled into the transformer and thereafter be brought up to the specified
parameter by circulation within the transformer. The Unused
Insulating Oil parameters including parameters of oil used at
24
manufacturer’s works, processed oil, oil after filtration and settling are
attached at Annexure–L. The oil test results shall form part of
equipment test report.
A minimum of 5% of the oil quantity shall be supplied as spare (in

addition to first filling) for maintaining required oil level in case of
leakage in tank, radiators, conservator etc.
Oil used for first filling, testing and impregnation of active parts at
manufacturer's works shall be of same type of oil which shall be
supplied at site and shall meet parameters as per specification.
13.1 Particles in the oil (For 400 kV transformer)
The particle analysis shall be carried out in an oil sample taken before
carrying out FAT at manufacturer’s works and after completion of
the oil filtration at site. The procedure and interpretation shall be in
accordance with the recommendation of CIGRE report WG-12.17-
“Effect of particles on transformer dielectric strength”. Particle limit as
shown below shall be ensured by manufacturer, implying low
contamination, as per CIGRE Brochure 157, Table 8. After filtration the
oil is to be flushed and particle count to be measured.
Limiting value for the particle count are 1000 particle/100 ml with
size ≥ 5 μm; 130 particle/100 ml with size ≥ 15 μm.
14.0 BUSHINGS
14.1 For various voltage class of transformer, type of bushings shall be

as follows:
Voltage Rating Bushing Type

145 kV, 245 kV and 420 kV bushings RIP/RIS
36 kV Bushings Solid porcelain or oil
communicating type
OIP: Oil Impregnated Paper (with porcelain/polymer housing); RIP: Resin

Impregnated Paper (with polymer housing); RIS: Resin Impregnated
Synthetic (with polymer housing)

25
14.2 Bushings shall be robust and designed for adequate cantilever strength
to meet the requirement of seismic condition, substation layout and
movement along with the spare transformer with bushing erected and
provided with proper support from one foundation to another
foundation within the substation area. The electrical and mechanical
characteristics of bushings shall be in accordance with IS/IEC: 60137.
All details of the bushing shall be submitted for approval and design
review.
14.3 Oil filled condenser type bushing shall be provided with at least
following fittings:
a) Oil level gauge

b) Tap for capacitance and tan delta test. Test taps relying on pressure
contacts against the outer earth layer of the bushing is not
acceptable
c) Oil filling plug & oil sample valve
14.4 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.
14.5 Bushing shall be provided with tap for capacitance and tan delta
test. Test taps relying on pressure contacts against the outer earth
layer of the bushing is not acceptable.
14.6 Where current transformers are specified, the bushings shall be

removable without disturbing the current transformers.
14.7 Bushings of identical rating of different makes shall be

interchangeable to optimise the requirement of spares. The standard
dimensions for lower portion of the condenser bushings shall be as
indicated in Annexure-M.
14.8 Polymer insulator shall be seamless sheath of a silicone rubber

compound. The housing & weather sheds should have silicon content
of minimum 30% by weight. It should protect the bushing against
environmental influences, external pollution and humidity. The
interface between the housing and the core must be uniform and
without voids. The strength of the bond shall be greater than the tearing
strength of the polymer. The manufacturer shall follow non-destructive
technique (N.D.T.) to check the quality of jointing of the housing
interface with the core. The technique being followed with detailed
procedure and sampling shall be finalized during finalization of MQP.
26
The weather sheds of the insulators shall be of alternate shed profile as
per IS 16683-3/IEC 60815-3. The weather sheds shall be vulcanized to
the sheath (extrusion process) or moulded as part of the sheath
(injection moulding process) and free from imperfections. The
vulcanization for extrusion process shall be at high temperature and
for injection moulding shall be at high temperature & high pressure.
Any seams/ burrs protruding axially along the insulator, resulting from
the injection moulding process shall be removed completely without
causing any damage to the housing. The track resistance of housing
and shed material shall be class 1A4.5 according to IS 9947. The
strength of the weather shed to sheath interface shall be greater than
the tearing strength of the polymer. The polymer insulator shall be
capable of high pressure washing.
14.9 End fittings shall be free from cracks, seams, shrinks, air holes and
rough edges. End fittings should be effectively, sealed to prevent
moisture ingress, effectiveness of sealing system must be supported by
test documents. All surfaces of the metal parts shall be perfectly
smooth with the projecting points or irregularities which may cause
corona. All load bearing surfaces shall be smooth and uniform so as to
distribute the loading stresses uniformly.
14.10 The hollow silicone composite insulators shall comply with the
requirements of IEC-61462 and the relevant parts of IEC-62217. The
design of the composite insulators shall be tested and verified according
to IEC-61462 (Type & Routine test).
14.11 Clamps and fittings shall be of hot dip galvanised/stainless steel.
14.12 Bushing turrets shall be provided with vent pipes, to route any gas
collection through the Buchholz relay.
14.13 No arcing horns shall be provided on the bushings.
14.14 Corona shield, wherever required, shall be provided at bushing

terminal (air end) to minimize corona.
14.15 Bushing shall be specially packed to avoid any damage during transit
and suitable for long storage, with non-returnable packing wooden
boxes with hinged type cover. Without any gap between wooden planks.
Packing Box opening cover with nails/screws type packing
arrangement shall not be acceptable. Manufacturer shall submit
drawing/ documents of packing for approval during detail engineering.
Detail method for storage of bushing including accessories shall be
brought out in the instruction manual.
27
14.16 Oil end portion of RIP/RIS type bushings shall be fitted with metal
housing with positive dry air pressure or oil filled metal housing and a
suitable pressure monitoring device shall be fitted on the metal housing
during storage to avoid direct contact with moisture with epoxy. The
pressure of dry air need to be maintained in case of leakage.
14.17 The terminal marking and their physical position shall be as per IS
2026.
14.18 Tan delta measurement at variable frequency (in the range of 20

Hz to 350 Hz) shall be carried out on each condenser type bushing
(OIP & RIP/ RIS) at Transformer manufacturing works as routine
test before despatch and the result shall be compared at site during
commissioning to verify the healthiness of the bushing.
14.19 Tan δ value of OIP/RIP/RIS condenser bushing shall be 0.005

(max.) in the temperature range of 10°C to 40°C. If tan delta is
measured at a temperature beyond above mentioned limit,
necessary correction factor as per IEEE shall be applicable.
15.0 Air insulated dry Cable Box for 33 kV XLPE cable (if applicable):
15.1 Cable boxes shall be of phase segregated air insulated type & shall be
of sufficient size to accommodate Purchaser’s cable & termination.
Phase segregation shall be achieved by insulating barriers.
15.2 Cable boxes shall have bus bars / terminal connectors of adequate size
& bolt holes to receive cable lugs.
15.3 Cable boxes shall be designed to accommodate all the cable joint
fittings or sealing ends required by the manufacturers of the cables,
including stress/cones or other approved means for grading the voltage
stress on the terminal insulation of cables operating at voltages of 33
kV between phases.
15.4 The cable boxes shall be fitted with suitable non-ferrous wiping glands
with combined armour and earthing clamps. The ends of all wiping
glands shall be tinned before dispatch to site. Wiping glands for single
core cables shall be insulated from the box. Wiping glands insulation
shall be capable of withstanding a dry high voltage test of 2 kV AC for
one minute. Sufficient wiping glands shall be provided for the
termination of required number of cables.

28
15.5 Where cable boxes are provided for three core cables, the seating
sockets on the two outer phases shall preferably be inclined towards
the centre to minimize bending of the cable cores. Where there is more
than one core per phase, the socket block shall be so designed as to
minimize bending of the cable cores.
15.6 A suitable removable gland plate of non-magnetic material shall also be

provided in the cable box.
15.7 The support from base for the cable box shall be of galvanized iron.
15.8 The contractor shall provide earthing terminals on the cable box, to suit
Purchaser’s GI flat.
15.9 Unless otherwise approved the creepage distances and clearance to

earth and between phases shall not be less than those specified below.
Creepage
over Creepage
Highest Clearance Clearance
porcelain over
System Insulating between to earth
to cable
Voltage medium phases direct
similar surface
kV (mm) (mm)
material (mm)
(mm)
36 Air 351 222 576 576
15.10 Terminals shall be marked in a clear and permanent manner.
15.11 Cable boxes shall have removable top cover & ample clearance shall be
provided to enable either transformer or each cable to be subjected
separately to high voltage test.
15.12 The minimum length provided for terminating 33kV cable shall be 1000
mm (from cable gland plate to the cable lug) for the cable boxes. The
final cable size, number & length of terminating XLPE cable shall be
furnished during detailed engineering.
15.13 Cable boxes shall be designed such that it shall be possible to move
away the transformer without disturbing the cable terminations,
leaving the cable box on external supports. Cable box shall have IP-55
protection as per IS:13974.
15.14 Unless otherwise specified main cabling jointing and filling of cable
boxes will be carried out by the purchaser or his Contractor as the case
29
may be.
16.0 NEUTRAL FORMATION AND EARTHING ARRANGEMENT
The neutral of the transformer shall be brought out through bushing.

The neutral terminal of transformer shall be brought to the ground level
by a brass/tinned copper grounding bar, supported from the tank by
using porcelain insulators. The end of the brass/tinned copper bar
shall be brought to a convenient location at the bottom of the tank, for
making connection (using bimetallic strip of adequate size) to
grounding mat through separate earth pits using two (2) numbers 75 x
12 mm galvanised steel flats. Aluminium clamps & connectors of
suitable size shall be provided for connection with neutral of the
transformer.
17.0 COOLING EQUIPMENT AND ITS CONTROL
17.1 Radiator based cooling for Power transformer
The transformer shall be designed with cooler system as specified in

Annexure-A and with following provisions, as applicable.
17.1.1 The cooler shall be designed using separately mounted radiator

banks or tank mounted radiators. Design of cooling system shall
satisfy the performance requirements.
17.1.2 In case of separately mounted radiator bank arrangement, radiator

bank shall generally be placed on left side of the tank while
watching from HV side of the transformer. However, the main tank
shall have provision such that cooler banks can be placed on either
side of the main tank by simple reconnection without the need of any
extra member/pipe maintaining the electrical clearances.
17.1.3 The radiator shall be of sheet steel complying with IS 513 and
minimum thickness 1.2 mm. Each radiator bank shall be provided
with the following accessories:
(a) Cooling Fans, Oil Pumps, Oil Flow Indicator (as applicable)
(b) Top and bottom shut off valve of at least 80mm size
(c) Drain Valve and sampling valve
(d) Top and bottom oil filling valves
30
(e) Air release plug at top
(f) Two grounding terminals suitable for termination of two (2) Nos.
75x12 mm galvanised steel flats.
(g) Thermometer pockets fitted with captive screw caps at cooler inlet
and outlet.
(h) Lifting lugs
17.1.4 Each radiator bank shall be detachable and shall be provided with
flanged inlet and outlet branches. Expansion joint (for separately/
ground mounted cooler banks) shall be provided on top and bottom
cooler pipe connection.
17.1.5 One number standby fan shall be provided with each radiator bank.
17.1.6 Cooling fans shall not be directly mounted on radiator. The

supporting frames for the cooling fans shall be fixed preferably on
separate support or to the main tank in such a manner that the fan
vibration does not affect the performance of the radiators and its valves.
Fans shall be located so as to prevent ingress of rain water. Each fan
shall be suitably protected by galvanised wire guard. The exhaust air
flow from cooling fan shall not be directed towards the main tank in
any case.
17.1.7 Two (2) nos., 100% centrifugal or axial in line oil pumps, if
applicable, (out of which one pump shall be standby) shall be provided
with each radiator bank. Measures shall be taken to prevent mal-
operation of Buchholz relay when all oil pumps are simultaneously
put into service. The pump shall be so designed that upon failure of
power supply to the pump motor, the pump impeller will not limit the
natural circulation of oil.
17.1.8 The changeover to standby oil pump in case of failure of service oil
pump shall be automatic.
17.1.9 An oil flow indicator shall be provided for the confirmation of the oil
flow direction. An indication in the flow indicator and potential free
contacts for remote alarm shall be provided.
17.1.10 Valves shall be provided across the pump and oil flow indicator to avoid
oil drain and long outage during maintenance / replacement of pump
and oil flow indicator.
17.1.11 Cooling fans and oil pump motors shall be suitable for operation from
415 volts, three phase 50 Hz power supply and shall be of premium
efficiency class IE3 conforming to IS: 12615. Each cooling fan and oil
31
pump motors shall be provided with starter, thermal overload and short
circuit protection. The motor winding insulation shall be conventional
class 'B' type. Motors shall have hose proof enclosure equivalent to IP:
55 as per IS/IEC 60034-5.
17.1.12 The cooler pipes, support structure including radiators and its
accessories shall be hot dip galvanised or corrosion resistant paint
should be applied to external surface of it.
17.1.13 Air release device and oil plug shall be provided on oil pipe connections.
Drain valves shall be provided in order that each section of pipe work
can be drained independently.
17.1.14 Automatic operation control of fans/pumps shall be provided (with

temperature change) from contacts of winding temperature indicator.
The manufacturer shall recommend the setting of WTI for automatic
changeover of cooler control over entire operating range depending on
types of cooling system like ONAN/ONAF/ODAF (or OFAF) or
ONAN/ONAF. The setting shall be such that hunting i.e. frequent start-
up operations for small temperature differential do not occur.
17.1.15 Suitable manual control facility for cooler fans and oil pumps shall be
provided. Selector switches and push buttons shall also be provided in
the cooler control cabinet to disconnect the automatic control and
start/stop the fans and pump manually.
17.1.16 Following lamp indications shall be provided in cooler control cabinet:
a) Cooler Supply failure (main)

b) Cooler supply changeover
c) Cooler Supply failure (standby)
d) Control Supply failure
e) Cooling fan supply failure for each bank
f) Cooling pump supply failure for each pump
g) Common thermal overload trip
h) Thermal overload trip for each fan/pump
i) No oil flow/reverse flow for pumps
j) Stand by fan/pump ON
One potential free initiating contact for all the above conditions shall
be wired independently to the terminal blocks of cooler control cabinet
and for single phase unit connection shall be extended further to
Common Marshalling Box.
17.1.17 The Cooler Control Cabinet/ Individual Marshalling Box shall have all
necessary devices meant for cooler control and local temperature
32
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/Individual Marshalling Box. All the CT secondary terminals in
the Cooler Control Cabinet shall have provision for shorting to avoid CT
open circuit while it is not in use.
17.1.18 All the necessary terminations for remote connection to Purchaser's

panel shall be wired upto the Common Marshalling Box (in case of 1-
Ph unit) or Marshalling Box (3-Ph unit).
17.1.19 AC power for Cooler Control Circuitry shall be derived from the AC
feeder. In case auxiliary power supply requirement for Cooler Control
Mechanism is different than station auxiliary AC supply, then all
necessary converters shall be provided.
18.0 VALVES
18.1 Type of valves shall be used for transformer as per following table. The
location and size of valves for other application shall be finalised during
design review. Utility may specify any other valve required for some
other applications.
Sr. Description of Valve Type

No.
1 Drain Valve Gate
2 Filter valve Gate
3 Sampling Valve Globe
4 Radiator isolation valve Butterfly
5 Buchholz relay isolation valve Gate
6 Sudden pressure relay Gate
7 OLTC tank equalizing valve Gate / Needle
8 OLTC Drain cum filling valve Gate
9 Valve for vacuum application on Tank Gate
10 Conservator Drain valve Gate
11 Aircell equalizing valve Gate/Globe/Ball

33
12 Valve for Conservator vacuum (top) Gate
13 Filter valve for Cooler Bank (Header) Gate
14 Cooler Bank isolation valve Butterfly
15 Pump Isolation valve (if applicable) Butterfly
16 Valve for N2 injection (NIFPS) Gate
(if specified by utility)
17 Valve for NIFPS Drain Gate
(if specified by utility)
18 Valve for UHF Sensors Gate
(applicable for 400kV voltage class
Transformer only)
18.2 All valves upto and including 50 mm shall be of gun metal or of

cast steel. Larger 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.
18.3 Suitable means shall be provided for locking the valves in the open and
close positions. Provision is not required for locking individual radiator
valves.
18.4 Each valve shall be provided with the indicator to show clearly the
position (open/close) of the valve.
18.5 Gland packing/gasket material shall be of “O” ring of nitrile rubber

for all the valve’s flanges. All the flanges shall be machined.
18.6 Drain valves/plugs shall be provided in order that each section of pipe
work can be drained independently.
18.7 All valves in oil line shall be suitable for continuous operation with
transformer oil at 115 deg C.
18.8 After testing, inside surface of all cast iron valves coming in contact
with oil shall be applied with one coat of oil resisting paint/varnish with
two coats of red oxide zinc chromate primer followed by two coats of
fully glossy finishing paint conforming to IS: 2932 and of a shade
(Preferably red or yellow) distinct and different from that of main tank
surface. Outside surface except gasket setting surface of butterfly
valves shall be painted with two coats of red oxide zinc chromate

34
conforming to IS: 2074 followed by two coats of fully glossy finishing
paint.
18.9 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.
18.10 Valves or other suitable means shall be provided to fix various on line
condition monitoring systems, if specified, to facilitate continuous
monitoring. The location & size of the same shall be finalised during
detail design review.
18.11 All hardware used shall be hot dip galvanised/stainless steel.
18.12 Flow sensitive conservator Isolation valve (if specified by the

utility)
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 conservator
oil from the main tank. The valve 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. It shall not operate when
oil pumps are switched on or off. 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 suitable platform or ladder (if
required) shall be provided to approach the valve for manual reset.
19.0 CABLING
19.1 All interconnecting control and power cables emanating from various
parts of transformer like turret CT, MBs, Fans, pumps, Buchholz, PRD
etc. shall be routed through covered cable tray or GI conduit and shall
be properly dressed. All cables shall be armoured type. Un-armoured
cables (if provided) in any circuitry, shall be through GI conduit and no
part shall be exposed. Cable terminations shall be through stud type
35
TB and ring type lugs. Type tested cables from approved sources shall
be provided. 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
tags/ numbers etc. as required shall be considered included in the
scope of supply. Typical technical specification for cables is
attached at Annexure-O. The cross section of “control cable” shall be
1.5 sq.mm (minimum) except for CT circuits which should be 2.5
sq.mm (minimum).
20.0 TAP CHANGING EQUIPMENT
The transformer shall be provided with Off Circuit (De-energized)/On

Load Tap changing equipment as specified in Annexure-A and shall
comply with IS 8468-1/IEC 60214-1.
20.1 Off Circuit Tap Changing (OCTC)/De-Energized Tap Changing

(DETC) Equipment
20.1.1 The tap changer shall be hand operated for switching taps by operating
external hand wheel.
20.1.2 Arrangement shall be made for securing & pad locking the tap changer
in any of the working positions & it shall not be possible for setting
or padlocking it in any intermediate position. An indicating device
shall be provided to show the tap in use.
20.1.3 The cranking device for manual operation of the off circuit tap changing
gear shall be removable & suitable for operation by a man standing on
ground level. The mechanism shall be complete with the following:
(a) A mechanical operation indicator.
(b) Mechanical tap position indicator which shall be clearly visible
from near the transformer.
(c) Mechanical stops to prevent over cranking of the mechanism
beyond the extreme positions.
(d) The manual operating mechanism shall be labeled to show the
direction of operations for raising the secondary voltage & vice
versa.
(e) A warning plate indicating “The switch shall be operated only when
the transformer has been de-energized” shall be fitted.

36
20.1.4 Measurement of Tan Delta values of OCTC to be done before installing
in the transformer.
20.1.5 Following signals to be provided:

(a) Out of step digital position indicator, showing mismatch between
tap positions of transformers in three phases.
(b) An analog signal (4-20 mA) for tap position of transformer.
20.2 On Load Tap Changing (OLTC) Equipment
20.2.1 Main OLTC Gear Mechanism
20.2.1.1 The transformer as specified in Annexure-A shall be provided with

voltage control equipment of the tap changing type for varying its
effective transformation ratio whilst the transformers are on load. The
OLTC shall conform to IS 8468/IEC 60214 (Part 1& 2). The requirement
of voltage regulation (on HV), location (physical and electrical) of tap
winding, range of voltage variation, no. of steps etc. shall be as given in
Annexure-A.
20.2.1.2 The OLTC shall be of high speed transition resistor type. OLTC shall
be motor operated suitable for local as well as remote operation. The
diverter switch or arcing switch s
20.2.1.3 hall 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 and the chamber shall be designed to withstand
the vacuum. The contacts shall be accessible for inspection without
lowering oil level in the main tank and the contacts shall be replaceable.
20.2.1.4 The voltage class, maximum tapping current, step voltage of OLTC shall
have adequate design margin for safe & reliable service life of both
OLTC and transformer. OLTC shall have long contact life, quick & easy
to disassemble diverter switch inserts, simple to adjust & control and
easy to replace diverter’s contacts etc.

37
20.2.1.5 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.
20.2.1.6 The OLTC oil chamber shall have oil filling and drain valve, oil sampling
valve, relief vent and level glass. Oil sampling valve, 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. Provision
of a suitable device like tie-in-resistor has to be made, wherever
required, to limit the recovery voltage to a safe value. The use of
tie-in-resistor (if used) shall be clearly marked in rating and diagram
plate of the transformer. The whole of the driving mechanism shall be
of robust design and capable of giving satisfactory service without
undue maintenance.
20.2.1.7 Tap changer shall be so mounted that bell cover of transformer can be
lifted without removing connections between windings and tap changer.
20.2.1.8 As an alternative to conventional OLTC with traditional diverter switch

immersed in oil (where arcing takes place in oil), vacuum type OLTC
(where arcing takes place in a hermetically sealed vacuum interrupter)
may also be provided. However, provisions as specified above shall be
followed as far as applicable.
20.2.2 Local OLTC Control Cabinet (Drive Mechanism Box)
20.2.2.1 OLTC shall be suitable for manual (handle operated) and electrical
(motor operated) operation. For local manual operation from Local
OLTC Control cabinet (Drive Mechanism Box), an external handle shall
be provided.
20.2.2.2 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 (preferably at a height less than1800mm). The
mechanism shall be complete with the following:
(a) Mechanical tap position indicator, which shall be clearly visible

near the transformer.
(b) 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.

38
(c) Mechanical stops to prevent over-cranking of the mechanism
beyond the extreme tap positions.
(d) 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.
(e) The manual operating mechanism shall be labelled to show the
direction of operation for raising the voltage and vice-versa.
(f) An electrical interlock to cut-off a counter impulse for reverse step
change being initiated during a progressing tap change, until the
mechanism comes to rest and resets circuits for a fresh position.
20.2.2.3 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 in use. It shall not be
possible for any two controls to be in operation at the same time.
Transfer of source in the event of failure of operating AC supply shall
not affect the tap changer. Thermal device or other means shall be
provided to protect the motor and control circuit.
20.2.2.4 The Local OLTC Drive Mechanism Box shall house all necessary devices
meant for OLTC control and indication. It shall be complete with the
following:
(a) A circuit breaker/contactor with thermal overload devices for

controlling the AC Auxiliary supply to the OLTC motor
(b) Emergency Push Button to stop OLTC operation
(c) Cubicle light with door switch
(d) Anti-condensation metal clad heaters to prevent condensation of
moisture
(e) Padlocking arrangement (or locking arrangement suitable for long
term operation) for hinged door of cabinet
(f) All contactors relay coils and other parts shall be protected against
corrosion, deterioration due to condensation, fungi etc.
(g) The cabinet shall be tested at least IP 55 protection class.
20.2.2.5 In case auxiliary power supply requirement for OLTC Drive Mechanism
(DM) Box is different than station auxiliary AC supply, then all
necessary converters shall be provided.

39
20.2.2.6 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.
20.2.2.7 Limit switches shall be provided to prevent overrunning 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.
20.2.2.8 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 or
provide 4-20mA transducer outputs for tap position indication in
Common Marshalling Box (CMB) (for single phase unit) and input to
digital RTCC/relevant BCU (as applicable)/SCADA system. The tap
position indicator shall also be provided in control room.
20.2.2.9 'Local-remote' selector switch shall be provided in the local OLTC

control cabinet. In Local mode, all electrical commands from remote
(i.e. from CMB, digital RTCC, SCADA, SAS 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
Driving Mechanism (DM) Box. In remote mode electrical commands
from CMB/ digital RTCC/SCADA/SAS etc. shall be executed. The
remote-local selector switch shall be having at-least two spare contacts
per position.
20.2.2.10 The following minimum LED indications shall be provided in DM box:
(a) INCOMPLETE STEP

(b) OLTC motor overload protection operated
(c) Supply to DM Motor fail
(d) OLTC IN PROGRESS
(e) Local / Remote Selector switch positions of DM
(f) OLTC upper/lower limits reached
(g) 415V Main AC supply ON
(h) 415V Standby AC supply ON

40
20.2.2.11 The following minimum contacts shall be available in DM Box and these
contacts shall be further wired to digital RTCC panel/relevant BCU (as
applicable):
(a) INCOMPLETE STEP which shall not operate for momentary loss
of auxiliary power.
(b) OLTC motor overload protection
(c) Supply to DM Motor fail
(d) OLTC IN PROGRESS
(e) Local/Remote Selector switch position
(f) OLTC upper/lower limits reached
20.2.2.12 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. Both ends of all the wires (control & power) connected to
Drive Mechanism Box must be provided with proper ferrule nos. for
tracing and maintenance.
20.2.2.13 A permanently legible lubrication chart and control circuit drawing

shall be fitted within the OLTC local control cabinet.
20.2.3 Remote Control & Monitoring of OLTC
For substations/ pooling stations having Substation Automation

System, Control & monitoring of OLTC shall be carried out through
Substation Automation System. Following functionalities specified for
digital RTCC shall be realised in soft logic in Substation Automation
System. All hardwire signals from/to OLTC shall be wired to Bay
Control Units (BCUs) provided by the owner/contractor, as applicable.
20.2.3.1 The digital RTCC relay shall have Automatic Tap Changer control and
monitoring relay with Automatic Voltage Regulating features to
remotely control and monitor OLTC.
20.2.3.2 Each digital RTCC relay shall be used to control one unit of
transformer. No. of relays including spare relay, if any, shall be
specified by the utility as per requirement.
20.2.3.3 All digital relays can be housed in the BCU panel.
20.2.3.4 Digital RTCC relay shall be microprocessor based adopting the latest
state of the art design & technology with in-built large LCD (or better)
display for ease of programming and viewing. The unit supplied shall
be field programmable so that in the event of change in transformer
41
location, it could be customized to suit site conditions without sending
back to works. The programming shall be menu driven and easily
configurable. If it is designed with draw out type modules, it should
take care of shorting all CT inputs automatically while drawing out. The
CT/VT ratio shall be field programmable and Relay shall display the
actual HV Voltage and current considering suitable multiplying factors.
The system shall be self-sufficient and shall not require any additional
devices like parallel balancing module etc.
20.2.3.5 It shall be possible to communicate/integrate with all digital RTCC

relays of different make located at different locations in the
substation by making hardwire and using IS/IEC 61850
communication link.
20.2.3.6 The digital RTCC relay shall have Raise/Lower push buttons, Manual/
Automatic mode selection feature, Local/Remote selection feature,
Master / Follower/ Independent/ Off mode selection feature for control
of OLTC. Touch screen option in the relay (instead of electrical push
button/switch) is also acceptable.
20.2.3.7 The digital RTCC Relay shall have multiple selectable set point voltages
and it shall be possible to select these set points from SCADA/ SAS,
with a facility to have the possibility of additional set points command
from SCADA/ SAS.
20.2.3.8 In Manual Mode: In this mode, power system voltage based automatic
control from digital RTCC relay shall be blocked and commands shall
be executed manually by raise/lower push buttons.
20.2.3.9 In Auto Mode: In Auto mode, digital RTCC relay shall automatically
control OLTC taps based on power system voltage and voltage set
points. An interlock shall be provided to cut off electrical control
automatically upon recourse being taken to the manual control in
emergency.
20.2.3.10 Master/Follower/Independent/Off mode
Master/Follower/Independent/Off mode is required in Digital RTCC

relay for parallel/group operation of transformers. Master-follower
scheme implies that controlled decision shall be taken by the Master
and control actions (Raise/Lower tap position) shall be executed
simultaneously by Master & Follower units. Same logic needs to be
implemented in digital RTCC relays.

42
Master Position: If the digital RTCC relay 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 digital RTCC relay 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
20.2.3.11 Raise/Lower control: The remote OLTC scheme offered shall have
provision to raise or lower taps for the Transformers.
20.2.3.12 Digital RTCC relays shall communicate with SCADA using IS/IEC
61850 through fibre optic port to monitor, parameterise and control the
OLTC. Any software required for this purpose shall be supplied. The
supplied software shall not have restriction in loading on multiple
computers for downloading and analyzing the data. Software shall
indicate the current overview of all measured parameters of the
connected transformer in real time.
20.2.3.13 Communication between the Digital RTCC relays to execute the

commands for parallel operation shall be implemented using required
communication protocol. Suitable communication hardware shall be
provided to communicate up to distance of 1 km between digital RTCC
relays. Scope shall also include communication cables between digital
RTCC relays. Cables as required for parallel operation of OLTCs of all
transformers (including existing transformers wherever required) from
Digital RTCC relays shall be considered included in the scope.
20.2.3.14 The Digital RTCC relay shall have additional programmable Binary
Inputs (minimum 7 Nos.) and Binary outputs (minimum 7 Nos.) for
future use. It shall be possible to have additional module for Binary
Input / output as well as Analogue input module depending upon
requirement.
20.2.3.15 The relays shall ensure completion of lowering/raising of the OLTC tap,
once the command is issued from the relay. "Step-by-Step" operation
shall be ensured so that only one tap change from each tap changing

43
pulse shall be effected. If the command remains in the "operate"
position, lock-out of the mechanism is to be ensured.
20.2.3.16 The relay shall incorporate an under voltage / over voltage blocking
facility which shall make the control inoperative if voltage falls/ rises
by percentage value of set point value with automatic restoration of
control when nominal voltage rises / falls to value.
20.2.3.17 The relay shall have facility to monitor operating hours of tap changer
and register the tap changer statistics. In the statistics mode, the relay
shall display the no. of tap changing operations occurred on each tap.
20.2.3.18 The relay shall have self-check of power on and shall continually
monitor all functions and the validity of all input values to make sure
the control system is in a healthy condition. Any monitoring system
problem shall initiate the alarm.
20.2.3.19 Following minimum indications/alarms shall be provided in Digital

RTCC relay either through relay display panel or through relay LEDs:
(a) INCOMPLETE STEP alarm
(b) OLTC motor overload protection alarm
(c) Supply to DM Motor fail alarm
(d) OLTC IN PROGRESS alarm
(e) Local / Remote Selector switch positions in DM Box
(f) OLTC upper/lower limits reached alarm
(g) OLTC Tap position indications for transformer units
(h) 415V, AC Mail Supply Fail.
(i) 415V, AC Standby Supply Fail
20.2.3.20 In case of parallel operation, OLTC out of step alarm shall be generated
in the digital RTCC relay for discrepancy in the tap positions.
21.0 SCADA INTEGRATION (if applicable)
All the online monitoring equipment i.e. Optical Temperature Sensors

& Measuring Unit, Online Dissolved Gas (Multi-gas) and Moisture
Analyzer, On-line insulating oil drying system (Cartridge type) etc.
provided for individual transformer, shall be IS/IEC 61850 compliant
(either directly or through a Gateway). These monitoring equipment are
required to be integrated with SAS through managed Ethernet switch
conforming to IS/IEC 61850. This Ethernet switch shall be provided in
IMB. The switch shall be powered by redundant DC supply (as per
available Station DC supply). Ethernet switch shall be suitable for
operation at ambient temperature of 50 Deg C. All required power &
44
control cables including optical cable, patch chord (if any) upto IMB,
all the cables from RTCC to DM and any special cable between IMB to
switchyard panel room/control room shall be in the scope.
However, fiber optic cable, power cable, control cables, as applicable,
between IMB to switchyard panel room/control room and power
supply (AC & DC) to MB and integration of above said IS/IEC-61850
compliant equipment with Substation Automation System may be a
part of sub-station contract.
Cooling and OLTC of transformers shall also be monitored and
controlled from SCADA. List of Signal exchange between Transformer
and SCADA may be mutually agreed between the owner and
manufacturer. Owner/contractor, as applicable, shall ensure provision
of adequate number of redundant Bay control Units (BCUs).
22.0 CONSTRUCTIONAL FEATURES OF COOLER CONTROL CABINET/

INDIVIDUAL MARSHALLING BOX/ OUTDOOR CUBICLE/DIGITAL
RTCC PANEL
22.1 Each transformer unit shall be provided with local OCTC/OLTC Drive
Mechanism Box (DMB), Cooler Control Cabinet/Individual Marshalling
Box, and Digital RTCC panel (as applicable).
22.2 Individual Marshalling Box (IMB) and Cooler Control Box shall be
tank mounted or ground mounted. All cabinets except CMB & Digital
RTCC panel shall be tank mounted. All separately mounted cabinets
and panels shall be free standing floor mounted type and have domed
or sloping roof for outdoor application. The gland plate shall be at least
450 mm above ground level.
22.3 The Cooler Control Cabinet (CCC)/Individual Marshalling Box (IMB) ,

and all other outdoor cubicles (except OLTC Drive Mechanism box)
shall be made of stainless steel sheet of minimum Grade SS 304
and of minimum thickness of 1.6 mm. Digital RTCC panel shall be
made of CRCA sheet of minimum thickness of 2.0 mm and shall be
painted suitably as per Annexure–K.
22.4 The degree of protection shall be IP: 55 for outdoor and IP: 43 for
indoor in accordance with IS/IEC: 60947.
22.5 All doors, removable covers and plates shall be gasketed all around with
suitably profiled. All gasketed surfaces shall be smooth straight and
reinforced if necessary to minimize distortion to make a tight seal. For
45
Control cubicle/Marshalling Boxes etc. which are outdoor type, all the
sealing gaskets shall be of EPDM rubber or any other (approved)
material of better quality, whereas for all indoor control
cabinets/Digital RTCC panel, the sealing gaskets shall be of
neoprene rubber or any other (approved) material of better quality.
The gaskets shall be tested in accordance with approved quality plan
and IS: 3400.
22.6 All the contacts of various protective devices mounted on the

transformer and all the secondary terminals of the bushing CTs shall
also be wired upto the terminal board in the Marshalling Box. All the
CT secondary terminals in the Marshalling Box shall have provision for
shorting to avoid CT open circuit while it is not in use.
22.7 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 controlled
space heater and cubicle lighting with ON-OFF switch shall be provided
in each panel.
23.0 AUXILIARY POWER SUPPLY FOR OLTC, COOLER CONTROL AND

POWER CIRCUIT
23.1 Two auxiliary power supplies of 415 volt, three phase four (4) wire
shall be provided by the Purchaser at Cooler Control Cabinet /
Marshalling Box. All loads shall be fed by one of the two sources
through an electrically interlocked automatic transfer scheme housed
in the Cooler Control Cabinet/Marshalling Box.
23.2 For each circuit, suitably rated power contactors, MCBs/MCCBs as

required for entire auxiliary power supply distribution scheme
including distribution to DM boxes, Online Gases and moisture
monitoring system, Online drying system and Fibre optic sensor Box
etc. (as applicable), shall be provided in cooler control cabinet/
Marshalling Box.
23.3 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
manufacturer/contractor (as applicable). Further any special cable (if
required) from MB to Owner’s Control Panels/Digital RTCC panels is
also in the scope of the manufacturer/contractor (as applicable).

46
23.4 All relays and operating devices shall operate correctly at any voltage
within the limits specified below:
Normal Variation in Frequency Phase/Wire Neutral

Voltage voltage (in Hz) connection
415 V ±10% 50±5% 3 Phase 4Wire Solidly
earthed
240 V ±10% 50±5% 1 Phase 2 Solidly
Wire earthed
220 V 190 V to 240 V DC Isolated 2 wire --
system
110 V 95 V to 120 V DC Isolated 2 wire --
system
48 V -- DC 2 wire system --
(+) earthed
Combine variation of voltage and frequency shall be limited to ±10%.
23.5 Design features of the transfer scheme shall include the following:
a) Provision for the selection of one of the feeder as normal source and
other as standby.
b) Upon failure of the normal source, the loads shall be automatically
transferred after an adjustable time delay to standby sources.
c) Indication to be provided at cooler control cabinet/Individual
Marshalling Box for failure of normal source and for transfer to
standby source and also for failure to transfer.
d) Automatic re-transfer to normal source without any intentional
time delay following re-energization of the normal source.
e) Both the transfer and the re-transfers shall be dead transfers and
AC feeders shall not be paralleled at any time.
24.0 BUSHING CURRENT TRANSFORMER AND NEUTRAL CURRENT

TRANSFORMER
24.1 Current transformers shall comply with IS 16227 (Part 1 & 2)/IEC 61869 (part
1 & 2).
24.2 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.

47
24.3 Current transformer secondary leads shall be brought out to a weather
proof terminal box near each bushing. These terminals shall be wired
out to common marshalling box using separate cables for each core.
24.4 Technical Parameters of Bushing CTs and Neutral CTs are provided at
Annexure–B. The CTs used for REF protection must have the identical
parameters in order to limit the circulating current under normal
condition for stability of protection. Bushing Current Transformer
parameters indicated in this specification are tentative and liable
to change within reasonable limits. Purchaser's approval shall be
obtained before proceeding with the design of bushing current
transformers.
24.5 Secondary resistance and magnetising current characteristics of PX

class (protection) CT of same rating shall be similar. This is applicable
for Neutral CT (outdoor) also and shall be reviewed during detail
engineering.
25.0 TOOLS & TACKLES
Each transformer shall be supplied with a full kit of tools & spanners
of required sizes; bushing handling & lifting tools with nylon rope/belt,
with a rack for holding them; required numbers of hydraulic jacks for
lifting the transformers, and for changing the plane of rotation of
wheels. All spanners shall be single ended and case hardened. Tirfors
with wire rope and slings with grippers etc. for hauling the transformer
to the plinth are to be supplied along with each transformer. Utility may
add/remove tools as per their requirement.
26.0 FITTINGS & ACCESSORIES
The following fittings & accessories shall be provided with each

transformer covered in this specification. The fittings listed below are
not exhaustive and other fittings which are required for satisfactory
operation of the equipment are deemed to be included.
For Transformer:
(a) Conservator for main tank with aircell, oil filling hole and cap,
isolating valves, drain valve, magnetic oil level gauge, prismatic oil
level gauge and dehydrating silica gel filter breather with flexible
connection pipes to be used during replacement of any silica gel
breather.
48
(b) Conservator for OLTC (for transformer) with drain valve, oil surge
relay, filling hole with cap, magnetic oil level gauge, prismatic oil
level gauge and dehydrating breather (for transformer only) with
flexible connection pipes to be used during replacement of any
silica gel breather.
(c) Pressure relief devices with special shroud to direct the hot oil
(d) Sudden pressure relief relay (for 220 kV and above Transformer)
(e) 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.
(f) Conservator air cell rupture detection relay
(g) Air release plug
(h) Inspection openings and covers
(i) Bushing of each type with metal parts and gaskets to suit the
termination arrangement
(j) Winding & Oil temperature indicators (local & remote)
(k) Cover lifting eyes, transformer lifting lugs, jacking pads, towing
holes and core and winding lifting lugs
(l) Protected type alcohol in glass thermometer or magnetic or micro-

switch type dial type temperature indicator as applicable (mercury
should not be used)
(m) Rating and diagram plates (in English & Hindi or as specified by
the utility) on transformers and auxiliary apparatus
(n) Roller Assembly (flanged bi-directional wheels)
(o) One complete set of all metal blanking plates & covers
(p) On load tap changing gear, OLTC/Off Circuit Tap Changer (OCTC)
DM Box, individual marshalling box, Cooler control cabinet, and
Digital RTCC Panel as applicable
(q) Cooling equipment including fans & pumps (as applicable)

49
(r) Bushing current transformers, Neutral CT (if applicable)
(s) Oil/water flow indicators (if applicable)

(t) Terminal marking plates
(u) Valves schedule plate
(v) Bottom oil sampling valve, Drain valves (provided to drain each
section of pipe work independently), Filter valves at top and
bottom with threaded male adaptors, Shut off valves on the pipe
connection between radiator bank & the main tank, Shut off
valves on both sides of Buchholz relay, Sampling gas collectors for
Buchholz relay at accessible height, Valves for Radiators, Valve
for vacuum application, Valves for cable box (if applicable), Valve
for on line DGA (if applicable), valves for Drying out system (if
applicable), Flow sensitive Conservator Isolation Valve (if
applicable), Gate Valve (4 Nos. of min. 50 NB) for UHF sensors for
PD Measurements (applicable for 400kV voltage class
Transformer only), valves for firefighting system (as applicable)
and other valves as specified in the specification.
(w) Ladder (suitably placed to avoid fouling with bushing or piping) to

climb up to the transformer tank cover with suitable locking
arrangement to prevent climbing during charged condition.
Additional ladder for conservator in case it is not tank mounted .
(x) Suitable platform for safe access of flow sensitive non-return valve
and buchholz relay shall be provided, in case these are not
accessible from transformer top.
(y) Haulage/ lifting lugs
(z) Suitable terminal connectors on bushings
(aa) Suitable neutral bus connection

(bb) Suitable terminal connectors of surge arrester for NGR
(cc) Brass/tinned copper grounding bar supported from the tank by

using porcelain insulator and flexible conductor for earthing of
neutral, HV & LV terminals as per specification
(dd) Oil Sampling Bottle & Oil Syringe (if specified)
27.0 INSPECTION AND TESTING

50
The manufacturer shall draw up and carry out a comprehensive
inspection and testing programme in the form of detailed quality plan
duly approved by Purchaser for necessary implementation during
manufacture of the equipment. Details regarding Quality Assurance
Programme covering quality assurance, inspection and testing have
been covered in Chapter-4: Quality Assurance Programme.
28.0 DRAWINGS/DOCUMENTS/CALCULATIONS
The list of drawing/documents/calculations to be submitted by the

manufacturer is given in Annexure-H.
All utilities are advised to digitalize drawing approval process to

speed up drawings & MQP submittals, comments, re-submittals
and final approval.
29.0 RATING & DIAGRAM PLATE
The transformer shall be provided with a rating plate of weatherproof

material, fitted in a visible position, showing the appropriate items
indicated below. The entries on the plate shall be in English in indelibly
marked.
Information to be provided on the plate:
For Transformer:
Manufacturer's name, country and city where the transformer was
assembled
MVA Rating, Voltage ratio, Type of transformer (for example 315MVA
400/220/33kV Auto Transformer)
Type of Cooling Applicable Standard
Rated Power at Rated frequency Hz
different cooling
HV MVA --/-- Number of phases
/--
LV (for single LV MVA % Impedance / Ohmic
winding) / (LV1 & Impedance
LV2) for two LV
windings

51
Rated Voltage (a) HV-LV*
HV kV Min. tap %
Tertiary winding kV Principal Tap %
Voltage (if
applicable)
LV(for single LV kV Max. Tap %
winding) / (LV1 &
LV2) for two LV
windings
Rated Current (b)
HV A (c)
LV (for single LV A Vector Group
winding)
(LV1 & LV2) for A Core mass Kg
two LV windings
Rated Thermal kA Copper Mass
Short Circuit (sec)
withstand
capability Current
and Duration
Basic Insulation (a) HV Kg
Level (Lightening
Impulse/Switching
Impulse/Power
Frequency
Withstand Voltage)
HV kVp/ (b)
kVp/
kVrms
Tertiary winding kVp/ (c) LV* Kg
kVp/
kVrms
LV (for single LV kVp/ (d) Regulating Kg
winding) / (LV1 &

52
LV2) for two LV kVp/
windings kVrms
Neutral kVp/ Core & Coil Mass Kg
kVp/
kVrms
Guaranteed Transportation Mass Kg
Temperature rise
over ambient
temperature of 50
Deg. C
(a) Top Oil 0C Tank & Fitting mass
(b) Winding 0C Type & total mass of Kg
insulating oil
Vacuum withstand mm of Total mass Kg

Capability of the Hg
tank
OLTC make and Quantity of oil in OLTC Ltrs
rating (current &
Voltage class)
Noise level at rated dB Transformer oil Ltrs
voltage and at Quantity
principal tap
Tan delta of Paint Shade
winding
Moisture content ppm No load loss at rated KW
voltage & frequency
Manufacturer’s Load loss at rated KW
Serial number current & frequency (at
750C) for HV & LV
winding
Year of
manufacture

53
Work Order No. Auxiliary loss at rated KW
voltage & frequency
Purchaser’s Order
No. & Date
OGA Drg. No.
Vector Group Diagram
Winding Connection diagram
(Connection between all windings including tap windings, ratings of built-
in current transformers, etc. shall be presented on the diagram)
Table giving details of Tap Chnager like tap position Nos. and
corresponding tapping voltage, tapping current & connection between
terminals for different tap positions etc.
Details of Current Transformers (e.g. Bushing CTs, CT for WTI) installed
in transformer like the location, core Nos., ratio(s), accuracy class, rated
output (VA burden), knee point voltage, magnetizing current, maximum
CT secondary resistance, terminal marking and application of the current
transformer
Warning: “Main conservator is fitted with an air cell”
Tie-in-resistor has been used in OLTC (if applicable)
Purchaser’s Name
When a transformer is intended for installation at high altitude, the

altitude, power rating and temperature rise at that altitude shall be
indicated on the nameplate.
Plates with identification and characteristics of auxiliary equipment

according to standards for such components (bushings, tap-changers,
current transformers, cooling equipment etc.) shall be provided on the
components themselves.
30.0 RESPONSIBILITIES OF MANUFACTURER AND UTILITY/ USER

DURING WARRANTY PERIOD OF TRANSFORMER :
30.1 The long term performance of transformer depends on

design/technology, quality of material used, robustness & consistency
of manufacturing process, installation, operation and maintenance etc.
54
The erection, testing and commissioning of transformer shall be
performed under strict supervision of representative of OEM and
provisions specified in Chapter 5– Transportation, erection, testing
& commissioning shall be followed.
30.2 Transformer failure generally follows the Bathtub Curve as shown

below:
30.3 As can be seen from the Bath Tub curve, the “Infant mortality” failures,
which are caused due to manufacturing related defects/issues that
occur in the first few years of service (say 1 or 2 years). But continued
successful operation of transformer primarily depends on operating
conditions and O&M practices being followed by utilities. Improper
maintenance or negligence on the part of user e.g. non-replenishment
of saturated silica gel, non-release of air trapped after air-cell
commissioning, oil seepages, lack of routine maintenance, failure to
check tan-delta & capacitance of winding and bushing, absence of
thermal scanning of terminal interfaces, lack of DGA monitoring etc.,
can also lead to serious consequences. It can therefore be said that the
responsibility of manufacturer and maintenance & monitoring
obligations of the end user are equally important for a long and trouble
free service life of transformer. Moreover, any abnormality observed
during operation needs to be addressed immediately. The transparency
in sharing of information, mutual co-operation and discussion on

55
issues/problems between user and manufacturer are the only way to
resolve many of these problems. The manufacturer can take this as an
opportunity to understand the issues and can improve on the design &
manufacturing practices. Similarly, the utility has the opportunity to
understand the deficiency from their side and should rectify/try to
improve on their actions as a responsible user. There is no single
conclusive test based on which utility should take drastic steps
regarding replacement/rejection of component/equipment.
30.4 The utilities should create their maintenance plans so that they adhere
to the recommended O&M procedures of the OEMs.
30.5 When failures or operational problems occur within the warranty

period, the manufacturer must take all necessary measures to help
minimize operational difficulties and outages whenever possible. The
following abnormalities should be brought to the notice of
manufacturer and the manufacturer shall respond/ attend
immediately, investigate and rectify the problem or advise the utility for
further course of action.
a) Fault inside the transformer and OLTC (including oil migration)

involving a shutdown of transformer at site after commissioning is
to be attended by manufacturer immediately. It is the responsibility
of the OEM to take immediate necessary action (e.g. any
replacement/repair of component required with co-ordination from
any third party, if required) for bringing back the transformer into
service. The root cause analysis shall be undertaken by OEM and
details shall be shared with utility for the benefit of both user and
OEM.
b) In case of DGA Status 3 (as per IEEE-C57.104) i.e. the concentration

of any fault gas is exceeding the values in Table -2 of IEEE-C57.104
(Refer Chapter 6 of the document) or the abnormal trend in variation
of key fault gases is observed, the utility should immediately consult
OEM for advice and for further course of action.
The transformer with DGA Status-3 does not necessarily give any
conclusive information regarding health of transformer or indicate
that transformer is faulty. It can only be concluded that its
behaviour is somewhat unusual and warrants additional
investigation and/or precautions. The transformer should be placed
under increased surveillance. Other diagnostic tests should also be
conducted to supplement the DGA for taking further course of action
in consultation with manufacturer.
56
c) In case, the winding tan delta goes beyond 0.005 or increases more
than 0.001 per annum w.r.t. pre-commissioning values, the utility
is to inform manufacturer for advice and for further course of action.
d) In case, the tan delta of bushing(s) goes beyond 0.005 or increases

more than 0.001 per annum w.r.t. pre-commissioning values when
measured in the temperature range of 10°C to 40°C (If tan delta is
measured at a temperature beyond above mentioned limit,
necessary correction factor as per IEEE shall be applicable.), the
utility is to inform manufacturer for advice and for further course of
action.
e) In case, the moisture content goes above 10 ppm at any temperature

during operation including full load, the utility is to inform
manufacturer for advice and for further course of action.
f) Any major deviation in Sweep Frequency Response Analysis (SFRA)

should be brought to the notice of manufacturer for advice and for
further course of action.
g) Leakage of Oil from transformer shall be construed as a serious

quality lapse on the part of the Original Equipment Manufacturer
(OEM). No leakage of oil is expected during the operating life of the
transformer and that should be ensured accordingly by OEM during
design & construction of tank & other gasketted joints. In case of
any leakage of oil during warranty period, the same shall be reported
in writing to the OEM immediately and OEM shall have to attend
and rectify the leakage within a period of 30 days from the date of
notice, at the cost of the OEM.
h) The utility shall carryout all diagnostic tests just before completion
of warranty period to ensure the healthiness of transformer and any
abnormality in test results shall be informed to the manufacturer
for immediate action and advice.
31.0 PHYSICAL INTERCHANGEABILITY OF TRANSFORMER OF

DIFFERENT MAKE
Block foundation shall be adopted to facilitate the physical inter-

changeability of transformers of different make on same foundation
thereby the outage time of replacement of spare/new transformer
would be minimized. The design shall take into account the provision

57
of soak pit and oil collecting pit for transformer. The details are given
at Annexure-N.
32.0 LIST OF CODES/ STANDARDS/ REGULATIONS/ PUBLICATIONS
The list of Codes/Standards/Regulations/Publications which are

generally used for manufacturing, testing, installation, maintenance,
operation etc. of transformer is given at Annexure-P.

58
CHAPTER-2
DESIGN REVIEW
1.0 Introduction
Design Review is a planned exercise to ensure both parties to the

contract- manufacturer and purchaser- understand the application,
purchaser specifications, applicable standards and Guaranteed
Technical Particulars (GTP) furnished by vendor. It is a scrutiny of design
(specific aspects of the electrical, mechanical and thermal design),
materials & accessories and manufacturing processes so as to ensure
that offered guaranteed technical particulars, are thoroughly met to
ensure quality and reliability. The exercise broadly facilitates and
emphasize the following:
 Manufacturer understands the application, project requirement, the

purchaser’s technical requirement, and specifications to ensure that
the design meets / complies those requirements.
 Purchaser understands that manufacturer uses proven materials,

design tools, methodology and experience to assure that the product
will meet purchaser’s requirement in all respect.
 Identify any new (prototype) features introduced by manufacturer

and evaluate their reliability and risks.
 To understand relevant design margins (calculated design withstand

strength versus stress during tests and long service) to meet test
requirements and life time performance as per manufacturer’s design
practice and experience.
 A good opportunity for a clear & mutual understanding and to

exchange experiences that can be used to improve the current design
and future specifications.
 Allow the purchaser to have clear understanding of the design,

technical capabilities, experience of manufacturer and the
manufacturing & testing facilities of manufacturer.
 Clarifications of various tests and mutual agreement on method of

tests and special acceptance of tolerance (e.g. Wave shape of impulse
wave, connection for switching surge test etc.).
Chapter-2: Design Review Page 1 of 7

 Mutual agreement between the purchaser & the manufacturer for the
confidentiality of information, which are proprietary in nature.
 Transportability to site. Any constraint and stringent limitation is to

be highlighted, if any.
 Service conditions. If any abnormal service condition exists customer

has to point out.
2.0 Stages of Design Review (DR)
Design Review (DR) may be required at following stages depending on the

nature of contract:
(A) Pre-Tender Design Review
 Technical capability and manufacturing experience of vendor
 Factory capability assessment by buyer as required (CIGRE TB 530:

Guide for conducting Factory Capability Assessment for Power
Transformers can be a good reference )
(B) Tender Stage Design Review –Technical Evaluation of offer
 The bidder has to comply with the parameters provided in the

specification/document. Deviation, if any, shall be clearly brought
for the information of the purchaser. The purchaser shall scrutinize
the deviations in line with the technical & commercial requirement
and shall evaluate the bid accordingly.
(C) Contract Design Review
The design review shall be carried out for the offered design of
transformer under the scope and Manufacturer shall submit all design
documents and drawings required for the purpose.
 Purchaser in consultation with the manufacturer shall carry out

Design Review (DR) of parts and accessories (make, model,
specifications for bushing, tap-changer, instruments etc.) as per
technical requirements and specifications for enabling the
manufacturer to order key raw materials and major accessories.
 Review of the electrical design including dielectric, losses, short

circuit, noise and thermal performance and mechanical layout
design including lead routing and bushing termination after route

survey (if any) shall be carried out for enabling the manufacturer to
order key raw materials and major accessories.
 Typical data/parameters indicated in the Annexure-C shall be filled

by the manufacturer and reviewed by the purchaser during design
review.
 Examination of all relevant type test reports of transformers

including its fitting and accessories.
 Checking of drawings and documents for the scope listed in

Annexure-I.
3.0 Mode of Design review
 Design review is initiated by purchaser or appointed representative.

Purchaser should ensure that those participating representative in
the review on his behalf have the necessary expertise to understand
and evaluate the design and production considerations under the
proposal.
 Minutes of design review will be part of contract documents, but the

discussions and information exchanged during design review
process shall be kept confidential and purchaser or appointed
representative shall not disclose or share design review details to
anyone without written consent of Original Equipment
Manufacturer (OEM).
 After completion of design review, a summary report indicating list

of items with actions required to be taken is to be sent to
manufacturer for correction and inclusion of any omissions.
 Purchaser may also visit the manufacturer’s works to inspect

design, manufacturing and test facilities at any time.
 Manufacturer, if desired by purchaser, should give in advance

sufficient design data to purchaser to prepare for the design review
meetings.
 “Guidelines for conducting design reviews for transformers”

CIGRE Technical Brochure 529-2013 may be followed. The
document/brochure broadly covers the following:
 The manufacturer should demonstrate how their design will

function reliably within the operating requirements including

transient conditions and meet the performance guarantees and
present evidence of calculations/analysis performed in order to
ensure that the specified requirements will be met.
 The manufacturer should describe the core design, explaining

how it will perform within the operating parameters. Core flux
density at rated and maximum voltage and frequency shall be
reviewed with special reference to the maximum permissible limit
to avoid overfluxing in any part of the core assembly including
magnetic shunts and safety margins for the particular core
construction type employed.
 The manufacturer should describe each of the windings in

sufficient detail to provide a clear understanding of the physical
arrangements.
 The manufacturer should demonstrate how the insulation is

designed to withstand the imposed stresses, i.e. indicate
insulation structure, corresponding stress and resultant
dielectric strength, including safety factors (margins).
 The manufacturer will provide a list of the make and type of

insulating materials used for the windings, leads and supports.
 The manufacturer should describe how the windings will be

adequately cooled.
 The manufacturer should present a description of the thermal

model of the windings and a summary of the calculated
temperatures for the various specified ratings/loading, including
any overload and cooling conditions. The calculation of hot spot
temperatures of the tank, core etc. to be discussed and
demonstrate their experience by using 2D or 3D electro-thermal
calculation using Finite-Element Method (FEM) etc.
 The manufacturer should demonstrate the ability to withstand

the electromagnetic forces and the thermal stresses produced
during the flow of a short-circuit current without damage.
 The manufacturer should describe the general assembly and

mechanical features for the core mechanical construction, coil
clamping including the clamping pressure used for sizing and
providing short circuit withstand capability and maintenance of
winding compression during coil drying, core drying and
assembly.

 The manufacturer will describe their methods for moisture
removal from the insulation ensuring the design dimensions of
the coils are achieved and moisture content is <0.5%.
 The manufacturer should describe the arrangements used for the

winding leads and interconnections.
 The manufacturer should describe how they achieve the control

of the leakage flux outside core and coils assembly, including Type
of shielding (collectors, rejectors), design and materials used.
 The manufacturer and customer should have a mutual and clear

understanding for the requirements for the sound level. Accurate
calculation of core & tank resonance frequencies allows accurate
prediction of the noise level at the design stage and later avoids
serious noise level problems later.
 The manufacturer should provide general construction including

tank details, details of gaskets, location of manholes & PRD,
external cooling system, conservator/preservation system,
provision for fire protection system etc.
 The intended shipping process should also be reviewed.
4.0 Calculation of Losses, weight of core and current density of winding

conductor
For the benefit of the utility the formula for calculation of No-Load loss
and Load loss, weight of core and current density of winding conductor
has been provided below. In addition, a typical example of calculation of
flux density, core quantity/ weight, no-load loss and weight of copper
has been provided in Annexure-F.
Calculation of no-load losses:
 No-Load losses = core loss in W/kg corresponding to flux density

as per lamination mill test report (extrapolated) x net weight of core
x building factor
 Flux density (T) = rated voltage (v) x104/ (4.44 x no. of turns x net
core area (cm2) x frequency (Hz))
 Net core area = [{0.785x (nominal core diameter)2 x filling factor}-

area of cooling duct, insulation] x space factor

 Building factor = extra loss factor over the test report value due to
handling and fabrication stress (>1)
 Space factor = Reduction factor (depends on thickness) to take care

of the insulation provided over the laminations (<1)
 Filling factor = per unit area occupied by core material in the

nominal core circle area (<1)
 Nominal diameter of core = diameter of circle touching the corners

of lamination steps
Calculation of load-losses at reference temperature & principal tap

position:
 Load loss at principal tap = I2R loss + Winding Eddy loss + Structural
stray losses
 I2R loss = Resistance at 75°C x (phase current)2 x no. of phases
 Resistance (R)= Resistance of winding (RW) + Resistance of leads (RL)
RW = W x D x π / (k x S)
RL = L / (k x S)
Where,
W= Number of turns
D= mean winding diameter
S= cross section area of all parallel conductor
K= Electrical conductivity of conductor/leads for reference
temperature of 75°C.
L= Length of lead
Winding eddy losses = Estimated from empirical formulae or

electromagnetic software
Structural stray losses = Estimated from empirical formulae or

electromagnetic software.
Calculation of weight of core:
Weight of core = (Total periphery of core) x (net core area) x (density of

CRGO material)

Calculation of current density of winding conductor:
Current density = A/S

Where A= Current in winding for specified tap position
S= (Cross-sectional area of the individual conductor) x (no. of parallel
conductor)
[The individual conductor area needs to be adjusted for corner radius as

per IS 13730 (part 27)]
5.0 References:
(a) CIGRE Technical Brochure No. 529 -2013 Guide lines for
conducting design reviews for Power Transformers
(b) CIGRE Technical Brochure No. 673-2016 Guide on Transformer
Transportation
(c) IEEE Standard C57.156-2016 Guide for tank rupture mitigation
of oil immersed transformers
(d) CIGRE Technical Brochure No. 530-2013 Guide for conducting
factory capability assessment for Power Transformers
(e) IEEE Standard C57.150-2012 Guide for Transformer
Transportation
(f) IS 2026 Power Transformers-Part 5 Ability to withstand short
circuit

CHAPTER- 3
QUALITY ASSURANCE PROGRAMME
1.0 INTRODUCTION
The best way to achieve continuous improvement in quality in any

manufacturing organization is to develop a quality plan and the
persons responsible for quality implementation should religiously
follow the defined quality plan.
Quality of a transformer/reactor can be improved by taking

effective steps at the initial stage itself which include ‘use of high
quality raw materials’ and ‘improved manufacturing processes’. It
is needless to mention that the performance of a
transformer/reactor largely depends on the excellence of design.
However, all good designs may not yield good end products unless
they are well supported by good materials, good and healthy
machines and skilled workmen (operators)/ workmanship.
To ensure that the equipment and services are in accordance with

the specifications, the transformer/reactor manufacturer shall
adopt suitable Quality Assurance Programme (QAP) to control
such activities at all points, as necessary. Such programmes shall
be outlined by the manufacturer and shall be finally accepted by
the Purchaser or its authorised representative after discussions.
The Quality Assurance programme shall be generally in line with
latest ISO-9001 (Quality Management System), ISO-14001
(Environmental Management System) and OHSAS 18001
(Occupational Health and Safety Management System). A Quality
Assurance Programme of the manufacturer shall generally cover
the following:
a) Organisation structure for the management and

implementation of the proposed Quality Assurance
Programme
b) Quality System Manual
c) Design Control System
d) Documentation Control System
e) Qualification and experience data for key Personnel
f) The procedure for purchase of materials, parts, components
and selection of sub-supplier’s services including vendor
analysis, source inspection, incoming raw material
inspection, verification of materials purchased etc.
g) List of manufacturing facilities available
h) Level of automation achieved and list of areas where manual
processing exists
Chapter-3: Quality Assurance Programme Page III-1

i) List of areas in manufacturing process, where stage
inspections are normally carried out for quality control and
details of such tests and inspections.
j) System for shop manufacturing and site erection control
including process controls and fabrication and assembly
controls
k) System for Control of non-conforming items and for corrective
& preventive actions based on customers’ feedback.
l) Inspection and test procedure both for manufacture and field
activities
m) System for Control of calibration of testing and measuring
equipment and the indications of calibration status on the
instrument
n) System for Quality Audits
o) System for indication and appraisal of inspection status
p) System for authorising release of manufactured product to
the Purchaser
q) System for handling storage and delivery
r) System for maintenance of records
s) Furnishing of quality plans for manufacturing and field
activities detailing out the specific quality control procedure
adopted for controlling the quality characteristics relevant to
each item of equipment/component
t) System of various field activities i.e. unloading, receipt at site,
proper storage, erection, testing & commissioning
The manufacturer shall use state-of-the-art technology and dirt,

dust and humidity controlled environment during various
processes of manufacturing and testing to ensure that end product
is of good quality and will provide uninterrupted service for
intended life period. All manufacturers, are expected to develop
their manufacturing facility at par with the leading manufacturers
with best global practices. An indicative list for facilities needed
to be available at manufacturer’s works has been provided at
Annexure-G. In case the manufacturers do not have the
required facilities as given in Annexure-G, it may be ensured
by the manufacturers that the same shall be made available
and put into use within two years of release of this document.
2.0 GENERAL REQUIREMENTS - QUALITY ASSURANCE
2.1 All materials, components and equipment required for

transformer/reactor manufacturing shall be procured,
manufactured, erected, commissioned and tested at all stages, as
per a comprehensive Quality Assurance Programme, the detailed
Quality Plans for manufacturing and field activities shall be drawn
up by the manufacturer/ contractor (as applicable) and will be
submitted to Purchaser for approval.

2.2 Manufacturing Quality Plan will detail out for all the components
and equipment, various tests/inspection, to be carried out as per
the requirements of purchaser specification and standards
mentioned therein and quality practices and procedures followed
by Manufacturer’s/Sub-supplier’s/Sub-supplier's Quality Control
Organisation, the relevant reference documents and standards,
acceptance norms, inspection documents raised etc., during all
stages of materials procurement, manufacture, assembly and final
testing/performance testing. The Quality Plan shall be submitted
to purchaser, for review and approval. Typical Manufacturing
Quality Plan (MQP) is provided at Annexure-E for reference. Any
change in practice or acceptance norms (with reference to various
tests / parameters in respective National / International standard)
would be suitably incorporated by manufacturer from time to time
and submit the same for approval of purchaser / utility.
2.3 List of testing equipment available with the manufacturer for

stage/final testing of transformer/reactor and test plant limitation,
if any, for the acceptance and routine tests specified in the relevant
standards shall be furnished by the manufacturer. These
limitations shall be very clearly brought out in 'The schedule of
deviations' for specified test requirements.
2.4 The transformer/reactor manufacturer, along with Quality Plans,

shall also furnish copies of the reference documents/plant
standards/acceptance norms/tests and inspection procedure etc.,
as referred in Quality Plans. These Quality Plans and reference
documents/standards etc. will be subject to Purchaser’s approval
without which manufacturer shall not proceed. These approved
documents shall form a part of the contract. In these approved
Quality Plans, Purchaser shall identify Customer Hold Points
(CHP), i.e. test/checks which shall be carried out in presence of
the Purchaser’s authorised representative and the work will not
proceed without consent of Purchaser in writing. All deviations to
approved quality plans and applicable standards must be
documented and referred to Purchaser along with technical
justification for approval and dispositioning.
2.5 All material used for equipment manufacture shall be of tested

quality as per relevant codes/standards. Details of results of the
tests conducted to determine the mechanical properties; chemical
analysis and details of heat treatment procedure, if any and
actually followed shall be recorded on certificates and time
temperature chart, as applicable. Tests shall be carried out as per
applicable material standards and/or agreed details.
2.6 No material shall be despatched from the manufacturer’s works

before the same is accepted, subsequent to pre-despatch final
inspection including verification of records of all previous

tests/inspections by Purchaser’s authorised representative and
duly authorised for despatch.
2.7 The manufacturer shall list out all major

items/equipment/components to be manufactured in house as
well as procured from sub-supplier. All the sub-suppliers proposed
by the manufacturer for procurement of major bought out items
including castings, forging, semi-finished and finished
components/equipment etc., list of which shall be drawn up by the
manufacturer and finalized with the Purchaser and shall be
subject to Purchaser's approval. The manufacturer’s proposal shall
include vendor’s facilities established at the respective works, the
process capability, process stabilization, quality systems followed,
experience list, etc. along with his own technical evaluation for
identified sub-suppliers enclosed and shall be submitted to the
Purchaser for approval in sufficient time so as not to impede the
progress of work on the facilities.
2.8 For components/equipment procured by the manufacturer for the

purpose of the contract, after obtaining the written approval of the
Purchaser, the manufacturer’s purchase specifications and
inquiries shall call for quality plans to be submitted by the
suppliers. The quality plans called for from the sub-suppliers shall
set out, during the various stages of manufacture and installation,
the quality practices and procedures followed by the vendor’s
quality control organisation, the relevant reference
documents/standards used, acceptance level, inspection of
documentation raised, etc. Such quality plans of the successful
vendors shall be finalised with the Purchaser and such approved
Quality Plans shall form a part of the purchase order/contract
between the manufacturer and sub-suppliers.
2.9 Purchaser reserves the right to carry out quality audit and quality
surveillance of the systems and procedures of the manufacturer’s
or their sub-supplier’s quality management and control activities.
The manufacturer shall provide all necessary assistance to enable
the Purchaser carry out such audit and surveillance.
2.10 The manufacturer shall carry out an inspection and testing

programme during manufacturing in his work and that of his sub-
supplier and at site to ensure the mechanical accuracy of
components, compliance with drawings, conformance to functional
and performance requirements, identity and acceptability of all
materials parts and equipment. Manufacturer shall carry out all
tests/inspection required to establish that the items/equipment
conform to requirements of the specification and the relevant
codes/standards specified in the specification, in addition to
carrying out tests as per the approved quality plan.

2.11 Quality audit/surveillance/approval of the results of the tests and
inspection will not, however, prejudice the right of the Purchaser
to reject the equipment if it does not comply with the specification,
when erected or does not give complete satisfaction in service and
the above shall in no way limit the liabilities and responsibilities of
the manufacturer in ensuring complete conformance of the
materials/equipment supplied to relevant specification, standard,
data sheets, drawings (approved by the Purchaser), and minutes
of various meetings with customer / Purchaser etc.
2.12 Any repair/rectification procedures to be adopted to make the job

acceptable shall be subject to the approval of the
Purchaser/authorised representative.
2.13 The Manufacturer / Sub-suppliers shall carry out routine test on

100% item at manufacturer / sub-supplier's works. The quantum
of check / test for routine & acceptance test by purchaser shall be
generally as per criteria / sampling plan defined in referred
standards. Wherever standards have not been mentioned quantum
of check / test for routine / acceptance test shall be as agreed
during detailed engineering stage.
2.14 The manufacturer/ contractor (as applicable) shall submit to the

Purchaser Field Welding Schedule for field welding activities (if
applicable) along with all supporting documents, like welding
procedures, heat treatment procedures, Non-Destructive Test
(NDT) procedures etc. before schedule start of erection work at site.
2.15 Transformer/reactor manufacturer shall also provide Field

Quality Plans that will detail out for all the equipment, the quality
practices and procedures etc. to be followed by the manufacturer’s
representative or authorised agency, during various stages of site
activities starting from receipt of materials/equipment at site till
commissioning.
2.16 All welding and brazing shall be carried out as per procedure
drawn and qualified in accordance with requirements of ASME
Section IX/BS-4870 or other International equivalent standard
acceptable to the Purchaser. All welding / brazing procedures
adopted/used at shop, will be made available to purchaser during
audit / inspection. Procedures to be adopted at site will be
submitted to purchaser for approval.
2.17 All brazers, welders and welding operators employed on any

part of the contract either in Manufacturer’s/his sub-
supplier’s works or at site or elsewhere shall be qualified as
per ASME Section-IX or BS-4871 or other equivalent
International Standards acceptable to the Purchaser.

2.18 Any of the offered software, if applicable shall not of β-version and
be also free from all known bugs and should be with cyber security
certificate.
3.0 QUALITY ASSURANCE DOCUMENTS
3.1 The manufacturer shall be required to submit the QA

Documentation in hard copies and DVD ROMs/Pen Drive
containing soft copy, as identified in respective quality plan.
3.2 Each QA Documentation shall have a project specific Cover Sheet

bearing name & identification number of equipment and including
an index of its contents with page control on each document. The
QA Documentation file shall be progressively completed by the
manufacturer’s sub-supplier to allow regular reviews by all parties
during the manufacturing.
3.3 Typical contents of QA Documentation is as below:-
a) Quality Plan for various components and accessories. A

typical quality plan for key components of transformer is
provided at Annexure-E.
b) Material mill test reports on components as specified by the
specification and approved Quality Plans.
c) Manufacturer’s works test reports/results for testing required
as per applicable codes and standard referred in the
specification and approved Quality Plans.
d) Non-destructive examination results/reports including
radiography interpretation reports. Sketches/drawings used
for indicating the method of traceability of the radiographs to
the location on the equipment.
e) Heat Treatment Certificate/Record (Time- temperature Chart),
if any.
f) All the accepted Non-conformance Reports
(Major/Minor)/deviation, including complete technical details
/repair procedure).
g) Customer Hold Points (CHP)/Inspection reports duly signed
by the Inspector of the Purchaser and Manufacturer for the
agreed Customer Hold Points.
h) Certificate of Conformance (COC) wherever applicable.
i) Material Dispatch Clearance Certificate (MDCC)
3.4 Similarly, the manufacturer/contractor (as applicable) shall be

required to submit hard copies and DVD/ Pen Drive containing soft
copy, containing QA Documentation pertaining to field activities as
per Approved Field Quality Plans and other agreed manuals/
procedures, prior to commissioning.

3.5 Before offering for Factory Acceptance Test of any equipment, the
Supplier shall make sure that the corresponding quality document
or in the case of protracted phased deliveries, the applicable
section of the quality document file is completed. The supplier will
then notify the Inspector regarding the readiness of the quality
document (or applicable section) for review:
a) If the result of the review carried out by the Inspector is

satisfactory, the Inspector shall stamp the quality document (or
applicable section) for release.
b) If the quality document is unsatisfactory, the Supplier shall
endeavour to correct the incompleteness, thus allowing to
finalize the quality document (or applicable section) by time
compatible with the requirements as per contract documents.
When it is done, the quality document (or applicable section) is
stamped by the Inspector.
Note:- The word ‘Inspector’ shall mean the authorised representative

and/or an outside inspection agency acting on behalf of the
purchaser to inspect and examine the materials and workmanship
of the works during its manufacture or erection.
4.0 QUALITY DURING INSPECTION & TESTING (including virtual

inspection) AND INSPECTION CERTIFICATES
4.1 Inspection, audit, assessment, test measurement and comparison

all describe the same phenomena of examining carefully to some
established criteria. Inspector should be prepared with the
following documents:
a) Contract documents together with technical specifications
b) Basic guideline regarding the scope of inspection
c) Approved drawings and reference standards (ISS/IEC/BS etc.)
d) Previous inspection reports of transformers of similar rating (if
available)
e) Type test certificates (if already conducted).
4.2 The Inspector shall have access at all reasonable times to inspect
and examine the materials and workmanship of the works during
its manufacture or erection and if part of the works is being
manufactured or assembled on other premises or works, the
Manufacturer shall obtain for the Inspector permission to inspect
as if the works were manufactured or assembled on the
Manufacturer’s own premises or works.
4.3 The Manufacturer shall give the Inspector ten (10) days written
notice of any material being ready for testing. Such tests shall be
to the Manufacturer’s account. The Inspector, unless the
witnessing of the tests is virtually waived and confirmed in writing,

will attend such tests within ten (10) days of the date on which the
equipment is noticed as being ready for test/inspection.
4.4 Virtual Stage inspection & Factory Acceptance Test (FAT)
The conventional practice of witnessing Stage inspection and

Factory Acceptance Test (FAT) of transformers and reactors as per
technical specification of the utility/purchaser requires physical
presence of utility’s/purchaser’s representative/inspector at
manufacturer’s works and involves considerable co-ordination
efforts and planning by both utility/purchaser and manufacturers,
especially in special situations like Covid-19 pandemic. The self-
certification/waiver of FAT is not desirable. Under the situation like
Covid-19 or if there is mutual agreement between the
manufacturer & the utility/purchaser, manufacturer can offer
virtual stage inspection or FAT or both, with similar
experience/confidence as on-site witness, as an alternative to
conventional method.
4.4.1 The resources required for virtual inspection/testing:
The following resources should form part of virtual

inspection/testing:
(a) High speed Wi-Fi Internet
(b) Necessary electronic devices like Mobiles, Tabs or iPads,

portable cameras, computers for test equipment or
instruments, Conference call setup with laptop, cameras in
test lab and test bay for clear view of the test bay as well as
transformer/reactor under test, connection leads and
measuring equipment etc. For better clarity and transparency,
wherever possible, screens of computers for test equipment or
instruments should be paralleled for direct view of the
customer. Example – Loss Measurement system, PD test
System, HV Test System etc.
(Note: Issues of screen blinking may be observed during

chopped wave lightning impulse due to earthing issues and
should be ignored)
(c) Qualified engineers well-conversant with technology shall be

deployed to effectively handle online stage inspection/FAT.
(d) Online applications like Microsoft Teams, Skype, Google meet,

Google hangout, WhatsApp, etc.
(e) Measuring Instruments with valid calibration certificates

(f) Recording facility of all the activities performed during stage
inspection/FAT as well as photography of recording of
important readings should form part of the Stage/Final
inspection reports of the product.
(g) The manufacturer shall nominate a nodal officer, who shall be

responsible for coordinating with the utility/purchaser and
camera operators for visual arrangement/facilities spread
across different locations within the manufacturer’s works.
(h) Different sections like Core - coil assembly area, winding area,
tank inspection area etc. shall be provided with adequate no.
of cameras or portable cameras can be used for clear and
proper visualisation of the test object.
(i) During stage inspection/FAT, the position of cameras (with

zoom in/out facility) shall be done in such a way that the test
object, measuring instruments and test equipment are clearly
visible.
4.4.2 Procedure for virtual inspection / testing:
(a) Manufacturer’s QA/QC in-charge will plan, verify the process

checklist and ensure that the Stage inspection/Routine/FAT
are conducted as per approved quality plan in line with the
Technical Specification.
(b) Manufacturer will submit soft copies of Photographs and

Calibration Certificates with proper index sheet duly certified
from their end in order to demonstrate readiness of
Transformer/Reactor for inspection/testing.
(c) The Date and time and arrangement for online stage
inspection/FAT shall be finalised in consultation with the
utility/purchaser.
(d) Online inspection/FAT shall be done through online

application platform like – Microsoft Teams, Skype, Google
meet, Google hangout, WhatsApp, etc., considering the system
compatibility and security in consultation with the
utility/purchaser. Online recording facility of the activities
performed or witnessed must be available at manufacturer’s
end at all time for customer’s reference/review/record.
(e) Utility’s/purchaser’s approval shall be taken in advance for

the virtual stage inspection/FAT including the specific online
application platform that will be used.

(f) Whenever required the Mock trial may be carried out at
manufacturer’s work to get hands on experience before
offering to customer.
(g) All issues must be discussed and resolved before

commencement of inspection/tests.
(h) The Test circuits and Test procedure shall be shared with
utility’s/purchaser’s inspector for clarity & better
understanding.
(i) Application link and security password shall be shared with

the utility’s/purchaser’s inspecting officer on the same day of
inspection and password must be secured to maintain the
confidentiality.
(j) While conducting remote FAT, due care must be taken to keep
the data safe while transmitting from factory to utility’s/
purchaser’s inspector through a web-based application. There
are various Cybersecurity requirements and InfoSec protocols,
which should be adhered to for safety like Database Security,
Strong Password Policy, Access Control, Restricted Access via
2-Factor Authentication for utility/purchaser, Single Session
or Timed Sessions, Resetting Passwords, Password Expiry
Policy, Validations for 3rd Party participants, Authentication
for users/test engineers etc.
(k) All tests shall be conducted as per relevant latest

standards/procedures mentioned in the Technical
Specification. The readings recorded in each test will be shown
to remote-end inspector live for witness/acceptance. At the
end of each test, either side shall discuss the summary of test
results to avoid ambiguity at later stage. During Temperature
Rise test, the HOT resistance has to be measured at the time
of shutdown of power supply to Transformer. The camera
position shall be suitably placed, so that the readings are
visible without any obstruction by the working personnel. As

far as possible, resistance measurement should be done inside
the Control Room to avoid any obstructions or interfere of
personnel.
(l) During testing, one camera shall always be focused towards

test bay area where the transformer / reactor is under test for
online overview of connections. If one camera is not enough to
see both transformer and test leads, more no. of cameras shall
be deployed. This will enable complete testing connection
overview to inspecting officer all the time.
(m) The camera must be operated by the authorised person of the

manufacturer as per the direction of the inspection team
[representatives of utility/purchaser]. The inspection team
should have the facility to communicate directly with the
manufacturer’s representative for a thorough & effective
inspection including the physical verification of the
dimension, surface defect etc.
(n) The image quality shall be good enough for assessment of the
condition of the transformer which may affect the quality &
performance of transformer. The factors affecting image
quality include:
 Poor image resolution.
 Image out of focus.
 Inadequate lighting /Glare from strong light
source/shadows
 Frequent loss of connectivity between the Inspection team
and the onsite Video monitors.
(o) The Two-way Audio-Video communication Scheme for stage

inspection/FAT of transformer/reactor through web shall be
as follows:

(p) The camera should be focused for continuous visibility of the
test values in the meters so that the utility’s/purchaser’s
inspector can see the test values throughout the Inspection.
(q) During the stage Inspection/FAT, test results/readings & test

connections shall be recorded and mailed to the utility’s/
purchaser’s inspector.
(r) The manufacturer has to prepare test report on daily basis

during testing period by the end of each day. Test Reports
must be issued by the testing in charge of manufacturer
indicating list of Tests carried out and the test results.
(s) For long duration tests (Temperature rise and partial

discharge and impulse), manufacturer shall ensure that
Cameras shall be provided near transformer/reactor under
test and the Power analyser or equipment’s computer so that
the readings can be seen simultaneously.
(t) After completion of inspection, OEMs representative should

sign off from the application.
(u) After getting stage inspection Clearance from

utility/purchaser, the transformer/reactor may be moved to
next stage of manufacturing process and after getting FAT
Clearance from utility/purchaser, the transformer/reactor
may be moved for processing of dispatch to site.

(v) All video recording of the inspection shall be done and it shall
be shared with the utility / purchaser and also to be
maintained by manufacturer/OEM for future reference.
(w) The MoM of the stage inspection/FAT shall be prepared by the

manufacturer/OEM and all points discussed & agreed
including rectification/punch points, completion date etc.
shall be communicated to the utility/purchaser.
(x) Final Stage inspection report/FAT reports, supporting

documents and photographs should be submitted to utility /
purchaser for their future reference and record.
The online virtual inspection & testing process at

manufacturer’s/OEM’s premises will benefit both manufacturer
and the utility/purchaser in terms of time, money &
manpower/human resources and would be easier and faster.
4.5 The Inspector shall within ten (10) days from the date of inspection
as defined herein give notice in writing to the Manufacturer, or any
objection to any drawings and all or any equipment and
workmanship which is in his opinion not in accordance with the
contract. The manufacturer shall give due consideration to such
objections and shall either make modifications that may be
necessary to meet the said objections or shall inform in writing to
the Inspector giving reasons therein, that no modifications are
necessary to comply with the contract.
4.6 When the factory tests have been completed successfully at the
manufacturer’s or sub-supplier’s works, the Inspector shall issue
a certificate to this effect within ten (10) days after completion of
tests but if the tests are not witnessed by the Inspector, the
certificate shall be issued within ten (10) days of the receipt of the
Manufacturer’s test certificate by the Inspector.
4.7 In all cases where the contract provides for tests whether at the
premises or works of the Manufacturer or any sub-suppliers, the
Manufacturer, except where otherwise specified shall provide free
of charge such items as labour, material, electricity, fuel, water,
stores, apparatus and instruments as may be reasonably
demanded by the Inspector to carry out effectively such tests on
the equipment in accordance with the Manufacturer and shall give
facilities to the Inspector to accomplish testing.
4.8 The inspection by the Inspector and issue of Inspection Certificate

thereon shall in no way limit the liabilities and responsibilities of
the manufacturer in respect of the agreed Quality Assurance
Programme forming a part of the contract.

4.9 All inspection, measuring and test equipment used by
manufacturer shall be calibrated periodically depending on its use
and criticality of the test/measurement to be done. The
manufacturer shall maintain all the relevant records of periodic
calibration and instrument identification, and shall produce the
same for inspection by purchaser. In case repair is carried out in
the measuring and test equipment it should be compulsorily re-
calibrated. All calibrated measuring and test equipment must be
properly sealed after calibration to stop any kind of manipulation
with the equipment. Wherever mutually agreed between
manufacturer & Purchaser, the manufacturer shall re-calibrate the
measuring/test equipment in the presence of the Inspector.
4.10 Preparation of inspection report is the concluding part of

inspection. Every inspection agency has its own style of
preparation of inspection report. However, since it is a quality
document, we must ensure that all relevant information and
enclosures are made available along with the report. The inspection
report has mainly three parts:
a) The first part contains details of equipment, contract detail,

quantity offered, sampling, observation noted during
inspection, remark on test results etc.
b) The second part contains reports on physical verification.
c) The third part of the report contains the routine test results of
the inspected transformers, temperature rise test results, if
carried-out, and few demonstrative sample calculations e.g.
Load Loss calculation at normal and extreme taps, Temperature
rise calculation, Noise level calculation etc.
5.0 INSPECTION AND TESTING
The inspection envisaged by the purchaser is given below.

However, the manufacturer shall draw up and carry out a
comprehensive inspection and testing programme in the form of
detailed quality plan duly approved by Purchaser for necessary
implementation during manufacture of the equipment. All
accessories and components of transformer shall be purchased
from source, approved by the purchaser. All process tests, critical
raw material tests and witness/ inspection of these testing shall
be carried out as per approved Manufacturing Quality Plan (MQP)
by the purchaser.
5.1 Factory Tests
5.1.1 The manufacturer shall carry out all type & routine tests specified
in “Annexure-D and Annexure-E”. All tests shall be done in line
with latest IS: 2026/IEC 60076 or as per procedure specified in

this document. Complete test report shall be submitted to
purchaser after proper scrutiny and signing on each page by the
test engineer of the manufacturer.
5.1.2 The manufacturer shall be fully equipped to perform all the

required tests as specified. He shall confirm the capabilities of the
proposed manufacturing plant in this regard. Any limitations shall
be clearly stated.
5.1.3 The manufacturer shall bear all additional costs related to tests
which are not possible to carry out at his own works.
5.1.4 In case, any failure observed during factory testing involving

winding/ winding shield/ static shield ring, then affected winding
of all phases shall be replaced by new one mutually agreed between
manufacturer & Purchaser.
5.1.5 Tank Tests
(A) Oil Leakage Test
All tanks and oil filled compartments shall be completely filled with
air or oil of a viscosity not greater than that of insulating oil
conforming to IEC 60296 at the ambient temperature and
subjected to a pressure equal to normal head of oil plus 35
kN/sq.m (5 psi) measured at the base of the tank. This pressure
shall be maintained for a period of not less than 12 hours for oil
and 1 hour for air during which no leakage shall occur.
(B) Vacuum Test
All transformer/reactor tanks shall be subjected to the

specified vacuum. The tank designed for full vacuum (760 mm
of mercury at sea level) shall be tested at an internal pressure
of 3.33 KN/Sq.m absolute (25 torr) for one hour. The permanent
deflection of flat plate after the vacuum has been released shall not
exceed the values specified below:
Horizontal Length of flat plate (in Permanent deflection (in

mm) mm)
Up to and including 750 5.0

751 to 1250 6.5
1251 to 1750 8.0
1751 to 2000 9.5
2001 to 2250 11.0
2251 to 2500 12.5

2501 to 3000 16.0
Above 3000 19.0
(C) Pressure Test
All transformer/reactor tanks, its radiator, conservator and other

fittings together or separately shall be subjected to a pressure
corresponding to twice the normal head of oil or normal oil
head pressure plus 35 KN/ sq.m whichever is lower, measured
at the base of the tank and maintained for eight hours. The
permanent deflection of flat plates after the excess pressure has
been released shall not exceed the figure specified above for
vacuum test.
5.2 Stage Inspection
5.2.1 Stage inspection will be carried out by the Inspector on Core,

Winding, core-coil assembly & Tank during the manufacturing
stages of the transformer/reactor. The manufacturer will have to
call for the stage inspection and shall arrange the inspection at
manufacturer’s premises or manufacturer’s sub-supplier’s
premises, as applicable, free of cost.
5.2.2 Stage inspection will be carried out on at least one

Transformer/reactor against an offer of minimum 50% of the
ordered quantity as mentioned in delivery schedule. On the basis
of satisfactory stage inspection, manufacturer will proceed further.
5.2.3 The manufacturer will offer the core for stage inspection and get
approval from purchaser during manufacturing stage. The BIS
certified prime core materials are only to be used. The
manufacturer has to produce following documents at the time of
stage inspection for confirmation of use of prime core materials.
a) Invoice of supplier
b) Mills’ approved test certificates
c) Packing list
d) Bill of lading
e) Bill of entry certificate by custom.
f) Description of material, electrical analysis, physical inspection,
certificate for surface defects, chemical composition certificate,
thickness and width of the materials
g) Place of cutting of core materials
To avoid any possibility of mixing of ‘Prime material’ with any other

second grade/ defective material, the imported packed slit coils
of CRGO materials shall be opened in the presence of the
Inspector. Only after the inspection and approval from

purchaser, the core material will be cut in-house or sent to
external agency for cutting individual laminations. In case the
core is sent to external agency for cutting, the Inspector will have
full access to visit such agency for the inspection of the cutting of
core. Core material shall be directly procured either from the
manufacturer or through their accredited marketing organisation
of repute and not through any agent.
5.2.4 Typical example for calculation of flux density, core quantity, no-
load loss and weight of copper during stage inspection is given in
the Annexure-F.
5.3 Type Tests on fittings
Following fittings shall conform to type tests and the type test
reports shall be furnished along with drawing of the
equipment/fittings.
a) Bushing (Type test as per IS/IEC:60137) (Seismic withstand

test for 400 kV and above voltage class)
b) OLTC (Test as per IS 8468/IEC:60214 and degree of protection
test for IP-55 on Driving mechanism box)
c) Buchholz relay
d) OTI and WTI
e) Pressure Relief Device (including degree of protection test for IP
55 in terminal box)
f) Sudden Pressure Relay (including degree of protection test for
IP 55 in terminal box)
g) Magnetic Oil Level gauge & Terminal Box degree of protection
test for IP-55.
h) 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: 7016
i) Marshalling & common marshalling box and other outdoor
cubicle (IP-55 test)
j) Bus post Insulators
k) Oil pump
l) Cooling fan & motor assembly
m) RTCC Panel (IP-43 test)
6.0 Pre-Shipment Checks at Manufacturer's Works
The following pre-shipment checks shall be done at manufacturer’s

works:
6.1 Check for inter-changeability of components of similar

transformers/reactors for mounting dimensions.

6.2 Check for proper packing and preservation of accessories like
radiators, bushings, dehydrating breather, rollers, Buchholz relay,
fans, control cubicle, connecting pipes, conservator etc.
6.3 Ensure following setting of impact recorder at the time of

installation with transformer/reactor unit before despatch
from factory:
1g: Start recording
2g: Warning
3g: Alarm
Further, drop-out setting shall be 1g and threshold setting

shall be in the range of 5g to 10g.
6.4 Check for proper provision for bracing to arrest the movement of
core and winding assembly inside the tank.
6.5 Gas tightness test to confirm tightness and record of dew point of
dry air inside the tank. Derivation of leakage rate and ensure the
adequate reserve dry air capacity.
6.6 Due security arrangements to be ensured during transportation to

avoid pilferage and tempering with the valves and other accessories
used while dry air filling.

Annexure-A
SPECIFIC TECHNICAL REQUIREMENT
TRANSFORMERS
1.0 250 MVA & 315 MVA, 400/33 kV 3-Phase Power Transformer
S. Description Unit Technical Parameters

No
1. Voltage
1 ratio (Line-to-Line) kV 400/33
2. Rated Capacity
HV MVA 250 315
LV1 MVA 125 157.5
LV2 MVA 125 157.5
Tertiary MVA Tertiary winding may be
provided if transformer is of 5
limbs construction.
3. No of phases 3-phase
4. No of Secondary windings Two windings
5. Vector Group YNynyn0
6. Type of transformer Power transformer
7. Applicable Standard IEC 60076/ IS 2026
8. Cooling type ONAN / ONAF / ODAF (or
OFAF)
9. Rating at different cooling % 60 / 80 / 100
10. Cooler Bank Arrangement 2 X 50%
11. Frequency Hz 50
12. Tap Changer (OLTC) / OCTC -5% to +5% in steps of 1.25%
for HV variation
13. Location of tap changer On HV neutral end
Annexure-A : Specific Technical Requirement Page 1 of 19

14. Impedance at 75°C, at highest
MVA base (at MVA of HV winding)
i) HV-LV1 & HV-LV2:
Max. Voltage tap % 30.2
Principal tap % 28
Min. Voltage tap % 26
ii) LV1-LV2 % 40 (min.)

iii) Tolerance on Impedance % As per IEC, unless specified
otherwise
15. Service Outdoor
16. Duty Cyclic
17. Overload Capacity IEC-60076-7
18. Temperature rise over 50°C
ambient temp.
i) Top oil measured by thermometer
O C 45
ii) Average winding measured by O C 50
resistance method
Winding hot spot rise over yearly
19. O C 61
weighted temperature of 32 °C
20. Tank Hotspot Temperature O C 110
Maximum design ambient
21. O C 50
temperature
22. Windings
i) Lightning Impulse withstand
Voltage
HV kVp 1300
LV1 & LV2 kVp 250

HV Neutral kVp 95
LV Neutrals kVp 250
Tertiary (if provided) kVp 250
ii) Chopped Wave Lightning Impulse
Withstand Voltage
HV kVp 1430
LV1 & LV2 kVp 275
iii) Switching Impulse withstand
Voltage
HV kVp 1050
iv) One Minute Power Frequency
withstand Voltage
HV kVrms 570
LV1 & LV2 kVrms 95
HV Neutral kVrms 38
LV Neutrals kVrms 95
Tertiary (if provided) kVrms 95
v) Neutral Grounding (HV & LV) Solidly grounded
vi) Insulation
HV Graded
LV1 & LV2 Uniform
vii) Tertiary Connection (if provided) Ungrounded Delta
viii) Tan delta of winding % ≤ 0.5
23. Bushing
i) Rated voltage
HV kV 420
LV1 & LV2 kV 52
HV Neutral kV 36
LV Neutrals kV 52
Tertiary (if provided) kV 52

ii) Rated current
HV A 1250
LV1 & LV2 A 3150
HV Neutral A 2000
LV Neutrals A 2000
Tertiary (if provided) A 1250
iii) Lightning Impulse withstand
Voltage
HV kVp 1425
LV1 & LV2 kVp 250
HV Neutral kVp 170
LV Neutrals kVp 250
Tertiary (if provided) kVp 250
iv) Switching Impulse withstand
Voltage
HV kVp 1050
v) One Minute Power Frequency
withstand Voltage
HV kVrms 695
LV1 & LV2 kVrms 105
HV Neutral kVrms 77
LV Neutrals kVrms 105
Tertiary (if provided) kVrms 105
vi) Tan delta of bushing at ambient ≤ 0.5
%
Temperature
vii) Minimum total creepage distances (Specific creepage distance:
31mm/kV corresponding to
the line to line highest system
voltage)
HV mm 13020
LV1 & LV2 mm 1612

HV Neutral mm 1116
LV Neutrals mm 1612
viii) Maximum Partial discharge level
at Um
HV pC 10
LV1 & LV2 pC 10
24. Maximum Partial discharge level pC 100
at 1.58 * Ur / √3
25. Maximum Noise level at rated dB 80
voltage, at principal tap & no
load and all cooling active
26. Termination details To be provided by the
purchaser as per its
requirement
27. Maximum Permissible Losses of
250 MVA 315 MVA
Transformers
i) Max. No Load Loss at rated voltage kW Losses based on maximum
and frequency flux density of 1.7 T at rated
ii) Max. Load Loss at rated current kW MVA, voltage & frequency
and at 75°C for HV and LV and maximum current
windings, at principal tap position density of 3.5 A/mm2 at all
iii) Max. Auxiliary Loss at rated kW taps may be provided by the
voltage and frequency Manufacturers.

2.0 125 MVA & 160 MVA, 400/33 kV 3-Phase Power Transformer
S.
Description Unit Technical Parameters
No.
1. Voltage ratio (Line-to-Line) kV 400/33
2. Rated Capacity (HV & LV) MVA 125 160
3. No of phases 3-phase
4. No of secondary windings One winding
5. Vector Group YNyn0
6. Type of Transformer Power Transformer
7. Applicable Standard IEC 60076 / IS 2026
8. Cooling ONAN / ONAF
9. Rating at different cooling % 70 / 100
11. Frequency Hz 50
-5% to +5% in steps of 1.25%
12. Tap Changer (OLTC)/OCTC
for HV variation
13. Location of tap change On HV neutral end
Impedance at 75°C at highest MVA
14.
base
Max. Voltage tap % 16.2
Principal tap % 15
Min. Voltage tap % 14
As per IEC, unless specified
15. Tolerance on Impedance %
otherwise
16. Service Outdoor
17. Duty Cyclic
Temperature rise over 50°C
19.
ambient temp
i) Top oil measured by thermometer O C 45
Average winding measured by
ii) O C 50
resistance method
20. O C 61
weighted temperature of 32°C
22. O C 50
temperature
23. Windings
Lightning Impulse withstand
i)
Voltage
HV kVp 1300
LV kVp 250
HV Neutral kVp 95

LV Neutral kVp 250
Chopped Wave Lightning Impulse
ii)
Withstand Voltage
HV kVp 1430
LV kVp 275
Switching Impulse withstand
iii)
Voltage
HV kVp 1050
One Minute Power Frequency
iv)
withstand Voltage
HV kVrms 570
LV kVrms 95
HV Neutral kVrms 38
LV Neutral kVrms 95
vi) Insulation
HV Graded
LV Uniform
vii) Tan delta of winding % ≤0.5
24. Bushing
i) Rated voltage
HV kV 420
LV kV 52
HV Neutral kV 36
LV Neutral kV 52
ii) Rated current
HV A 1250
LV A 3150
HV Neutral A 2000
LV Neutral A 2000
iii)
Voltage
HV kVp 1425
LV kVp 250
HV Neutral kVp 170
LV Neutral kVp 250
iv)
Voltage
HV kVp 1050
v)
withstand Voltage
HV kVrms 695
LV kVrms 105
HV Neutral kVrms 77

LV Neutral kVrms 105
Tan delta of bushing at ambient ≤ 0.5
vi) %
Temperature
(Specific creepage distance:
Minimum total creepage 31mm/kV corresponding to
vii)
distances the line to line highest system
voltage)
HV mm 13020
LV mm 1612
HV Neutral mm 1116
LV Neutral mm 1612
Maximum Partial discharge level
viii)
at Um
HV pC 10
LV pC 10
Maximum Partial discharge level
25. pC 100
at 1.58 * Ur / √3
Maximum Noise level at rated
26. voltage, at principal tap & no dB 80
load and all cooling active
requirement
Maximum Permissible Losses of
28. 125 MVA 150 MVA
Transformers
Max. No Load Loss at rated voltage Losses based on maximum
i) kW
Max. Load Loss at rated current MVA, voltage & frequency
ii) and at 75°C for HV and LV kW and maximum current
windings, at principal tap position density of 3.5 A/mm2 at all
Max. Auxiliary Loss at rated taps may be provided by the
iii) kW
voltage and frequency Manufacturers.

3.0 (a) 100 MVA, 125 MVA & 160 MVA, 220/33 kV 3-ph Power Transformer
(b) 100 MVA, 125 MVA & 160 MVA, 230/33 kV 3-ph Power Transformer
Cl. Description Unit Technical Parameters

No.
1. Voltage ratio (Line-to-Line) kV (a) 220/33
(b) 230/33
2. Rated Capacity (HV & LV) MVA 100 125 160
3. No of phases 3 (Three)
4. No of secondary windings One winding
6. Type of transformer Power transformer
8. Cooling type ONAN / ONAF

10. Frequency Hz 50
12. Tap Changer
i) Type On-load tap changer /OCTC
ii) -5% to +5% in steps of 1.25%
Tap range and steps
for HV variation
iii) Location of tap changer On HV neutral end
13. Impedance at 75°C, at highest MVA
base
i) Max. Voltage tap % 16.2
ii) Principal tap % 15.0
iii) Min. Voltage tap % 14.0
iv) Tolerance on Impedance As per IEC
14. Service Outdoor
15. Duty Cyclic
17. Temperature rise over 50°C ambient
Temp
ii) Average winding measured by O C 50
resistance method
18. O C 61
weighted temperature of 32°C
20. O C 50
temperature
21. Windings

i) Lightning Impulse withstand Voltage
HV kVp 950
LV kVp 170
HV Neutral kVp 95
LV neutral kVp 170
ii) Chopped Wave Lightning Impulse
Withstand Voltage
HV kVp 1045
LV kVp 187
iii) Switching Impulse withstand
Voltage
HV kVp 750
iv) One Minute Power Frequency
withstand Voltage
HV kVrms 395
LV kVrms 70
HV Neutral kVrms 38
LV neutral kVrms 70
vi) Insulation
HV Graded
LV Uniform
vii) Tan delta of winding % ≤ 0.5
22. Bushing
i) Rated voltage
HV kV 245
LV kV 36
HV Neutral kV 36
LV Neutral kV 36
ii) Rated current
HV A 1250
LV A 3150
HV Neutral A 3150
LV neutral A 3150
iii) Lightning Impulse withstand Voltage
HV kVp 1050
LV kVp 170
HV Neutral kVp 170
LV neutral kVp 170
iv) Switching Impulse withstand
Voltage
HV kVp 850
v) One Minute Power Frequency
withstand Voltage

HV kVrms 505
LV kVrms 77
HV Neutral kVrms 77
LV Neutral kVrms 77
vi) Tan delta of bushing at ambient ≤ 0.5
%
Temperature
vii) Minimum total creepage distances (Specific creepage distance:
voltage)
HV bushing mm 7595
LV bushing mm 1116
HV neutral / LV neutral mm 1116
viii) Maximum Partial discharge level at
Um
HV pC 10
23. Maximum Partial discharge level at pC 100
1.58 * Ur / √3
24. Maximum Noise level at rated dB 80
voltage, at principal tap & no load
and all cooling active
requirement
26. Maximum Permissible Losses of 100 125 160
Transformers
ii) Max. Load Loss at rated current and kW MVA, voltage & frequency
at 75°C for HV and LV windings at and maximum current
principal tap position density of 3.5 A/mm2 at all
iii) Max. Auxiliary Loss at rated voltage kW taps may be provided by the
and frequency Manufacturers.

4.0
(a) 80 MVA & 100 MVA, 132/33 kV, 3-Phase Power Transformer
(b) 80 MVA & 100 MVA, 110/33 kV, 3-Phase Power Transformer
S.
Description Unit TECHNICAL PARAMETERS
No.
Voltage ratio (Line-to-Line) kV (a) 132/33

1.
(b) 110/33
2. Rated capacity (HV and LV) MVA 80 MVA 100 MVA
5. Type of transformer Power Transformer

7. Cooling type ONAN/ONAF
10. Frequency Hz 50
11. Tap changer
On-load tap changer
i) Type
(CFVV)/OCTC
-5% to +5% in steps of
ii) Tapping range and steps
1.25% for HV variation
HV-LV Impedance at 75 °C, at
12. highest MVA base
13. Tolerance on Impedance % As per IEC
14. Service Outdoor
15. Duty Cyclic
16. Overload Capacity IEC 60076-7

Temperature rise over 50°C ambient
17. temp.

ii) O C 50
resistance method
18. 61
19. Tank hot spot temperature 110

20. O C 50
temperature
21. Windings
i)
Voltage
650 (132 kV)
HV kVp
550 (110 kV)
LV kVp 170
HV Neutral kVp 95
LV Neutral kVp 170
ii)
Withstand Voltage
715 (132 kV)
HV kVp
605 (110 kV)
LV kVp 187
iii)
Voltage
540 (132 kV)
HV kVp
460 (110 kV)
iv)
withstand Voltage
275 (132 kV)
HV kVrms
230 (110 kV)
LV kVrms 70
HV Neutral kVp 38
LV Neutral kVp 70
v) Neutral Grounding (HV and LV) Solidly grounded
vi) Insulation
HV Graded
LV Uniform
vii) Tan delta of winding % ≤0.5%
22. Bushings

i) Rated voltage
HV kV 145
LV, LV Neutral & HV Neutral kV 36
ii) Rated current (Min.)
HV A 1250
LV A 3150
HV Neutral & LV Neutral A 3150
iii)
Voltage
HV kVp 650
LV, HV Neutral and LV Neutral kVp 170
iv)
withstand Voltage
HV kVrms 305
LV, HV Neutral and LV Neutral kVrms 77
v) %
Temperature
vi) Minimum total creepage distances
voltage)
HV mm 4495
LV, HV Neutral and LV Neutral mm 1116
Maximum Partial discharge level at
vii) pC 10
Um on HV and LV
23. pC 100
1.58*Ur/√3
75
24. voltage, at principal tap & no load dB
Termination details To be provided by the
25. purchaser as per its
requirement
26. Maximum Permissible Losses of 80 MVA 100 MVA
Transformers
and frequency flux density of 1.7 T at
ii) Max. Load Loss at rated current and kW rated MVA, voltage &
frequency and at 75°C at principal frequency and maximum
tap between HV & LV current density of 3.5

iii) Max. Auxiliary Loss at rated voltage kW A/mm2 at all taps may be
and frequency provided by the
Manufacturers.

5.0
(a) 31.5 MVA and 50 MVA, 132/33 kV, 3-Phase Power Transformer
(b) 31.5 MVA and 50 MVA, 110/33 kV, 3-Phase Power Transformer
S.
Description Unit TECHNICAL PARAMETERS
No.
Voltage ratio (Line-to-Line) kV (a) 132/33

1.
(b) 110/33
2. Rated capacity (HV and LV) MVA
5. Type of transformer Power Transformer

7. Cooling type ONAN
9. Frequency Hz 50
10. Tap changer
On-load tap changer
i) Type
(CFVV)/OCTC
-5% to +5% in steps of
ii) Tapping range and steps
1.25% for HV variation
HV-LV Impedance at 75 °C, at
11. highest MVA base
12. Tolerance on Impedance % As per IEC
13. Service Outdoor
14. Duty Continuous
15. Overload Capacity IEC 60076-7

Temperature rise over 50°C ambient
16. temp.
iii) Top oil measured by thermometer O C 45

iv) O C 50
resistance method
17. 61
18. Tank hot spot temperature 110

19. O C 50
temperature
20. Windings
i)
Voltage
650 (132 kV)
HV kVp
550 (110 kV)
LV kVp 170
HV Neutral kVp 95
LV Neutral kVp 170
ii)
Withstand Voltage
715 (132 kV)
HV kVp
605 (110 kV)
LV kVp 187
iii)
Voltage
540 (132 kV)
HV kVp
460 (110 kV)
iv)
withstand Voltage
275 (132 kV)
HV kVrms
230 (110 kV)
LV kVrms 70
HV Neutral kVp 38
LV Neutral kVp 70
v) Neutral Grounding (HV and LV) Solidly grounded
vi) Insulation
HV Graded
LV Uniform
vii) Tan delta of winding % ≤0.5%
21. Bushings
i) Rated voltage
HV kV 145

LV, LV Neutral & HV Neutral kV 36
ii) Rated current (Min.)
HV A 1250
LV A 1250
HV Neutral & LV Neutral A 1250
iii)
Voltage
HV kVp 650
LV, HV Neutral and LV Neutral kVp 170
iv)
withstand Voltage
HV kVrms 305
LV, HV Neutral and LV Neutral kVrms 77
v) %
Temperature
vi) Minimum total creepage distances
voltage)
HV mm 4495
LV, HV Neutral and LV Neutral mm 1116
pC 10
Um on HV
22. pC 100
1.58*Ur/√3
75
23. voltage, at principal tap & no load dB
Termination details To be provided by the
24. purchaser as per its
requirement
25. Maximum Permissible Losses of 31.5 MVA 50 MVA
Transformers
and frequency flux density of 1.7 T at
ii) Max. Load Loss at rated current and kW rated MVA, voltage &
frequency and at 75°C at principal frequency and maximum
tap between HV & LV current density of 3.5
iii) Max. Auxiliary Loss at rated voltage kW A/mm2 at all taps may be
and frequency provided by the
Manufacturers.

Annexure-B
TECHNICAL PARAMETERS OF BUSHING CURRENT TRANSFORMERS
1.0 Parameters of Current Transformer for 315MVA / 250MVA (3-Ph),

400/33 kV Transformers
Description Current Transformer Parameters

HV HV Neutral LV LV Neutral
Side Side Side Side
Ratio
CORE 1 1000/1 1000/1 3000/1 3000/1
CORE 2 - -
600/1 -
Minimum knee point voltage or burden and accuracy class
CORE 1 1000V, PX / PS 1000V, PX 3000V, PX / 3000V, PX / PS
/ PS PS
CORE 2 -
0.2S Class -
-
20VA ISF≤5
Maximum CT Secondary Resistance

CORE 1 2.5 Ohm 2.5 Ohm 7.5 Ohm 7.5 Ohm
CORE 2 - - - -
Application
CORE 1 Restricted Earth REF REF REF
Fault (REF)
CORE 2 Metering - - -
Maximum magnetization current (at knee point voltage)
CORE 1 60 mA 60 mA 30 mA 30 mA
-
CORE 2 - - -
Notes:
1. Parameters of WTI CT for each winding shall be provided by the
manufacturer / contractor.
2. The CTs used for REF protection must have the identical parameters in
order to limit the circulating current under normal condition for stability
of protection.
Annexure-B: Technical Parameters of Bushing Current Transformers & Neutral Current

Transformers Page 1 of 6
2.0 Parameters of Current Transformer for 160MVA / 125MVA (3-Ph),
400/33 kV Transformers

Side Side Side Side
Ratio
CORE 1 1000/1 1000/1 3000/1 3000/1
CORE 2 - -
300/1 -
CORE 1 1000V, PX / PS 1000V, PX 3000V, PX / 3000V, PX / PS
/ PS PS
CORE 2 -
0.2S Class -
-
20VA ISF≤5

CORE 2 - - - -
Application
Fault (REF)
CORE 1 60 mA 60 mA 30 mA 30 mA
-
CORE 2 - - -
Notes:
of protection.

3.0 Parameters of Current Transformer for 160 MVA / 125MVA (3-
Ph), 220 (or 230)/33 kV Transformers

Side Side Side Side
Ratio
CORE 1 800/1 800/1 3000/1 3000/1
CORE 2 - -
600/1 -
CORE 1 800V, PX / PS 800V, PX / 3000V, PX / 3000V, PX / PS
PS PS
CORE 2 -
0.2S Class -
-
20VA ISF≤5

CORE 1 2 Ohm 2 Ohm 7.5 Ohm 7.5 Ohm
CORE 2 - - - -
Application
Fault (REF)
CORE 1 100 mA 100 mA 30 mA 30 mA

-
CORE 2 - - -
Notes:
2. The CTs used for REF protection must have the identical
parameters in order to limit the circulating current under normal
condition for stability of protection.

4.0 Parameters of Current Transformer for 100MVA (3-ph), 220 (or
230)/33 kV Transformers

Side Side Side Side
Ratio
CORE 1 800/1 800/1 2000/1 2000/1
CORE 2 400/1 - - -
PS PS
CORE 2 0.2S Class - - -
15VA ISF ≤ 5

CORE 1 2 Ohm 2 Ohm 5 Ohm 5 Ohm
CORE 2 - - - -
Application
CORE 1 Restricted REF REF REF
Earth Fault
(REF)
CORE 1 100 mA 100 mA 30 mA 30 mA

-
CORE 2 - - -
Notes:
of protection.

5.0 Parameters of Current Transformer for 80MVA / 100 MVA (3-ph),
132 (or 110)/33kV Transformers

Side Side Side Side
Ratio
CORE 1 800/1 800/1 3000/1 3000/1
CORE 2 600/1 - - -

CORE 1 800V, PX / PS 800V, PX / PS 3000V, PX / 3000V, PX / PS
PS
CORE 2 0.2S Class - -
15VA ISF ≤ 5

CORE 1 2 Ohm 2 Ohm 7.5 Ohm 7.5 Ohm
CORE 2 - - - -
Application
Earth Fault
(REF)
CORE 1 100 mA 100 mA 30 mA 30 mA

-
CORE 2 - - -
Notes:
of protection.

6.0 Parameters of Current Transformer for 31.5MVA/ 50MVA MVA (3-
ph) 132 (or110)/33kV Transformers

Side Side Side Side
Ratio
CORE 1 800/1 800/1 1000/1 1000/1
CORE 2 400/1 - - -

PS PS
CORE 2 0.2S Class - -
15VA ISF ≤ 5

CORE 2 - - - -
Application
Earth Fault
(REF)
CORE 1 100 mA 100 mA 30 mA 30 mA

-
CORE 2 - - -
Notes:
order to limit the circulating current under normal condition for
stability of protection.

Annexure-C
GUARANTEED AND OTHER TECHNICAL PARTICULARS FOR POWER

TRANSFORMERS
(To be filled in by the manufacturer)
A. GENERAL
Sl. Description Unit Specifi Offered

No. ed by by
Buyer manufa
-cturer
1. General Information
i) Supplier
ii) Name of Manufacturer
iii) Place of Manufacture (Country & City)
iv) Type of transformer (Core/Shell)
2. Applications
i) Indoor/Outdoor
ii) 2wdg/3wdg
iii)
3. Corrosion Level at Site
i) Light ii) Medium iii) Heavy iv) Very Heavy

4. Site altitude above mean sea level M --
5. Seismic zone and ground acceleration at site (both --

in horizontal & vertical direction)
6. Maximum and minimum ambient temperature at

site
7. Applicable Standards
i) IEC: 60076
ii) IS : 2026
iii) Any other, please specify
8. Rated Capcity / Full load rating (HV/LV (or MVA
LV1/LV2)
9. 3-Phase
10. Rated No Load Voltages (HV/LV (or LV1/LV2)/ kV
Tertiary
11. Currents at normal tap (HV/LV(or LV1/LV2)/ Amp
tertiary
12. Rated Frequency Hz
13. Connections and phase displacement symbols
(Vector Group)
14. Weight Schedules (Minimum with no negative
Annexure-C: Guaranteed & Other Technical Particulars Page 1 of 13

tolerance)
i) Active part (Core + coil ) Kg
ii) Insulating Oil (excluding mass of extra oil) Kg
iii) Tank and Fittings Kg
iii) Total weight Kg
iv) Transportaion Weight Kg
v) Overall dimensions L x B x H mm
vi) Size of heaviest package L x B x H mm
vii) Weight of heaviest package Kg
viii) Weight of 5% extra oil Kg
ix) Weight of core Kg
x) Weight of copper (HV/Tertiary/LV(or LV1/LV2/ Kg

Regulating)
xi) Insulating Oil volume (excluding 5% extra oil) Ltrs
xii) Quantity of oil in OLTC Ltrs
15. Transport limitation

16. LV Winding
i) Stabilizing tertiary (Yes/No)

ii)
17. Tappings
i)Type (OLTC/OCTC) and make of tap changer

ii)Position of Tapping on the winding
iii)Variation on
iv)Range of variation %
v)No. of Steps
vi) Whether control suitable for :
 Remote/local operation
 Auto/manual operation
vi)Parallel Operation Requirements
18. Impedance and Losses
i) Guaranteed No load loss at rated voltage and kW

frequency
Tolerance (to be considered for loss evaluation) %
ii) Guranteed I2R Loss at rated current & kW
frequency (at 750C) at principal tap
iii) Eddy current and stray loss at rated current & kW

frequency (at 750C) at principal tap
iv) Load Loss(I2R+Eddy and Stray) at rated current kW
& frequency (at 750C) at principal tap
v) Guaranteed Auxiliary loss at rated voltage and kW
frequency
vi) Calculated Fan Loss kW
vii) Air core reactance of HV winding %
viii)Guaranteed Impedance (at Highest MVA base) %
(a) HV-Tertairy (at Pricipal tap)
(b) HV-LV (or LV1/LV2) (at Pricipal tap)
(c) Tertairy -LV(at Pricipal tap)
Tolerance
ix) Impedance at extreme tappings at Highest MVA %
base [for
HV-LV for two winding transformer]
a) Max. Voltage tap
b) Min. Voltage tap
Tolerance %
x) Zero sequence impedance at principal tap (for 3-
phase transformers)
19. Capacitance to earth for HV/Tertiary/LV (or pF
LV1/LV2)
20. Regulation at full load at 75 0C winding
temperature at:
a) upf
b) 0.8 pf
21. Guaranteed maximum Magnetizing Current at %
rated Voltage
22. Efficiency : %
At 100% load upf
0.8 lead
0.8 lag
At 75% load upf
0.8 lead
0.8 lag
At 50% load upf
0.8 lead
0.8 lag
23. Load at Maximum efficiency %
24. Any limitations in carrying out the required test?
If Yes, State limitations
25. Fault level of system (in kA) and its duration (in sec) kA
(sec)
26. Calculated short Circuit current (in kA) withstand kA
capability for 2 seconds without exceeding
temperature limit (i.e. Thermal ability to withstand
SC current)
27. Test current (in kA) and duration (in ms) for short kA &
Circuit current test (i.e. Dynamic ability to msec
withstand SC)
28. Over fluxing withstand time (due to combined msec
voltage & frequency fluctuations):
110%
125%
140%
150%
170%
29. Free space required above the tank top for removal
of core
30. Maximum Partial discharge level at 1.58 Ur/√3 pC
B. MAGNETIC SYSTEM
Sl. Description Unit Specif Offered
No. ied by by
Buyer manufa-
cturer
1. Core Type:
i) 3 Phase 3 Limb (3 wound limbs)
ii) 3 Phase 5 Limb (3 wound limbs)
iii)
2. Type of Core Joint:

i) Mitred
ii) Step Lap
3. CRGO :
i) Make & Country of Origin
ii) Thickness, mm
iii) Max. Specific loss at 1.7 T, 50Hz, in Watts/kg
iv) Grade of core as per BIS
v) Insulation between core lamination
vi) BIS certified (Yes/No)
4. Minimum Gross & Net Area of: cm2
i) Core
ii) Limb
iii) Yoke
iv) Unwound limb
(May be verified during manufacturing stage – at
the discretion of buyer)
5. Stacking Factor %
6. Voltage per turn V
7. Apparent Core Density for Weight Calculation
8. Minimum Net Weight of Silicon Steel Lamination kg
CRGO (may be verified during manufacturing stage
by calculation)
9. Maximum Flux density at 90%, 100% and 110% T
voltage and frequency (may be verified during
manufacturing stage by calculation)
10. W/kg at working flux density
11. Building Factor Considered

12. Calculated No Load Loss at rated voltage and kW
Frequency
(Net Weight x W/kg x Building factor)
13. Magnetizing inrush current Amp
14. No load current at normal ratio and frequency for : Amp

85% of rated voltage
15. Core Isolation test kV
16. Core bolt in limb / yoke Yes/
No
17. Core bolt insulation withstand voltage for one kV
minute
18. Maximum temperature rise of any part of core or its 0C
support structure in contact with oil
C. CONDUCTING SYSTEM
Sl. Description Unit Offered
No. by manufacturer
HV IV LV Reg
ulat
ing
1. Type of Winding
Helical/Disc/Layer/inter wound
2. Type of Conductor
PICC/CTC/CTCE/CTCEN/BPICC
3. Minimum Yield Strength of Conductor for N/mm2

0.2% elongation
4. Maximum Current density at CMR and A/mm2

conductor area at any tap: & sq.
mm
i) HV
ii) Tertiary
iii) LV (or LV1/LV2)
5. Maximum current density under short A/mm2
circuit:
i) HV
ii) Tertiary
iii)LV (or LV1/LV2)
6. Bare Weight of copper without paper Kg
insulation and lead (Minimum)
7. Per Phase Maximum resistance of winding ohm
at rated tap at 75 OC
8. Number of Turns/Phase
9. Insulating material used for HV/IV/LV
winding
10. Insulating material used between :
i) HV and IV winding
ii) IV and LV winding
iii) LV winding and core
iv) Regulating winding and adjacent
winding/core
11. Details of special arrangement provided to
improve surge voltage distribution in the
winding
12. Dielectric Shielding used:
i) Interleaved winding
ii) Wound in Shield
iii) Others
13. Magnetic Shielding used:
i) Yoke Shunt on core clamp

ii) Magnetic shunt on tank
iii) Electromagnetic (Copper/Aluminum)
shield on tank
iv) Others
14. Noise level when energized at normal dB
voltage and frequency without load
D. COOLING SYSTEM
Sl. Description Unit Speci Offered
No. fied by
by manufa
Buyer c-turer
1. Type of Cooling
[ ONAN/ONAF (or) ONAN / ONAF / OFAF (or ODAF)]
2. Percentage Rating Corresponding to Cooling Stages
(HV/Tertiary/LV (or LV1/LV2)
3. No. of Cooler banks (2x50% / 1x100% etc.)
4. Temperature gradient between windings and oil
5. Time in minutes for which the transformer can run at min
full load without exceeding maximum permissible
temperature at reference ambient temperature when
supply to fans is cut off
6. Guaranteed Maximum Temperature rise at 1000 mts. 0C
altitude and at actual altitude at site at ambient
temperature at cooling specified at sl. No. 1:
i) Top Oil by thermometer

ii) Average Winding by resistance
iii) Winding hot spot

7. Type of Cooler:
i) Radiator Bank
ii) )
iii) Tank Mounted
iv) Header Mounted
v) Separately Mounted
vi) Degree of Protection of terminal box
8. Cooling Fans:
i) Type
ii) Size
iii) Rating (kW)
iv) Supply voltage
v) Quantity (Running + Standby) per cooler bank
vi) Whether fans are suitable for continuous operation
at 85% of their rated voltage calculated time
constant:
 natural cooling
 forced air cooling
vii) Degree of Protection of terminal box
9. Oil Pumps:
i) Type
ii) Size
iii) Rating (lpm and kW)
iv) Supply voltage
v) Quantity (Running + Standby) per cooler bank
vi) Efficiency of motor at full load
vii) Temperature rise of motor at full load
viii) BHP of driven equipment
Coolers (Oil to Air):
10.
i) Quantity (Running + Standby)
ii) Type and Rating
11. Coolers (Oil to Water):
i) Quantity (Running + Standby)

ii) Type and Rating
iii) Oil flow rate (lpm)
iv) Water flow rate (lpm)
v) Nominal Cooling rate (kW)
vi) Material of tube
12. Radiators:
i) Width of elements (mm)

ii) Thickness (mm)
iii) Length (mm)
iv) Numbers
13. Cooler loss at rated output, normal ratio, rated voltage, kW
rated frequency at ambient temperature of 50oC
E. DIELECTRIC SYSTEM
Sl. Description Unit Offered by
No. manufacturer
1. Geometric Arrangement of winding with
respect to core
e.g: Core-Tertiary-LV-HV-Reg Coarse-Reg Fine
2. Regulating Winding:
i) Body Tap
ii) Separate
3. HV Line Exit point in winding:
i) Top
ii) Center
4. Varistors used across Windings Yes/
If yes, Details No
5. Insulation Levels of windings HV Te LV HV LV-N

rt (or -N
ia LV
r 1/
y LV
2)
i) Lightning Impulse withstand voltage kVp
(1.2/50µs)
ii) Chopped wave Lightning Impulse kVp
withstand voltage
iii) Switching Impulse withstand voltage kVp
(250/2500µs)
iv) Power frequency withstand voltage kVrms
(one minute / 5 minutes)
6. Tan delta of windings at ambient temperature %
F. ACCESSORIES
Sl. Description Unit Offered Spe
No. by manufacturer cifie
d by
Buy
er
1. Tap Changers
i) Control
a-Manual b-Automatic
c-Remote d-Local
ii) Voltage Class and Current Rating of Tap
Changers
iii) Make and Model
iv) Make and Type of Automatic Voltage

Regulator (AVR)
v) Tie-in resistor requirement (to limit the
recovery voltage to a safe value) and its
value
vi) OLTC control and monitoring to be carried Y/N
out through Substation Automation
System
vii) Power Supply for control motor
(No. of Phases/Voltage/Frequency)
viii) Rated Voltage for control circuit V
(No. of Phases/Voltage/Frequency)
2. Tank
i) Tank Cover: Conventional/Bell/Bottom
Plate
ii) Material of plate for tank
iii) Plate thickness : side, bottom, cover Mm
iv) Rail Gauge Mm
v) Minimum Clearance height from rail for Mm
lifting Active Part
vi) Wheels : Numbers/Plane/Flanged/Uni-
Directional/Bi-Directional/Locking Details
vii) Vacuum withstand Capability mm
(a) Tank of Hg
(b) Radiators/Conservator/Accessories
viii) High Pressure withstand Capability mm
(a) Tank of Hg
(b) Radiators/Conservator/Accessories
ix) Radiator fins / conservator plate Mm
thickness
x) Tank Hot spot temperature O C
3. Bushings: HV IV LV HV-N
LV-N
i) Termination Type
a-Outdoor
b-Cable Box (oil/Air/SF6)
c-Plug in Type
ii) Type of Bushing: OIP/RIP/RIS/oil

communicating
iii) Bushing housing - Porcelain / polymer

iv)Rated Voltage Class kV
v) Rated Current A
vi)Lightning Impulse withstand voltage kVp
(1.2/50µs)
vii) Switching Impulse withstand voltage kVp
(250/2500µs)
v) One minute Power frequency withstand kVrms
voltage
(dry & wet)
viii) Minimum Creepage Distance Mm
ix) Quantity of oil in bushing and
specification of oil used
x) Make and Model
xi) Tan delta of bushings %
xii) Max Partial discharge level at Um pC
xiii) Terminal Pad details
xiv) Weight of assembled bushings Kg
xv) Whether terminal connector for all
bushings included in the scope of supply
4. Minimum clearances between bushings
(for HV, Tertiary and LV)
(a) Phase to phase
(b) Phase to ground
5. Indicator / Relay
i) Winding temperature thermometer/

indicator:
Range
Accuracy
ii) Oil temperature thermometer/ indicator:
Range
Accuracy
iii) Temperature sensors by fiber optic (if
provided)
iv) Oil actuated/gas operated relay
v) Oil level Indicators:
Main Conservator
OLTC Conservator
vi) Oil Sight Window:
Main Tank
Main Conservator
OLTC Conservator
6. Conservator:
i) Total volume
ii) Volume between highest and lowest
visible oil levels
7. Conservator Bag (air cell)
i) Material of air cell
ii) Continuous temperature withstand
capacity of air cell
8. Air cell rupture relay provided Yes
/ No
9. Pressure Relief Device:
i) Number of PRDs provided

ii) Location on the tank
iii) Operating pressure of relief device
10. Sudden Pressure Relay / Rapid Pressure rise Y/N
relay provided; if yes,
i) Location on the tank
ii) Operating pressure
11. Dehydrating Breathers(Type & No. of
breathers)
(a) For main Conservator tank
(b) For OLTC conservator
12. Flow sensitive Conservator Isolation Vlave Y/N
Provided
13. Tap Changer protective device
14. TType and material of gaskets used at gasketed
joints
15. Bushing CTs: (HV side and /LV side)
i) Voltage class kV
ii) No. of cores
iii) Ratio
iv) Accuracy class
v) Burden VA
vi) Accuracy limit factor
vii) Maximum resistance of secondary winding Ω
viii) Knee point voltage V
ix) Current rating of secondaries A
16. Neutral CTs:
i) Voltage class kV
ii) No. of cores
iii) Ratio
iv) Accuracy class
v) Burden VA
vi) Accuracy limit factor
vii) Maximum resistance of secondary winding Ω
viii) Knee point voltage V
ix) Current rating of secondaries A
17. Transformer Oil
i) IS 335 / IEC60296 / as per specification
ii) Inhibited/ un-inhibited
iii) Mineral / Natural Ester / Synthetic Ester
iv) Spare oil as percentage of first filling
v) Manufacturer
vi)Quantity of oil (before filling and before
commissioning)
vii)Moisture content (mg/L or ppm)
viii) Tan delta (Dielectric Dissipation Factor) at
90oC

ix) Resistivity (Ω-cm))
x) Breakdown Voltage (before and after
treatment) (kV)
xi) Interfacial tension at 20 oC (N/m)
xi) Pour point (oC)
xii) Flash point(oC)
xiii) Acidity (mg KOH/gm)
xiv) Inhibitors (for inhibited oil) (%)
xv) Oxidation Stability
18. Press Board:
i) Make
ii) type
19. Conductor Insulating Paper
i) Kraft paper
ii) Thermally upgraded Kraft paper
iii) Nomex
20. Provision for fire protection system (as per Y/N
spec), if yes, provide details
21. Insulation of core bolts, washers, end plates
etc.
22. Weights and Dimensions:
i) Weights:
a. Core
b. Windings
c. Tank
d. Fittings
e. Oil
f. Total weights of complete transformers
with oil and fittings
ii) Dimensions;
a. Overall Height above track
b. Overall length
c. Overall breadth
iii) Minimum bay width required for

installation of the transformer
iv) Weight of the heaviest package of the

transformer arranged for transportation
23. Lifting Jacks
i) Number of jacks included

ii) Type and Make
iii) Capacity
iv)Pitch
v) Lift
vi)Height in close position
24. Rail Track gauges
i) 2 Rails or 3 rails or 4 rails

ii) Distance between adjacent rails on shorter
axis
iii) Distance between adjacent rails on longer
axis

Annexure-D
Test Plan for Transformers
No. Test Um Um
≤ 170kV  170kV
1. Measurement of winding resistance at all taps Routine Routine
2. Measurement of voltage ratio at all taps Routine Routine
3. Check of phase displacement and vector group Routine Routine
4. Measurement of no-load loss and current Routine Routine
measurement at 90%, 100% & 110% of rated voltage
and rated frequency
5. Magnetic balance test (for three phase Transformer Routine Routine
only) and measurement of magnetizing current
6. Short Circuit Impedance and load loss measurement Routine Routine
at principal tap and extreme taps
7. Measurement of insulation resistance & Polarization Routine Routine
Index
8. Measurement of insulation power factor and Routine Routine
capacitance between winding to earth and between
windings
9. Measurement of insulation power factor and Routine Routine
capacitance of bushings
10. Full wave lightning impulse test for the line terminals Type -
(LI) (for Um<=
72.5kV)
Routine
(for
72.5kV<
Um≤170
kV)
11. Chopped wave lightning impulse test for the line Type Routine
terminals (LIC)
12. Lightning impulse test for the neutral terminals (LIN) Type Type
Annexure-D: Test Plan Page 1 of 10

13. Switching impulse test for the line terminal (SI) Type Routine
(Not applicable for Um≤72.5 kV)
14. Applied voltage test (AV) Routine Routine

15. Line terminal AC withstand voltage test (LTAC) Routine Type
(Not applicable for Um≤72.5 kV)
16. Induced voltage withstand test (IVW) Routine -

17. Induced voltage test with PD measurement (IVPD) Routine* Routine
18. Measurement of transferred surge on Tertiary due to - Type
HV lightning impulse
19. Measurement of transferred surge on Tertiary due to - Type
HV Switching impulse
20. Test on On-load tap changer (Tap changer fully Routine Routine
assembled on the transformer)
21. Measurement of dissolved gasses in dielectric liquid Routine Routine
22. Check of core and frame insulation Routine Routine
23. Leak testing with pressure for liquid immersed Routine Routine
transformers (tightness test)
24. Appearance, construction and dimension check Routine Routine
25. Measurement of no load current & Short circuit Routine Routine
Impedance with 415 V, 50 Hz AC.
26. Frequency Response analysis (Soft copy of test report Routine Routine
to be submitted to site along with test reports )
27. High voltage withstand test on auxiliary equipment Routine Routine
and wiring after assembly
28. Tank vacuum test Routine Routine
29. Tank pressure test Routine Routine
30. Check of the ratio and polarity of built-in current Routine Routine
transformers
31. Temperature rise test Type Type
32.
33. Short duration heat run test (Not Applicable for unit Routine Routine
on which temperature rise test is performed )

34. Over excitation test (applicable for 765 kV transformer - Routine
only)
35. Measurement of Zero seq. reactance Type Type
(for three phase Transformer only)
36. Measurement of harmonic level in no load current Type Type
37. Determination of acoustic sound level Type Type
38.
39. Dynamic Short circuit withstand test as specified in the
specification
*The requirements of the IVW test can be incorporated in the IVPD test so that
only one test is required.

Test Procedures (for Transformer)
General
Tests shall be carried out as per following procedure. However, IS 2026/IEC

60076 (with latest amendments) shall be followed in general for other tests.
Manufacturer shall offer the transformer unit for type testing with all major
fittings including radiator bank, Marshalling Box, Common Marshalling Box,
RTCC (as applicable) assembled.
1. Core assembly dielectric and earthing continuity test
After assembly each core shall be tested for 1 minute at 2000 Volts between
all yoke clamps, side plates and structural steel work (core to frame, frame to
tank & core to tank).
The insulation of core to tank, core to yoke clamp (frame) and yoke clamp
(frame) to tank shall be able to withstand a voltage of 2 kV (DC) for 1 minute.
Insulation resistance shall be minimum 1 GΩ for all cases mentioned above.
2. Measurement of winding resistance
After the transformer has been under liquid without excitation for at least 3
h, the average liquid temperature shall be determined and the temperature of
the winding shall be deemed to be the same as the average liquid temperature.
The average liquid temperature is taken as the mean of the top and bottom
liquid temperatures. Measurement of all the windings including compensating
(in case terminal is available at outside) at normal and extreme taps.
In measuring the cold resistance for the purpose of temperature-rise

determination, special efforts shall be made to determine the average winding
temperature accurately. Thus, the difference in temperature between the top
and bottom liquid shall not exceed 5 K. To obtain this result more rapidly, the
liquid may be circulated by a pump.
3. No-load loss and current measurement
As per IEC 60076-1:2011 clause 11.5
4. Measurement of short-circuit impedance and load loss
The short-circuit impedance and load loss for a pair of windings shall be
measured at rated current & frequency with voltage applied to the terminals
of one winding, with the terminals of the other winding short-circuited, and
with possible other windings open circuited. The difference in temperature
between the top and bottom liquid shall not exceed 5 K. To obtain this result

more rapidly, the liquid may be circulated by a pump. Loss measurement for
all combinations (HV-IV, HV-LV, IV-LV and at Normal and extreme taps).
5. Short term heat run test (Not Applicable for unit on which temperature
rise test is performed)
In addition to the type test for temperature rise conducted on one unit, each
cooling combination shall routinely be subjected to a short term heat run test
to confirm the performance of the cooling system and the absence of
manufacturing defect such as major oil flow leaks that may bypass the
windings or core.
DGA samples shall be taken at intervals to confirm the gas evolution.
For ODAF or OFAF cooling, the short term heat run test shall be done with
the minimum number of pumps for full load operation in order to shorten the
temperature build up. Each short term heat run test is nevertheless expected
to take about 3 hours.
For ODAF or OFAF cooled transformers an appropriate cross check shall be

performed to prove the effective oil flow through the windings. For this purpose
the effect on the temperature decay by switching the pumps off/ on at the end
of the heat run should demonstrate the effectiveness of the additional oil flow.
Refer to SC 12, 1984 cigre 1984 SC12-13 paper by Dam, Felber, Preiniger et
al.
Short term heat run test may be carried out with the following sequence:
 Heat run test with pumps running but oil not through coolers.
 Raise temperature to 5 deg less than the value measured during
temperature rise test.
 Stop power input and pumps for 6 minutes and observe cooling down
trend
 Restart pumps and observe increased cooling trend due to forced oil flow
This test is applicable for the Transformer without Pump also (ONAN or ONAF
rating). For such type of transformer test may be carried out with the following
sequence:
Arrangement shall be required with pump of suitable capacity (considering the

oil velocity) without cooler bank.
 Raise the oil temperature 20-25 deg C above ambient.
 Stop power input and pumps for 6 minutes and observe cooling down
trend.
 Restart pumps and observe increased cooling trend due to forced oil flow.

6. Temp. Rise Test as per IEC: 60076
Headspace extraction and Gas chromatographic analysis on oil shall also be

conducted before, during and after this test and the values shall be recorded
in the test report. The sampling shall be in accordance with IEC 60567.
The temperature rise test shall be conducted at a tap for the worst
combination of loading (3-Winding Loss) for the Top oil of the transformer.
3-Winding Loss = HV (Max MVA) + LV (Max MVA).
The Contractor before carrying out such test shall submit detailed calculations
showing losses on various taps and for the three types of ratings of the
transformer and shall recommend the combination that results in highest
temperature rise for the test.
The Temperature rise type test results shall serve as a “finger print” for the
units to be tested only with short term heat run test.
Headspace extraction and Gas chromatographic analysis on oil shall also be

conducted before, during and after this test and the values shall be recorded
in the test report. The sampling shall be in accordance with IEC 60567.
Oil sample shall be drawn before and after heat run test and shall be tested
for dissolved gas analysis. Oil sampling to be done 2 hours prior to
commencement of temperature rise test. Keep the pumps running for 2 hours
before and after the heat run test. Take oil samples during this period. For
ONAN/ONAF cooled transformers, sample shall not be taken earlier than 2
hours after shut down. The acceptance norms with reference to various gas
generation rates shall be as per IEC 61181.
The DGA results shall generally conform to IEC/IEEE/CIGRE guidelines.
i. Test conditions for temperature rise test:
 This test shall be generally carried out in accordance with IEC 60076-2
 For each cooling combination with cooler bank, tests shall be done on
the maximum current tap for a minimum of 12 hours for ONAN/ONAF
and 24 hours for ODAF or OFAF with saturated temperature for at least
4 hours while the appropriate power and current for core and load losses
are supplied.
 The total testing time, including ONAN heating up period, steady period
and winding resistance measurements is expected to be about 48 hours.

 DGA tests shall be performed before and after heat run test and DGA
results shall generally conform to IEC/IEEE/CIGRE guidelines.
ii. Test records:
Full details of the test arrangements, procedures and conditions shall be

furnished with the test certificates and shall include at least the following.
iii. General:
 Purchaser’s order number and transformer site designation.

 Manufacturer’s name and transformer serial number.
 Rating of transformer
 MVA
 Voltages and tapping range
 Number of phases
 Frequency
 Rated currents for each winding
 Vector Group
 Cooling Type
 Measured no-load losses and load losses at 75° C.
 Altitude of test bay.
 Designation of terminals supplied and terminals strapped.
iv. Top oil temperature rise test:
A log of the following quantities taken at a minimum of 30 minute intervals:
 time
 Voltage between phases
 Current in each phase and total power
 Power in each phase and total power
 Ambient temperature
 Top oil temperature
 Cooler inlet and outlet oil temperatures
 Hot spot temperatures (make use of probes) (if applicable)
 Colour photographs of the four sides and top of the transformer together
with the corresponding series of thermal images (colour) during starting
of the test then after every four hours till the temperature stabilised and
finally during temperature stabilised for each rating
(ONAN/ONAF/ODAF (or OFAF); ONAN/ONAF).

Notes:
The probes may be left in position provided the reliability and integrity of unit
will not be jeopardized during its long life expectancy.
v. Winding temperature rise test
 Record the ‘cold’ resistance of each winding and the simultaneous top
oil and ambient air temperatures, together with the time required for
the effect to disappear.
 Record the thermal time constant of the winding.
 Log the half-hourly readings of the quantities as for the top oil
temperature rise test.
 Provide a table of readings, after shut-down of power, giving the
following information;
a) Time after shut- down:

b) Time increment:
c) Winding resistance: At least 20 minutes reading
d) Resistance increment:
e) X, where x is the time after shut-down divided by the thermal time
constant of the winding: and
f) Y, where Y = 100 ( 1-e –x )
(Any graphical/computer method used to determine the temperature
of a winding by extrapolation to the instant of power shut-down shall
produce a linear curve.)
 Provide a record of all calculations, corrections and curves leading to

the determination of the winding temperatures at the instant of shut-
down of power.
 Record any action taken to remedy instability of the oil surge device
during initiation of the oil circulating pumps.
Temperature measurements as per special probes or sensors (fibre optic)

placed at various locations shall also be recorded.
7. Dielectric Tests
Following Test shall be performed in the sequence given below as per IEC
60076-3:2013 clause 7.2.3 shall be followed:
a) Lightning impulse tests (LIC, LIN)

b) Switching impulse (SI)
c) Applied voltage test (AV)
d) Line terminal AC withstand test (LTAC)
e) Induced voltage test with partial discharge measurement (IVPD)

8. Measurement of transferred surge on LV or Tertiary due to HV
Lightning impulse
Following tests shall be carried out with applying 20% to 80% of rated
Impulse & Switching impulse (upto 60% for IV, Sr. No. 7 & 8 of below table)
voltage. Finally, measured value shall be extrapolated for 100% rated
voltage.
Table for Transfer surge (Impulse) at Max, Nor. and Min. Voltage Tap
Similar tests to be conducted for switching surge transformer at Max, Nor.

and Min. Voltage Tap.
Where 1.1 : HV Terminal

2.1 : IV Terminal
3.1 & 3.2 : LV or Tertiary Terminal
Acceptance criteria
Transfer surge at Tertiary should not exceed 250kVp at any conditions for
400kV Voltage class Transformer. For other transformer it shall be below
the impulse level of LV winding.
9. Chopped wave & full wave lightning impulse test for the line terminals
(LIC & LI) and Switching impulse test
Chopped wave lightning impulse and Switching impulse test shall be

performed at normal and extreme taps on Unit-1, Unit-2 and Unit-3
respectively for 1-Ph unit, otherwise R ph, Y Ph and B Ph respectively for 3-
Ph unit. All the parameters as per IEC shall be mentioned in the report.

10. Measurement of power taken by fans and oil pumps (100 % cooler bank)
Losses of each fan and pumps including spare shall be measured at rated
voltage and frequency. Fans and Pumps shall be mounted with cooler bank
as per approved drawing during measurement. Serial No, Applied voltage,
measured current, frequency and make shall be furnished in the test report.
11. Short duration (LTAC) AC withstand test (LTAC)
For 765kv Class transformer, the IV terminal voltage shall be shall be

raised to 570kVrms or below so that maximum HV voltage shall be shall
be limited to 970kV rms. Test method shall be as per IEC.
12. Dynamic short circuit withstand test
The test shall be carried out as per IEC 60076-5. Dynamic short circuit
test shall be carried out in HV-LV combination at nominal & extreme tap
positions. For LV winding, dynamic short circuit shall be carried out on
HV. Type tests shall be carried out before short circuit test. Following shall
also be conducted before and after Short Circuit test:
i) Dissolved gas analysis

ii) Frequency response analysis
iii) All routine tests
Detail test procedure shall be submitted by contractor & shall be approved

before short circuit test.
13. Routine tests on Bushings: Routine test on bushings shall be done as

per IEC 60137.
********************************************************

Annexure-E
Sr. No. Item/Components List of Tests Sampling Reference/ Acceptable Value Category of Responsibility*
rate Standard Sub- Manufacturer Customer
Vendor
A Raw Material & Components
1. Winding Conductor (PICC)/ (a) Visual & Dimensional check of Conductor: One IS 1897 Bare conductor: P V W/V
(CTC)/ Lead wires Thickness & width of bare conductor, sample per IS 13730
thickness of paper, surface covering, no. of type per lot As per Width(mm) Tolerance (in ± mm)
conductors, finish of conductor and finish approved Up to 3.15 - 0.03
of PICC/CTC drawing 3.16 to 6.30 - 0.05
6.31 to 12.5 - 0.07
12.51 to 16 - 0.10
> 16 - 0.13
Thickness (mm) Tolerance (in ±mm)

For Width (mm)
(2-16) (16-40)
0.8 to 3.15 - 0.03 0.05
3.15 to 6.30 - 0.05 0.07
6.30 to 10 - 0.07 0.09
Insulated conductor:
Paper Covering Tolerance (%)
thickness (mm)
0.25 to 0.5 - 10
Over 0.5 to 1.3 - 7.5
Over 1.3 - 5
(b) Resistivity at 20 deg.C IS 13730 For annealed conductor: P V W/V

0.01727 ohm/mm2/m (max)
For half hard conductor:

0.01777 ohm-mm2/m (max)
(c) Insulation test for bunched IS 13730 Maximum Charging current 1A at P V W/V
conductor/between strands of CTC (if 250V AC/ 500V DC for 1 minute.
applicable)
(d) Elongation test for annealed conductors (if IS 7404 Thickness elongation P V -
applicable) IS 13730 (mm) %
Up to 2.5 30 ( min.)
>2.5-5.6 32 (min.)
(e) Proof strength of work hardened conductor IS 7404 As per design requirement P V -
IS 13730
TC --- Test Certificate PD- Perpendicular Direction CD- Cross Direction MD- Machine Direction PICC-Paper Insulated Copper Conductor CTC- Continuously Transposed Conductor
* Category of Responsibility: P - Actual Test Performance V - Verify and Accept W - Witness Actual testing, verify and accept
Annexure-E: Manufacturing Quality Plan Page 1 of 23
Annexure-E
Vendor
(f) Radius of corner of bare conductor IS 7404 Thickness Corner Radius

IS 13730 (mm) (mm) P V V
Up to 1.0 - 0.50 x nominal
thickness
1.01 to 1.60 - 0.50
1.61 to 2.24 - 0.65
2.25 to 3.55 - 0.80
3.56 to 5.60 - 1.00
(Tolerance ±25%)
(g) Copper purity As per plant OEM Standard V V V

standard
(h) Oxygen Content As per plant OEM Standard V V V
standard
(i) Epoxy Bonding Strength (Bonded CTC) As per plant As per plant standard P V V
standard
2. Kraft Insulating Paper (a) Visual check & Measurement of One IEC 60554- Paper to be smooth, unglazed P V --
(for covering of PICC/CTC) Thickness sample per 3-1 surface, free from dust particles and
type per lot IEC 60554- no surface defect
3-5 Thickness tolerance within
IEC specified value ±10%
(b) Density 60554-2, Nominal value ±0.05 gm/cm3
(c) Substance (grammage) Methods of Thickness(µm) Sub(g/m 2 )
Test 50 40
65 52
75 60
90 72
Tolerance:
For material ≤45 g/m 2 ±10%
For material >45 g/ m2 ±5%
(d) Moisture Content 8 % max
(e) Tensile Index (Machine Direction) 93 NM/gm (min)
(f) Tensile Index (Cross-machine 34 NM/gm (min)
Direction)
(g) Elongation at Break (MD) As per IEC 60554-3-1
(h) Elongation at Break (CD) As per IEC 60554-3-1
(i) Electric Strength in Air As per IEC 60554-3-1
(j) Ash Content 1 % max
(k) PH of Aqueous extract 6 to 8
(l) Conductivity of Aqueous extract 10 mS/m (max)
(m)Air Permeability 0.5 to 1.0 µm/Pa.s
(n) Tear Index (MD) 5 mN m2/g (min)
(o) Tear Index (CD) 6 mN m2/g (min)
(p) Water Absorption (Klemn Method) 10 %
Annexure-E
Vendor
(q) Heat Stability Type test report

i) Reduction of Degree of
Polymerization
ii) Reduction of Bursting Strength
iii) Increase of Conductivity of
Aqueous extract.
(r) DP Value As per IEC 60554/Manufacturer’s std.
practice
(s) Storage Period As per Manufacturer’s std. practice
(t) Storage in controlled Environment As per Manufacturer’s std. practice
3. Thermally upgraded Manufacturer’s std. practice As per Manufacturer’s std. practice
Paper/Aramid Paper (if
applicable)
4. (i) CRGO Mother coil / Check following documents Each Lot IS 3024 As per approved design P V V
Laminations (a) Invoice of Supplier (100% of IS 649
(b) Mill’s Test certificate coils) IEC 60404
(c) Packing List ASTM 4343
(d) Bill of Lading
(e) Bill of Entry
(f)manufacturer’s identification
slip/unique numbering of prime
CRGO coil
Check points:
(a) Visual check, check for coil width & 10% of coils Visually defect free, as per design
thickness from nameplate requirement
(b) Cutting Burr One sample Less than 20 micron burr/ As per IS/
per lot mutual agreement while ordering
(c) Bend / Ductility test As per IS 649/IS 3024

Completion of one 160o bend without
fracture
(d) Surface insulation resistivity check Average value: 10 Ω cm2 (min.)
Individual value: 05 Ω cm2 (min.)
(e) Accelerated Aging test (type test) 4% (max.) increase in measured
specific total loss
(f) Test on stacking factor As per table no. 4 of IS 3024
(g) Test for specific Watt loss test One IS 3024 As per table no. 2 of IS 3024 -- P V
(h) Magnetic Polarisation sample IS 3024 As per appropriate tables of IS 3024 -- P V
(i) Grade of CRGO from Approved Approved Drawing/Document/ P V V
offered lot drawing/ Manufacturer standard
(j) Permeability at 800 A/m Document P V V
Annexure-E
Vendor
Test Method
IS 3024/ IS
649
(k) Compliance to Quality Control Order of IS 3024 P V V
DHI
5. Pre-compressed (a) Visual & dimensional check, thickness, One sample IEC 60641-3-1 No surface defects P V V
Press Board/ Laminated width and length of each size
IEC60763-3-1
pre-compressed (b) Apparent Density (g/cm3 ) (thickness) Up to 1.6 mm TK - 1.0-1.2
IEC 60641-2,
pressboard per lot of >1.6-3 mm - 1.1-1.25
pressboar IEC60763-2
>3-3.6 mm - 1.15-1.30
d Methods of Test >6-8 mm - 1.2-1.3
(c) Compressibility in air (C) (in %) Up to 1.6 TK - 10 %
>1.6-3 mm - 7.5 %
>3-3.6 mm - 5%
>6-8 mm - 4%
(d) Reversible part Compressibility in air Up to 1.6 TK - 45 %;
(Crev) (in %) >1.6-3 mm - 50 %
>3-3.6 mm - 50 %;
>6-8 mm - 50 %
(e) Oil Absorption Up to 1.6 mm TK - 11 min
> 1.6-3 mm - 9 min
> 3 - 3.6 mm - 7 min
> 6-8 mm - 7 min
(f) Moisture Content 6% max. / As per relevant std. &
Manufacturer’s std. practice
(g) Shrinkage in air (MD, CD & PD) MD - 0.5 % max, CD- 0.7 % max, Thick
– 5 % max
(h) pH of aqueous extract 6-9 for solid boards
(i) Conductivity of aqueous extract Up to 1.6 - 5 max (mS/m)

> 1.6-3 mm- 6 max,
> 3-3.6 mm - 8 max
> 6-8 mm TK - 8-10 max
(j) Dielectric Strength in Air Up to 1.6 - 12 kV/ mm
> 1.6-3 mm - 11 kV/mm
> 3-3.6 mm - 10 kV / mm
> 6-8 mm TK - 9 kV/mm
(k) Dielectric Strength in Oil Up to 1.6 - 40 kV/ mm
> 1.6-3 mm - 35 kV/mm
> 3-3.6 mm - 30 kV / mm
> 6-8 mm TK - 30 kV/mm
(l) Ash Content (%) 1 % maximum
(m) Elongation (MD, CD) MD CD

Annexure-E
Vendor
Up to 1.6 - 3 % 4 %
>1.6-3 mm - 3 % 4 %
>3-3.6 mm - 3% 4%
>6-8 mm TK - 3 % 4 %
(n) Tensile strength (MD, CD) As per relevant std./ Manufacturer’s std.
practice
(o) Internal Ply Bond strength (for laminated As per relevant std./ Manufacturer’s std.
pre compressed boards) practice
 Dried (tested at 23°C)
 Dried (tested at 120°C retention)
 Oil impregnated (tested at 23°C)
 Aged for 1 week at 120°C in oil
(tested at 23°C retention)
(p) Flexural strength (MD, CD) (for Laminated As per relevant std./ Manufacturer’s std.
pre compressed Boards) (MPa) practice
(q) Contamination Dielectric Liquids (for As per relevant std./ Manufacturer’s std.
laminated pre compressed press boards) practice
 Neutralization value (mg KOH/g)
 Sludge content (mg/l)
 Dissipation factor
6. Perma-wood (a) Visual & dimensional check, thickness, One IS 3513 Shall be free from surface defect P V V
width & length sample of IS 1708
(b) Density each size IS 1736 0.8 to 1.3 gm/cc
(c) Moisture content per lot IS 1998 IS 3513/IS 1708
(d) Oil Absorption at 90 °C IEC 61061 Min 5%
(e) Dielectric Strength at 90 °C Min 60 KV
(f) Tensile strength Approved Min for LD - 700 KV /cm2
(g) Compressive strength test document Min for LD - 1400 KV /cm2
(h) Shear strength age-wise Min for LD - 450 KV /cm2
(i) Thickness Thickness (mm) Tolerance
(±mm)
10 to 25 - 1.2
26 to 50 - 1.4
51 to 150 - 2.0
(j) Shrinkage (MD, CD) IEC 61061/Plant standard

(k) pH Value
(l) Breakdown voltage, parallel to the
laminations
7. Porcelain Bushings (a) Visual & dimensional check. 10% IS 3347 As per approved drawing, IS P V V
(Hollow) Sample IS 8603 3347/IS 8603
per lot IEC 60137 As per IS 3347/IS 8603/ IEC
(b) Power frequency voltage withstand test
As per IS/ 60137
Annexure-E
Vendor
IEC
8. Polyester Resin (a) Visual Check One sample IS 15208 Free from visual defect P V --
Impregnated Glass Fiber per lot per
Tape size To be used within self-life period not to
(b) Verification of shelf life
be used after expiry of period
(c) Dimensional Check

 Thickness  0.25 to 0.35 mm (± 0.07) / as per
manufacturer’s design
 Width  20 to 50 mm (± 2)
(d) Tensile Strength 200 N/mm (min)
(e) Resin Content 27 (± 3%)
(f) Softening point of resin Max 200 °C

(g) Storage Condition As per cl. 15.3 of IS 15208
(h) Elongation 4% (Max)
9. Lacquer (in case it is Manufacturer’s std. practice As per Manufacturer’s std. practice P V --
used)
10. Condenser Bushing Routine Test 100% IEC 60137

(OIP/RIP/RIS) No visible damage P W W
(a) Visual and Dimensional check
(b) Lightening impulse withstand test (if As per IEC 60137
applicable)
(c) Measurement of dielectric dissipation Tan Delta - 0.5% P V
factor and capacitance at room
temperature
(d) Dry power frequency voltage withstand As per approved GTP P W V
test
(e) Measurement of Partial Discharge (PD) As per IEC - No flash-over/ puncture W V
(f) Pressure Test (for OIP condenser No leakage P W V
bushing)
(g) Test tap insulation test As per IEC 60137
(h) Tightness test No leakage P W V
(i) Creepage distance As per approved GTP P W W
(j) Test of oil before carrying out routine test  BDV: Min 70 kV P W V
on bushing (for OIP bushing)  Water content: Max 5 ppm
 BDV  Tan Delta at 90⁰C Max:0.0025
Annexure-E
Vendor
 Water content  IFT at 27⁰C: Min 0.04 N/m

 Tan delta at 90°C
 IFT at 27°C
Method & Positioning of Storage As per bushing manufacturer’s P --
guideline
11. Buchholz Relay Routine test 100% IS 3637 P W V
(a) Type & make As per approved drawing
(b) Porosity No leakage
(c) High voltage 2 KV for 1 min. withstand
(d) Insulation resistance Minimum 10 MΩ by 500 V DC megger
(e) Element test No leakage at 1.75 Kg /cm2 oil
pressure for 15 mins
(f) Gas volume test at 5° ascending towards GOR - 1: 90 to 165 CC
conservator GOR - 2: 175 to 225 CC
GOR - 3: 200 to 300 CC
(g) Loss of oil & Surge test GOR - 1: 70 to 130 CC
GOR - 2: 75 to 140 CC
GOR - 3: 90 to 160 CC
12. Bimetallic Terminal Routine test 100% IS 5561 P W V
Connector
(a) Dimensional As per approved drawing
(b) Visual check Free form defects
(c) Tensile strength As per type test report
(d) Resistance As per type test report
(e) Galvanizing test (if required) As per type test report
13. Marshalling Box/ Cooler (a) Dimensional & Visual check 100% Approved As per approved drawing P P/W W/V
Control Cabinet (workmanship, clearances, ferruling, drawing and
labeling, accessories, earthing terminals, specification
mounting/ lifting details, 20% spare TBs
etc.)
(b)Verification of paint shade, thickness & As per approved drawing
adhesion
(c) All Functional Check at max & min rated As per approved drawing
operating voltage, electrical control
operations, alarms, interlocks and
sequential operations
(d)BOM check for Component type, make & As per approved drawing
rating
(e) DOP check by thin paper insertion As per technical specification
method
Annexure-E
Vendor
(f) Degree of Protection (IP Class) As per type test report / approved
verification drawing
(g) Check for sealing gasket (EPDM rubber Free form defects
for outdoor/ neoprene rubber for indoor)
Routine test
a. HV test at 2kV (for 1 min) for 1 min withstand
auxiliary winding
b. Verification of wiring and its routing Firm and aesthetic
c. IR test at 500 V for 1 min 1 min withstand
14. Remote Tap Changer (a) Dimension & Visual Check 100% Approved As per approved drawing P P/W W/V
Control Panel (if drawing and
applicable) specification 1 min withstand
(b)2kV test for Auxiliary wiring
(c) Paint shade & Thickness As per approved drawing
(d)Wiring routing check Firm and aesthetic
(e) Functional Check As per approved drawing
(f) Verification of BOQ As per approved drawing
15. Air cell (Flexi Air Make, Visual check of surface finish of 100% IS 3400 No surface defects. P W V
Separator) complete air cell & Dimensions As per approved drawing
Routine test
(a) Pressure test at 0.105 Kg /cm2 (10Kpa) No leakage for 24 hours P W V
for 24 hrs
(b) 10 times inflation and deflation test at No deformation P W V
0.105 Kg /cm2
Type tests on basic fabric One Tensile strength & elongation at P W V
i. Oil side coating compound sample per break: ISO 1421
ii. Air side inner/outer coating lot of raw Tear resistance: ISO 4674-1
material
iii. Rubber coating (inner/outer) Coating adhesion: ISO 2411
iv. Coated fabric Gas permeability: ISO 7229
16. Roller Assembly (a) Visual & Dimensions.
One sample IS 5517 Free from surface defect P V --
per lot IS 2004
(b) Mechanical Properties & Chemical One IS 28 For shaft as per MS EN8, BS 970-1
composition of raw material used sample per IS 2026 For roller wheel of cast iron IS 210
for shaft & roller forging melt/heat For roller wheel of Cast steel IS 1030
treatment
batch
17. Oil & Winding Temperature (a) Type & make 100% -- As per approved drawing P P/W V
Indicator (b) Accuracy ± 1.5% of FSD
Annexure-E
Vendor
(c) HV test at 2kV for 1 min between all Withstand for 1 min
terminals & earth
(d) Switch contact operation test Operation within ± 2.5° C of setting
(e) Contact Rating As per Manufacturer’s std.

18. Pressure Relief (a) Type & Make 100% As per specification As per approved drawing & free from P P/W W/V
Device defect
(b) Air Pressure Test Operate at Specified pressure ± 0.07
(c) Liquid Pressure Test kg/cm2
(d) Switch/contact testing Satisfactory operation at pressure
release
(e) Leakage test at 75% operating pressure No leakage for 24 hrs
(f) HV test 2 kV withstand for 1 min
(g) Functional test/Calibration As per Manufacturer’s std.
(h) Contact Rating
19. Magnetic Oil Level Gauge (a) Type & make 100% -- As per approved drawing & free from P P/W W/V
(MOG) defect
(b) Dial Calibration for level Check pointer position for Max, Min
and center level
(within tolerance as per specifications)
(c) 2kV HV test for 1 min between all terminal Withstand for 1 minute
& earth
(d) Leak test with air for 6 Hours No leakage at 4 kg /cm2
(e) Switch/contact operation test Operate at Min level indication
(f) Contact Rating As per Manufacturer’s std.
20. Valves (a) Type, make & visual check for material of 100% IS 778 As per approved drawing & no visible P W V
(Gate, Globe & Butterfly) valve body, gate wedge, spindle and gland defect
(b) Dimension check
(c) For Gate & Globe Valve: No leakage
(i) Body test at 1.5 MPa (2 minutes)
(ii) Seat test at 1.0 MPa (2 minutes)
(iii) Seepage test at 2 kg/cm 2 for 12 hrs.
(d) For Butterfly valve:
(i) Pressure test through body and spindle
(i) No leakage at 5 kg/cm2 for 10 minutes
(ii) Pressure test for diaphragm
(iii) Oil seepage test (oil 105± 5 oC, pressure (ii) Max 6 drops/min at 1.5 kg/cm2
of 1.5 kg/cm2 for 24 hrs.) (iii) No leak in body and spindle
Max 6 drops/min through disc
21. Transformer Oil Routine Test 100% IS: 335 As per technical specification P W W
IEC 60296
Annexure-E
Vendor
IS 6855
22. Tank, Tank-cover, Turret, (a) Visual check of welding joints including 100% CBIP Free from defect P W V
Conservator & Accessories earthing connection, matching of tank with One per Manual on
cover& Dimensional check after final design Transformer
welding 2013
(b) Visual Check for a fit up for butt welds on Check for proper welding
tank walls, base & cover
(c) DP test on Butt welds after fit up & load Check for proper welding
bearing welds (lifting logs, bollards, jacking
pads)
(d) Air leakage test on assembled tank with No leakage
turrets & on conservator
(e) Visual check of paint shade, paint film Paint thickness
thickness (inside & outside) & film Outside: 155 micron
adhesion, primer application Inside: 30 micron
No peel-off
Or
As per approved drawing
(f) WPS (Weld procedure specification) Details to be furnished As per
approval Specification/ASME Sec IX
(g) PQR (Process Qualification Record) Details to be furnished As per
Specification/ASME Sec IX
(h) Welders Qualification Details to be furnished As per P W V

Specification/ASME Sec IX
(i) UT (Ultrasonic test) of tank MS Plate of Details to be furnished As per
thickness >12mm. Specification/ASME Sec IX
(j) RT (Radiography test) of butt weld in bottom Details to be furnished As per
plate of tank after fit up (if any) Specification/ASME Sec IX
(k) Verification of PWHT (Post weld heat Details to be furnished As per
treatment) Specification/ASME Sec IX
(l) Surface cleaning by Shot/sand blasting Details to be furnished as per
Specification
(m) Tank - i. Withstand-Twice the normal P W V
i. Pressure test (PT) head of oil or normal head+ 35
ii. Vacuum test (VT) KN/m2 whichever is lower,
iii. Adhesion test maintained at base of bank for 8
iv. Visual Inspection inside transformer hrs.
tank before PT & VT test ii. Withstand- 3.33 KN/ m2 for 1 hr.
iii. Details to be furnished as per
manufacturer’s standard.
iv. Inputs required as per
specification
Annexure-E
Vendor
(n) Chemical composition & mechanical IS 2062 As per relevant standards P W V

property of steel (for tank, tank-cover, BS 4360
conservator, turrets and accessories)
23. Radiators (a) Chemical composition & 100% BS EN As per relevant standards P W W/V
mechanical property of raw material 50216-1
(b) DP test on lifting lugs welds IS513 No welding defect
(c) Surface cleaning of header support Manufcaturer’s Free from surface defect
and bracing details by sand/shot drawing
blasting
(d) Air pressure test on elements As per relevant standards /CBIP
(e) Dimensional check after final welding As per approved drawing
(f) Air pressure test on radiator 2 kg /cm2 for 30 minutes - no
assembly by water dipping method leakage
(g) Visual check of paint shade, paint As per tech spec, coating thickness
film thickness & film adhesion more than 70 micron
(h) WPS (Weld Procedure Specification) Details to be furnished, if applicable
approval as per Specification/ASME Sec IX
(i) PQR (Process Qualification Record) Details to be furnished, if applicable
as per Specification/ASME Sec IX
(j) Welders Qualification As applicable As per Specification/
ASME Sec IX
24. OLTC / OCTC (a) HV test on Auxiliary circuit (2kV for 100% IS 8468 To Withstand for 1 min P P/W V
(as applicable) 1min). IEC 60214
(b) Operational test of complete OLTC Satisfactory operation
including functional check of driving
mechanism
(c) Pressure test on diverter switch oil No leakage at 10 Psi for 1 hour
compartment
(d) Mechanical Operation test of diverter No defect after 5000 operations
switch (endurance test)
(e) Mechanical test of tap selector motor 500 satisfactory operations between
drive extreme taps
(f) Sequence test Switching time within permissible
limit
(g) Visual & Dimensional check Free from defects, dimensions as
per drawing
(h) Operational test on Surge relay Satisfactory working of trip & reset
(i) Milli volt drop/contact resistance As per standard
measurement after Mechanical test.
(j) Condition of Silver plating on Good condition
contacts
(k) Measurement of Tan delta To be provided (value to be used for
benchmark) as per manufacturer’s
standard
Annexure-E
Vendor
(l) Helium Test (barrier board leakage To be provided as per manufacturer’s

test)- For externally mounted OLTC standard
25. Digital RTCC Relay/ Automatic (a) Check of Binary input and output 100% as per specification/manufacturer’s
Voltage Regulating Relay (AVR) signal along with HMI display standard
(if applicable) nomenclature
(b) Check availability of spare binary
input and output terminal
(c) Check communication interface
(d) Test for complete function include
tap position indication, raise and
lower command execution
26. Cooling Fans & motor (a) Type, Make & visual check 100% IS 2312 As per approved drawing, no visual P W V
damage/ defect
(b) Power consumption, rating test As per approved drawing
(c) HV test (3kV Power frequency Should withstand
withstand test for 1 min)
(d) Insulation resistance value 2 MΩ (minimum) with 500 V DC
megger
27. Nitrile Rubber (a) Visual check 1 sample/ ISO 7619-1 Free from cracks and pin holes P W V
Gasket (b) Dimensions Lot ISO 815
ISO 37 Within tolerance
(c) Shore Hardness ISO 3865 70 ± 5 IRHD
(d) Tensile Strength IS 11149 12.5 N/mm2 min
(e) Compression set test 35% ( max) at 70 ± 1° C
(f) Elongation at break 250% min
(g) Accelerated aging in air (at 100 ± 2° C Change in harness: ±15 IRHD
for 72 hours) Tensile strength change: 20% (max)
Elongation change: max +10%/ -25%
(h) Accelerated aging in oil (at 100 ± 2° C Change in hardness: ±8 IRHD
for 72 hours) Tensile strength change: 35% (max)
Volume change: +20%/ -8%
(i) Time period between manufacturing To be used within self-life period, not
of gasket and its use to be used after expiry period
28. EPDM Gasket for Marshalling (a) Visual Check 1 sample/ IS 11149 Free from cracks & pinholes P W V
Box (b) Dimensional check (Thickness & Lot Within tolerance
Width)
(c) Tensile Strength As per IS 11149
(d) Elongation at break As per IS 11149
(e) Shore Hardness check as per DIN- As per IS 11149
53505
(f) Compression test (in air) as per DIN, As per IS 11149
ISO 815
Annexure-E
Vendor
29. Bushing CT Dimensions (Visual check for ID/OD, 100% IS 16227 As per approved drawing
thickness) IEC 61869-2
Routine test
(a) Verification of terminal marking & As per IS 16227/ IEC 61869-2
polarity
(b) Overvoltage inter-turn test Rated current withstand for 1 min
(c) Determination of error As per IS 16227/ IEC 61869-2
(d) HV Test (Dry power frequency 3 kV AC for 1 min withstand
withstand test on secondary winding)
(e) Accuracy Ratio As per IS 16227/ IEC 61869-2
(f) Secondary winding resistance for As per IS 16227/ IEC 61869-2
PS/PX class
(g) Knee point voltage & excitation
current for PS/PX class
30. Oil circulating pump (a) Visual check 100% IS 9137 no visual damage/ defect P P/W V
(as applicable) (b) No load running test (rpm, input Satisfactory performance & no load
power and current) losses within limit
(c)
(d) HV test (2kV power frequency Should withstand
withstand voltage test for 1 min)
(e) Oil pressure test on pumps at No leakage
5kg/cm2 for 30 min
(f) Locked rotor test Satisfactory operation of protection
31. Oil flow Indicator (a) Type, Make & Visual check 100% -- (a) As per standard document, no visual P P/W V
(as applicable) (b) Dial & Calibration damage/defect
(c) Contact Rating (b) As per standard document
(d) Dielectric Test between terminals (c) As per standard document
and earth (d) Shall withstand 2 kV for 1 min
(e) Leak test at 7 kg/cm2 for 2 min (e) No leak
(f) Alarm & trip operation check
(g) Full flow check
32. Power/Control Cable Review of Supplier’s TC for physical & Random -- As per standard document P P V
electrical tests as per
specification/drawing.
33. Silica Gel Breather (a) Dimension, Type and model check 100% - (a) Within tolerance, Type and model as P W -
(b) Check of healthiness & colour of per drg
Silica gel (b) No visible defect, Gel colour is
(c) Pressure test by blanking oil cup blue/Orange
end (c) No leak at 0.35 kg/cm2
(for 30 Min)
Annexure-E
Vendor
34. Drum for insulating oil (a) Visual check of inside cleanliness 100% IS 1783 –1 As per specifications/ IS 1783-1
and outside coat
(b) Dimensional check (thickness, height
& diameter)
(c) Leakage test on drum
(d) Drop test
(e) Hydraulic test
Annexure-E
Sr. No. Item/Process Sampling Reference / Acceptable Value Category of Responsibility*
rate Standard Sub- Vendor Manufacturer Customer
B IN-PROCESS INSPECTION
I CRGO Lamination for core
1. Visual check, check length & slitting One sample IS 3024 Prime CRGO and Free from defect -- P V
dimension of each lot
2. Dimensional check of CRGO As per design Drawings -- P V
3. Check for burr Less than 20 micron -- P V
4. Check for Edge bow As per IS 3024 -- P V
L< 250mm, H<= 2mm
L>= 250 mm, H<= 3mm
II Core Building
1. Visual check (frame assembly, 100% -- Free from defect -- P W

arrangement of insulation, bonding of
polyester tape)
2. Measurement of Total stack height As per design within specified tolerance of design -- P W
3. Core Diameter drawings within specified tolerance of design -- P W
4. Check window width, window height and within specified tolerance of design -- P W
diagonal of frame
5. Assembly of limb Insulation & plates As per design -- P V
6. Rectangularity of Core As per design -- P V
Assembly
7. Check for Overlaps & air gap at joints As per design -- P V
8. Check leaning/ inclination of Core No leaning -- P V
9. Earthing of Core (check of insulation resistance Proper connection -- P V
between CC-CL, CC-Yoke bolt, CL-Yoke Bolt by
2kV megger)
10. Limb Clamping & Binding As per design drawings -- P V
11. Insulation test between core & core clamp / As per shall withstand 2.5 kV DC for 1 min. -- P W
frame specification
12. Yoke Bolt Tightness Design drawing As per design P V
13. Loss measurement on built up core assembly As per Within limit as per GTP -- P W
OR validation by software specification/GTP
14. Built-up core sample collection for watt loss 1 sample To be furnished As per declared/offered value of Watt -- P V
verification per design loss value
III Winding/coil
1. Nos. of discs 100% As per approved As per Factory drawing -- P V
drawings /
Factory drawing
Annexure-E
2. No of turns / disc 100% As per approved As per Factory drawing -- P V

drawings/Factory
drawing
3. Dimensional checks 100% As per approved As per Factory drawing -- P V
i) Outer diameter drawings/
ii) Inner diameter
iii) Unshrunk height Factory drawing
iv) Radial thickness
4. Brazing procedure and brazer's qualification -- Customer As per approval - P V
approval
5. Visual inspection of brazed joints 100% As per brazing As per approval - P V
procedure
6. Visual check for transposition 100% As per design As per design - P V
drawings
7. Visual check for terminal marking & length 100% As per design As per design - P V
drawings
8. Insulation arrangement including end 100% As per design As per design - P V
insulation drawings
9. Lead & coil identification & marking 100% As per design As per design - P V
drawings
10. Continuity test (testing of winding continuity/ 100% -- No breaking of continuity - P V
brazing test)
11. Coil clamping for shrinking & shrunk coil 100% As per design As per design P V
height and clamping force drawings
12. Check arrangement of fiber optic sensor (FOS) 100% As per design As per design P V
(if applicable) drawings
13. Inter-turn Insulation 100% As per design As per design - P V
drawings
IV Core Coil Assembly
1. Visual Check of level of bottom yoke 100% -- As per design - P W
(bearing beam)
2. Visual Check assembly of the magnetic shields -- As per design - P W
(if applicable)
3. Visual Check strip barrier assembly on all limbs -- As per design - P W
4. Visual Check position of lead take out of HV -- As per design - P W
5. Visual Check clamping of upper yoke -- As per design - P W
6. Visual Check torque/ pressure of tensile bolt -- As per design - P W
7. Visual Check insulation resistance between -- As per design - P W
cooling duct by 500 V megger
8. Check IR between core and frame at 2 kV by -- As per design - P W
Megger.
Annexure-E
Check of insulation resistance between CC-CL,

CC-Yoke Bolt, CL-Yoke Bolt-2kV Megger
9. Visual check for inter-coil insulation -- As per design - P W

10. Lead & coil identification & marking -- As per design - P W
11. Brazing / Crimping of Joints -- Shall be smooth and no sharped age - P W
12. Visual check for completeness, cleanliness, -- Complete assembly shall be free from - P V
clearance of live parts, absence of sharp edges, dust / particles
placement of lead support assembly
13. Ratio test As per IS 2026 / Tolerance as per standards - P V
(Not applicable for Reactors) IEC 60076
14. Magnetic balance test As per IS 2026 / Tolerance as per standards - P V
15. Magnetizing current test, polarity & vector As per IS 2026 / Tolerance as per standards - P V
group (Not applicable for Reactors) IEC 60076
16. Alignment of Spacers/Blocks -- Aligned - P V
17. HV test Manufacturer’s 10kV for 1 min withstand - P W
standard
Core and Coil Assembly As per design As per plant standard
(including core cheese assembly) drawings
(For reactor only)
1. Check for alignment of core.
2. Verification of placement of first core cheese
assembly of core cheese
3. Vertically of limbs and limb Height
4. Visual Physical Verification
V DRYING OF ACTIVE PART: Vapor Phase Drying (VPD) Validation
1. Check of temp of Evaporator 100% Manufacturer’s Manufacturer’s standards/drawings/ - P V
2. Check temp of Main heating standards/drawings checklist
3. Check temp of Sprayed Kerosene /checklist
4. Check Vacuum Pressure (mbar) of VPD Graph of Vacuum Vs Time and
5. Check Vacuum Pressure (mbar) of Fine Temperature Vs time to be submitted
vacuum for review
6. Check Water Extraction (g / Hr / Ton of
Insulation) / Process Termination parameters
7. Check total process time (Hrs.)

8. Check Oil characteristics before impregnation
a. Electric strength
As per Annexure-L of the document
b. Water content
c. Tan delta at 90⁰C
d. Resistivity at 90⁰C(For Information)
Annexure-E
e. IFT at room temperature

VI Connections and checks before tanking
1. OLTC / OCTC fitting & connections 100% Manufacturer Manufacturer standard -- P ---
(Not applicable for Reactors) standard
2. Check for cable sizes 100% As per design As per design -- P V
drawings
3. Check for clearance from tank walls 100% As per design As per design -- P V
drawings
4. Visual checks for crimped joint 100% -- Shall be smooth and no sharped age -- P V
5. Visual checks for bushing CT assembly 100% -- Assembly tightness -- P V
tightness
6. Ratio test 100% As per IS 2026 / Tolerance as per standards -- P V
VII Tank
1. Thickness of walls 100% As per approved As per approved drawings -- P V
drawings
2. Dimensions 100% As per approved As per approved drawings -- P V
drawings
3. Visual internal Inspection 100% As per approved As per approved drawings P V
drawings
4. Pressure test 100% As per specification To withstand, permanent deflection -- P W
shall not exceed as per specification
5. Vacuum test 100% As per specification To withstand, permanent deflection -- P W
shall not exceed as per specification
VIII Opening, Tanking and Oil filling
1. Drying 100% Manufacturer Low voltage tan delta and PI values shall -- P
standard be checked periodically and after
achieving the satisfactory values the
process will be declared complete
2. Checks for complete tightness before 100% Manufacturer As per design -- P
taking standard
(a) Tightness of all joints / screws
(b) Application of thread locking
adhesive
(c) Padding of top yoke
(d) Pressing of active parts
(e) Fitting of wall shunts & packing
(f) Electrical clearance of core/coil
assembly after completion of
terminal gear connections.
Annexure-E
3. Cleanliness of tank before tanking 100% Manufacturer Shall be clean. -- P ---

standard
4. Tanking of active parts and check for 100% As per design As per design -- P V
clearance including clearance of the leads drawings
from tank walls & Core/frame earthing.
5. 2kV HV test between 100% As per To withstand 2kV for 1 min -- P V
(a) Core & end frame specification
(b) Core & yoke bolts
(c) End frame and yoke bolts
6. Check for oil quality before impregnation 100% As per As per specification -- P V
specification
7. Proper scarfing of insulation during tapping of 100% Manufacturer Manufacturer standard P V
terminal gear joints, position of leads. standard
8. Oil filling & Air release 100% Manufacturer Manufacturer standard -- P ---
standard
9. Impregnation process 100% Manufacturer Sufficient impregnation time shall be -- P ---
standard given before conducting the electrical
test on the transformer
Annexure-E
Sr. No. Test Sampling Reference / Acceptable Value Category of Responsibility*
rate Standard Manufacturer Customer
A. Acceptance Tests 100% Specification

For Transformers:
IS: 2026
IEC 60076 As per approved drawings
1. Appearance, construction and P W
dimension check as assembled for other applicable
testing standard
2. Check validity of calibration of all test As per Specification/ IS: 2026/ IEC - V
equipment and measuring 60076/ other applicable standard
instruments (e.g. HV test equipment,
Loss measurement kit, Partial
Discharge kit, impulse units etc.)
3. Measurement of winding resistance at P W
all taps
4. Measurement of voltage ratio at all P W
taps
5. Check of phase displacement and P W
vector group
6. Measurement of no-load loss and P W
current measurement at 90%, 100%
& 110% of rated voltage and rated
frequency
7. Magnetic balance test (for three phase P W
Transformer only) and measurement
of magnetizing current
8. Short Circuit Impedance and load P W
loss measurement at principal tap
and extreme taps
9. Measurement of insulation resistance P W
(IR) & Polarization Index (PI)
10. Measurement of insulation power P W
factor and capacitance between
winding to earth and between
windings
11. Measurement of insulation power P W
factor and capacitance of bushings
12. Tan delta of bushing at variable P W
frequency (Dielectric frequency
response)
13. Full wave lightning impulse test for P W
the line terminals (LI)
(for 72.5kV< Um≤170 kV)
Annexure-E
14. Chopped wave lightning impulse test P W

for the line terminals (LIC)
(for transformers with Um>170 kV)
15. Switching impulse test for the line P W
terminal (SI)
(for transformers with Um>170 kV)
16. Applied voltage test (AV) P W
17. Line Terminal AC withstand voltage P W
test (LTAC)
(for transformer with 72.5 kV< Um
≤170 kV)
18. Induced voltage withstand test (IVW) P W
(for transformers with Um ≤170 kV)
19. Induced voltage test with PD P W
measurement (IVPD)
20. Test on On-load tap changer (Ten P W
complete cycle before LV test) and
other tests such as One complete
operating cycle at 85 % of auxiliary
supply voltage ,one complete
operating cycle with Transformer
energized at rated voltage and
frequency at no load .Ten tap
change operation with +/- 2 steps of
principal tap with as far as possible
the rated current of Transformer
with one winding short circuited
etc. as per IS 2026
21. Measurement of dissolved gasses in P W
dielectric liquid from each separate oil
compartment
except diverter switch compartment.
22. Check of core and frame insulation P W
23. Leak testing with pressure for liquid P W
immersed transformers (tightness
test)
24. Measurement of no load current & P W
Short circuit Impedance with 415 V,
50 Hz AC.
25. Frequency Response analysis after P W
completion of test for max, min &
Annexure-E
normal tap (Soft copy of test report to

be submitted to site along with test
reports )
26. High voltage withstand test on P W
auxiliary equipment and wiring after
assembly
27. Tank vacuum test (at tank supplier P W
premises during tank manufacturing)
28. Tank pressure test (at tank supplier P W
premises during tank manufacturing)
29. Check of the ratio and polarity of P W
built-in current transformers
30. Short duration heat run test (Not P W
Applicable for unit on which
temperature rise test is performed)
31.
B. Type Tests/Special test One from Lot Specification/ Specification/ IS:2026 / IEC
For Transformers: IS:2026 / IEC 60076/other applicable standard
1. Measurement of transferred surge on 60076/other P W
Tertiary due to HV lightning impulse applicable
2. Measurement of transferred surge on standard P W
Tertiary due to HV switching impulse
3. Full wave lightning impulse test for P W
the line terminals (LI)
(for Um<= 72.5kV)
4. Chopped wave lightning impulse test P W
for the line terminals (LIC) (for
transformer with Um≤170 kV)
5. Lightning impulse test for the neutral
terminals (LIN)
6. Switching impulse test for the line P W
terminal (SI)
(applicable for Um>72.5 kV & ≤170
kV)
7. Temperature rise test P W

8. Measurement of Zero seq. reactance P W
(for three phase Transformer only)
Annexure-E
9. Measurement of harmonic level in no P W

load current
10. Determination of sound level P W
11.
12. Short circuit withstand capability P W
test (Dynamic)
RAtRating
Annexure–F
Typical example for calculation of flux density, core quantity,

no-load loss and weight of copper
Calculation of flux density, core quantity, no-load loss and weight of copper for a
specific transformer has been given below. Similar calculations for any rating of
transformer can be carried out and relevant data may be obtained from the
manufacturer.
Example: 75 MVA, 220/11, YNd11, 3 Phase, Power transformer,
Tap Range: -2.5% to +7.5% , Off-circuit Switch (Linear) connection
Measured data of core step width and thickness:

STEP WIDTH THICKNESS THICKNESS AREA OF AREA OF SUM OF
NO. STEP STEP STEP
AREA
(mm) (mm) (mm) (mm )
2 (mm )
2 (mm2)
1 260 8.25 8.25 2145.00 2145.00 4290.00
2 300 8.41 8.41 2523.00 2523.00 5046.00
3 320 8.17 8.17 2614.40 2614.40 5228.80
4 360 8.48 8.48 3052.80 3052.80 6105.60
5 380 8.52 8.52 3237.60 3237.60 6475.20
6 400 8.45 8.45 3380.00 3380.00 6760.00
7 440 8.42 8.42 3704.80 3704.80 7409.60
8 460 14.4 14.4 6624.00 6624.00 13248.00
9 500 10.05 10.05 5025.00 5025.00 10050.00
10 520 19.06 19.06 9911.20 9911.20 19822.40
11 560 25.43 25.43 14240.80 14240.80 28481.60
12 600 14.5 14.5 8700.00 8700.00 17400.00
13 620 15.5 15.5 9610.00 9610.00 19220.00
14 640 15.79 15.79 10105.60 10105.60 20211.20
15 660 19.1 19.1 12606.00 12606.00 25212.00
16 680 23.2 23.2 15776.00 15776.00 31552.00
17 700 23.07 23.07 16149.00 16149.00 32298.00
18 720 40.05 40.05 28836.00 28836.00 57672.00
19 740 71.67 71.67 53035.80 53035.80 106071.60
GROSS AREA (mm2): 422554.00

Stacking Factor = 0.96 to 0.97
NET CORE AREA (A)=Gross Area x Stacking factor= 422554 x 0.96 mm2 =
4056.52 cm2
CALCULATION OF FLUX DENSITY:
Phase voltage = 4.44 f x Bmax x A x N x 10-4

Where,
Phase voltage = 11 kV
Frequency (f) =50 Hz
A= 4056.52 cm2
N= No. of turns on 11 kV side =72
RAtRating
Maximum flux density, Bmax = (11000)/(4.44*50*4056.52*72*10-4) = 1.696 T
CALCULATION OF WEIGHT OF CORE:
D h
L H
Net core area (A) = 4056.52 cm2

Window height (L) = 2000 mm
Yoke height (h) =740 mm
Core Height (H) = L+ 2 x h= 2000 + (2 x 740 )=3480 mm
Window width (D) =810 mm
Limb Pitch = D+h = 810+740 = 1550 mm
There are 3 core heights and 4 window widths
Hence, total periphery of the core = 3H+4D = (3x3480) +(4x810)

= 13680 mm =1368 cm
Weight of the core

= Total periphery of the core x Cross-section area of core x Density of CRGO steel
=1368.0 x 4056.52 x 7.65 x 10-3
= 42452.3 kg
Guaranteed weight as per GTP= 42000 kg
Average Core Lamination Thickness =0.23 mm

Cooling duct thickness measured =4.24 mm
CALCULATION OF NO LOAD LOSS FROM SUPPLIER'S LOSS CURVES:
Weight of core lamination = 42452.3 kg
Flux density at normal tap at 100% rated voltage=1.696 T
Referring to supplier's curves for core losses against working flux density
The value of watts/kg at 1.7 Tesla. = 0.78 approx
No load loss = Core weight x Watts/kg at 1.7 Tesla x Building Factor x 10-3 kW
= 42452.3 x 0.78 x 1.11x 10-3= 36.755 kW
(Where the value of building factor taken is 1.11)
Guaranteed No Load Loss = 39.0kW

RAtRating
Calculated No load loss < (Guaranteed loss figure)
Estimation of copper quantity during stage Inspection
A. Weight of bare copper by ID/OD METHOD
Mean
Periphery Outer Dia (OD) Radial Dia (OD-
(P) =P/3.14 depth (RD) RD)
(mm) (mm) (mm) (mm)
LV Winding 3035 966.1 77.60 888.5
HV Winding 4585 1459.5 169.50 1290.0
Regulating 4585 1459.5 169.50 1290.0
(Tap) Winding
No. of Turns:
LV Winding: 72 HV Winding: 811 Tap Winding : 84
Type of Conductor in LV winding – Continuously Transposed Cable (CTC)

No. of Coils in LV Winding =1
No. of Cables parallel in LV Winding =2
No. of strands per cable in LV Winding = 77
Type of Conductor in HV winding – Twin Paper Insulated Copper Conductor

(TPICC)
No. of Coils parallel in HV Winding =2
No. of Cables per turn in HV Winding=2
No. of strands per cable in HV Winding=2
Type of Conductor in Tap winding – Paper Insulated Copper Conductor (PICC)

No. of Coils parallel in Tap Winding=2
No. of Cables per turn in Tap Winding=3
No. of strands per cable in Tap Winding=1
No. of phases = 3
Measured Strand dimension

Size of LV strand = 5.067 x 1.929 mm (with 0.1 mm enamel and 0.04 mm epoxy)
So bare size of LV strand = (5.067-0.1) x (1.929 -0.14*) mm (* Low chip epoxy used)
= 4.967 x 1.789 mm
Enamel coating on each side of strand
Epoxy ( Low chip epoxy: only between radial stand and

Full epoxy: between radial and axial strand)
Bare Size of HV strand = 9.880 x 1.792 mm

Bare Size of Tap strand = 7.845x 3.012 mm
Area of each LV Cable = Strand area x No of strands/Cable
RAtRating
= [(4.967x1.789)-0.363)] x 77 = 656.27 mm2

Area of each HV Cable = Strand area x No of strands/Cable
= [(9.88x1.792)-0.363)] x 2 = 34.68 mm2
Area of each Tap Cable = Strand area x No of strands/Cable
= [(7.845x3.012)-0.55] x 1 = 23.08 mm2
Bare Cu Weight of LV winding

= 3 x  x Mean Diameter x No. of Turns x Area of cable x No. of cables per turn x
Cu Density
= 3 x 3.142 x 888.5 x 72 x 656.27 x 2 x 8.89x 10-6 = 7036 kg
Bare Cu Weight of HV winding

Cu Density x No. of parallel Coils
= 3 x 3.142 x 1290 x 811 x 34.68 x 2 x 8.89x 10-6x 2= 12161 kg
Bare Cu Weight of Tap winding

Cu Density x No. of parallel Coils
= 3 x 3.142 x 1290 x 84 x 23.08 x 3 x 8.89x 10-6x 2= 1258 kg
Total Bare Copper weight = 7036+12161+1258 = 20455 kg
B. WEIGHT OF BARE COPPER BY PER UNIT LENGTH METHOD
Measured bare cable Cu weight of LV winding per 650 mm = 3718 gm

bare cable Cu weight of LV winding per unit length = 5720 gm/meter
Measured bare cable Cu weight of HV winding per 595 mm = 184 gm

bare cable Cu weight of HV winding per unit length = 309.3 gm/meter
Measured bare cable Cu weight of Tap winding per 745 mm = 160 gm

bare cable Cu weight of Tap winding per unit length = 214.8 gm/meter

= 3 x  x Mean Diameter x No. of Turns x No. of cables per turn x weight of unit
length
= 3x 3.142x888.5x72x 2 x5720 x 10-6 = 6898 kg

length x No. of parallel Coils
= 3x3.142x1290x811x2x309.3x2x 10-6 = 12200 kg

length x No. of parallel Coils
= 3 x3.142 x 1290x 84 x 3 x 214.8 x2x 10-6 = 1316 kg
Total Bare Copper weight = 6898+12200+1316 = 20414 kg
C. WEIGHT OF BARE COPPER BY RESISTANCE METHOD

RAtRating
Measured Ambient temperature = 31 oC

Measured Resistance of each strand of LV = 0.42760 ohm
Measured Resistance of each LV cable = 0.42760/77
= 0.005553ohm
Measured Resistance per strand of each HV coil (46 disc from HV center)
= 3.121 ohm
Measured Resistance per strand of each HV coil (Last 4 disc of HV bottom)

= 0.26834 ohm
So Total Measured Resistance per Stand of each HV coil (50 disc from HV centre)
= 3.121 + 0.26834
=3.38934 ohm
So Total Measured Resistance per Cable of each HV coil (50 disc from HV centre)
= 3.38934/2 = 1.69467 ohm
Measured Resistance per cable of each Tap coil (2 disc of Tap coil) = 0.067465 ohm
So, Total Measured Resistance per cable of each Tap coil (8 disc of Tap coil)
= 0.067465 x 8/2 =0.26986
Resistivity (ρ) of Copper (at 20 oC) = 0.017241 ohms- mm2/meter
Resistance Conversion factor at 20 oC = (235+20)/(235+31)= 0.95865

Resistance of LV Winding at 20 oC = Resistance of LV Winding x Resistance
Conversion factor
= 0.005553 x 0.95865 = 0.005324 ohm
Resistance per cable of each HV coil at 20 oC = Resistance of HV cable x Resistance
Conversion factor
=1.69467 x 0.95865 =1.6246 ohm
Resistance per cable of each Tap coil at 20 oC = Resistance of Tap cable x
Resistance Conversion factor
= 0.26986 x 0.95865
= 0.2587 ohm
R = ρ (L/A)
ρ : Resistivity, L : Length in Meters, A : Area of conductors in mm2
Length of each LV cable = (R x A)/ ρ = 0.005324x 656.27/ 0.017241

= 202.27 x103 mm
Length of each HV cable = 1.6246 x 34.68/ 0.017241
= 3267.86 x103 mm
Length of each Tap cable = 0.2587 x 23.08/ 0.017241
= 346.31 x103 mm
= 3 x length of per cable x area of each cable x no. of parallel cables x Cu density
= 3 x 202.27 x103 x 656.27 x 2 x 8.89x 10-6
= 7081 kg

= 3 x length of per cable x area of all parallel conductors x Cu density x No. of
parallel Coils
= 3 x 3267.86 x103 x 34.68 x 2 x 8.89x 10-6 x 2
= 12090 kg
RAtRating

= 3 x length of per cable x area of all parallel conductors x Cu density x No. of
parallel Coils
= 3 x 346.31 x 103 x 23.08 x 3 x 8.89x 10-6 x 2
= 1279 kg
Total Bare Copper weight = 7081+12090+1279= 20450 kg
D. CURRENT DENSITY CALCULATION:
LV winding:
Current = 2272.73 A; Conductor area = 656.27x2= 1312.54 mm2
Current density = 2272.73 / 1312.54 = 1.73 A/mm2
HV winding: (Minimum Tap)

Current = 201.88 A; Conductor area = 34.68 x2x2= 138.72 mm2
Tap Winding: (Minimum Tap)

Current = 201.88 A; Conductor area = 23.08 x3x2= 138.48 mm2
Annexure-G
BASIC MANUFACTURING FACILITY & MANUFACTURING ENVIRONMENT
Customer/Purchaser always desires that transformer manufactured and

delivered is of good quality and must perform trouble free service for its
“Specified Design Life”. The consistency in quality of material used &
manufacturing process are main cause for variation in quality of transformer.
It is also equally very important that transformer is manufactured in a clean
dust free and humidity controlled environment. Any compromise on this
aspect will have adverse effect in expected design life of transformer, however
good is the quality of material used. A broad list of facilities the transformer
manufacturers should have are given below:
Basic manufacturing facility
Following manufacturing facility should be available for use with transformer
manufacturer:
1. EOT Crane for main manufacturing bay and other shops (With Load Cell).
2. Vapor Phase Drying Oven (adequately sized to accommodate offered
transformer and have facility to record temperature, vacuum, moisture
etc.)
3. Air Casters for material handling
4. Core cutting line (if applicable)
5. Vacuum auto claves
6. Air oven
7. Adjustable Horizontal and vertical winding machine
8. Winding Mandrels
9. Hydraulic Press
10. Brazing equipment
11. Mechanical platform
12. Tools and fixtures
13. Mechanical power press
14. Welding machines
15. Crimping tools
16. Faraday’s cage
17. Motor Generator Set/ Static Power System Set
Annexure-G: Basic Manufacturing Facilities and manufacturing Environment Page 1 of 3

18. Testing transformer
19. Capacitor bank
20. Impulse voltage generator
21. Capacitance & Tan delta bridge
22. Power Analyser
23. Current & Voltage transformer
24. Partial Discharge (PD) measuring kit (for all manufacturers) & PD
Diagnostic Kit (for 400 kV & above voltage class Transformer
manufacturer)
25. Temperature data logger
26. Noise measurement kit
27. Thermo vision camera
28. Loss measurement kit
29. Insulation tester
30. Winding resistance meter
31. Turn ratio meter
32. Transformer oil test lab
33. Dissolved Gas Analysis (DGA) test kit
34. Sweep Frequency Response Analyser (SFRA) kit
35. Frequency Domain Spectroscopy (FDS) kit
36. NABL Accredited laboratory for testing
37. Oil Storage tanks
38. Oil filter plant with requisite level of vacuum and filter
39. Tensometer for Oil Surface tension
40. Particle Count Kit (for 400 kV & above Transformer)
41. Multimeters

Manufacturing environment (Clean, dust free and humidity controlled
environment)
A. Transformer must be manufactured in a bay having positive pressure

w.r.t. external environment. Winding shall be manufactured in an clean,
dust free and humidity controlled environment. The dust particle shall be
monitored regularly in the manufacturing areas. Further, there shall be
positive atmospheric pressure, clean, dust free and humidity controlled
environment for following:
1. Insulation storage
2. Core storage
3. Glue stacking area
4. Core cutting line
5. Winding manufacturing bay
6. Core building area
7. Core coil assembly area
8. Testing lab
9. Packing & dispatch area
B. Following accessories to be kept in clean and covered location:

1. Piping
2. Radiator
3. Tank
4. Bushing (as per manufacturer’s guideline)
5. Marshalling box
6. Turret
7. Conservator
8. Insulating oil

Annexure- H
List of drawings/documents to be submitted by the manufacturer
1.0 Each drawing shall be identified by a drawing number and each

subsequent resubmission/revision or addition to the drawing shall
be identified by a revision number. All drawings shall be thoroughly
checked for accuracy & completeness and signed. Any mistakes or
errors in drawings shall not form a basis for seeking extension of
delivery period.
2.0 In addition to any other drawings which the manufacturer may like
to supply, the following drawings/ calculations/ documents/
catalogues shall be submitted in hard and soft copy:
(a) Guaranteed Technical Particulars (GTPs) and other Technical

particulars
(b) Rating and Diagram Plate giving details of terminal marking
and connection diagram
(c) General Arrangement (GA) drawing (as built drawing) of
transformer showing Plan, Elevation, End view (left side &
right side view looking from HV side) and 3D view identifying
various fittings & accessories, dimensions, weight,
clearances, quantity of insulating oil, centre of gravity etc.
(d) View showing maximum lifting height of core-coil assembly
and maximum clearance over tank top required for taking out
the bushing.
(e) List of all accessories, description, make, weight and quantity
(f) Bill of Materials (BoM) with description, make & quantity
(g) Foundation Plan showing Rail gauge, fixing details of
foundation bolts, clamping arrangement to restrict movement
during earthquake & location of jacking pads and loading
details
(h) Bushing Drawing showing dimensions, electrical &
mechanical characteristics, mounting details and test tap
details (as applicable)
i) HV Bushing
ii) LV (or LV1/LV2)Bushing
iii) Tertiary Bushing
iv) Neutral Bushing
(i) Transport Dimension Drawing indicating transport weight,
transport condition (oil filled/ gas filled), lifting bollards,
Annexure-H: List of drawings/documents to be submitted by manufacturer Page 1 of 3

jacking pads, pulling eyes, quantity and location of impact
recorder etc.
(j) General Arrangement Drawing of Cooler Control Cabinet,
Marshalling box
(k) General Arrangement Drawing of RTCC panel (if applicable)
(l) GA drawing for Junction Box (if applicable)
(m) GA drawing for Cable Box (if applicable)
(n) Cooler Control Scheme: Schematic wiring diagram of cooling
arrangement along with write up on scheme
(o) Tap Changer Control Scheme (if applicable): Schematic wiring
diagram of OLTC along with write up on scheme
(p) Mounting Arrangement and wiring diagram of remote WTI
along with write up.
(q) Alarm/Trip Indication Scheme
(r) Valve Schedule Plate drawing showing all valves, air vents,
drain plugs etc. with type, size, material and quantity of
valves
(s) Technical literature of all fittings and accessories
(t) Calculation in support of thermal withstand capability of
transformer due to short circuit
(u) Calculation of hot spot temperature
(v) Value of air core reactance with a typical write-up of
calculation
(w) Magnetisation Characteristics of bushing CTs and neutral
CTs
(x) Hysteresis Characteristics of iron core
(y) Over fluxing withstand duration curve
(z) Typical heating and cooling curves
(aa) Drawing showing winding arrangement & geometrical
sequence w.r.t core with winding ID/OD, height & separation
distance between windings etc.
(bb) Twin bi-directional roller assembly drawing
(cc) Oil Flow Diagram
(dd) List of spares
(ee) Connection diagram of all protective devices to marshalling
box showing physical location
(ff) Insulating oil storage tank drawing
(gg) Oil sampling Bottle details
(hh) Customer inspection schedule
(ii) Test procedure of transformer/reactor
(jj) Manufacturer Quality Program (MQP) and Field Quality Plan
(FQP)

(kk) Field Welding Schedule for field welding activities (if
applicable)
(ll) Type test reports
(mm) O&M manual (hard copy and soft copy) of
transformer/reactor inter-alia including instructions for
Aircell, Oil filling, Bushing removal and Core Coil Assembly
un-tanking etc.

Annexure – I
SCOPE OF DESIGN REVIEW
Sr. No. Description

1. Core and Magnetic Design
2. Over-fluxing characteristics up to 1.7 Um (for transformer) and Linear
characteristics (for reactor)
3.
4. Inrush-current characteristics while charging
5. Winding and winding clamping arrangements
6. Characteristics of insulation paper
7. Typical data and parameters mentioned in GTP
8. Short-circuit withstand capability including thermal stress / withstand
capability for 2 seconds .
9. Thermal design including review of localized potentially hot area
10. Structural design
11. Overvoltage withstand capability of reactor
12. Cooling design
13. Overload capability
14. Calculations of losses, flux density, core quantity etc.
15. Calculations of hot spot temperature
16. Eddy current losses
17. Seismic design, as applicable
18. Insulation co-ordination
19. Tank and accessories
20. Bushings
21. Mechanical layout design including lead routing and bushing termination
22. Tapping design (as applicable)
23. Protective devices
24. Number, locations and operating pressure of PRD )
25. Location, Operating features and size of Sudden Pressure Relay/ Rapid
Pressure Rise Relay
26. Radiators and Fans
27. Sensors and protective devices– its location, fitment, securing and level
of redundancy
28. Oil and oil preservation system
29. Corrosion protection
30. Electrical and physical Interfaces with substation
31. Earthing (Internal & External)
32. Processing and assembly
33. Testing capabilities
34. Inspection and test plan
35. Transport and storage
36. Sensitivity of design to specified parameters
37. Acoustic Noise
38. Spares, inter-changeability and standardization
39. Maintainability
40. Conservator capacity calculation
41. Winding Clamping arrangement details with provisions for taking it “in
or out of tank”
42. Conductor insulation paper details
43. Location and numbers of Optical temperature sensors (if provided)
44. The design of all current connections
45. Location & size of the Valves
46. Manufacturing facilities and manufacturing environment (clean, dust
free, humidity controlled environment) as per Annexure G
Annexure-J
CRITERIA FOR SELECTION OF SIMILAR REFERENCE TRANSFORMER

FOR DYNAMIC SHORT CIRCUIT WITHSTAND TEST
A transformer is considered similar to another transformer taken as a

reference if it has the following characteristics in common with the latter:
 Same type of operation, for example generator step-up unit,

distribution, interconnection transformer;
 Same conceptual design, for example dry type, oil-immersed type, core
type with concentric windings, sandwich type, shell type, circular coils,
non-circular coils;
 Same arrangement and geometrical sequence of the main windings;
 Same type of winding conductors, for example aluminium, aluminium

alloy, annealed or work-hardened copper, metal foil, wire, flat
conductor, continuously transposed conductors and epoxy bonding, if
used;
 Same type of main windings, for example helical-, disc-, layer-type,

pancake coils;
 Absorbed power at short circuit (rated power/per unit short-circuit

impedance) between 70% and 130% of that relating to the
reference transformer;
 Axial forces and winding stresses occurring at short circuit not

exceeding 120 % of those relating to the reference transformer;
 Same manufacturing processes;
 Same clamping and winding support arrangement.
(Note:-A format for comparison of characteristics as given above of

successfully type tested reference transformer and of transformer short
circuit strength of which shall be evaluated (offered transformer) has been
provided below. Data of a typical sample reference transformer has been
filled for reference and guidance of utility to compare a Short Circuit tested
transformer with the offered transformer in order to verify the similarity
criteria.)
Annexure-J: Criteria for selection of similar reference transformer for dynamic short circuit
withstand test Page 1 of 27
DATE : Format for determining similar reference Manufacturer NAME
DOC No.: transformer for short Circuit withstand
Page: -- of -- Strength
Details of Details of SC tested transformer Is Reference document

offered charact /Remarks if any
transformer eristic
short circuit similar
strength of ?
which is being
evaluated
General Information
Customer and Purchase
Order No.:
Project Name:
Transformer General
Rating Description
315MVA, 400/220/33KV
(MVA, Voltage Ratio,
AUTOTRANSFORMER, 3 phases, --kA
tested short circuit
current):
Annexure-J: Criteria for selection of similar reference transformer for dynamic short circuit withstand test Page 2 of 27
Unit number/ Serial no:
Short circuit test -NA-
KEMA, Netherland
laboratory detail:
Short circuit test report -NA-
reference No. & Date:
Characteristics as per IEC 60076-5 :2006
1 Type of Transformer AUTO transformer Yes/No Reference:
based on operation: 1. *Rating & Diagram plate
2. Approved GTP
e.g. Generator Step up
unit; Distribution;
Interconnecting; Auto;
Station auxiliary etc.
2 Factory of production, Reference:
material used (Material Short circuit test report
of conductor, cellulose
insulating material,
oil, grade of CRGO
material), and as built
Drawing
3 Tested Short Circuit Reference:
Current and duration Short circuit test report along
of Dynamic short with as built drawing
circuit current (250ms
/ 500ms)
4 Conceptual design OIL-IMMERSED, CORE TYPE, Yes/No Reference:
CONCENTRIC WINDINGS, CIRCULAR 1. Rating & Diagram plate
e.g. Dry / oil-immersed
COILS 2. Approved GTP
type ; Core type with
concentric windings /
sandwich type, shell
type, Circular coils /
non-circular coils
5 Arrangement and CORE - LV (TER) – REG – IV - HV Yes/No Reference:
geometrical sequence 1. Winding assembly drawing
of main windings in Short circuit test report if
available
e.g.; Core-LV-HV-T
2. *Or Representative Coil
assembly drawing reference
6 Type of conductors for LV Tap IV HV Yes/No Reference:
each winding 1. *Test Certificates submitted
Condu COPP COPPE COPP COPP by the conductor Vendor for
e.g aluminium / ctor ER R ER ER each winding
aluminium alloy,
Type CTC CTC CTC CTC 2. Approved GTP
annealed or work-
hardened Copper; metal Epoxy Yes
foil / wire / flat Yes Yes Yes
coated
conductor /
Continuously Proof
Transposed conductor; stress
Epoxy bonding (Yes/No); N/mm
work hardened Proof (min)
stress (min) N/mm2
7 Type of each windings Wind LV Tap IV HV Yes/No Reference:
ing 1. In case Short ckt. test report
is inclusive of detail on
5a e.g. Helical- Type Layer Multi- Disc Dis  Winding type
/Layer- / /Disc start c  Lead entry detail
Disc- type / Layer 2. Representative Coil assembly
pancake coils drawing reference
Line Top/B Top/Bott Top/Bo Cen
e.g. Line lead Lead ottom om ttom ter
entry (top, entry entr
5b y
bottom ,
Center, Edge )
8 Absorbed power at Sc. Max Min Nor Yes/No Reference:
Short Circuit Tested Voltage Voltage Voltag 1. Short ckt test report
Transfor Tap Tap e Tap inclusive of Routine test
(= Rated Power/per unit
mer Impedance values
short circuit impedance)
Rated 315 315 315
[The ratio shall be
MVA
between 70 % to 130% of
that rating of the Impedan 10.4% 12.5% 15.4%
reference transformer] ce
measure
d after
sc. test
Absorbe
d power 3028.8 2045.4
(MVA) 5 2520.00 5
9 Axial force and As per Table given in IS 2026-5/IEC Yes/No Reference:
winding stresses 60076-5.
occurring at short
(A typical example with data of forces
circuit as per IS table 1. As per calculation made /
and stresses has been provided at the
results of the simulation
(Simulated as in Same end of this Annexure-J.)
software used
Declared Program or (Name of software used
same Calculation
:…….)
method used)
[The axial forces and
winding stresses
occurring at SC shall not
exceed 120% of that of
reference transformer]
10 Same manufacturing General Process reference to be Yes/No Reference:

process provided 1. *Standard QAP plan
submitted
Manufacturing process as per Standard
2. Standard document for
common practice & QAP plan for the
Manufacturing Practice (On
subject rating & type
site availability)
11 Same clamping and General conceptual description to be Yes/No Reference:
winding support provided 1. Clamping arrangement:
arrangement Provide basic details
1. Core clamping drawing with support 2. Winding bottom support
[Core Clamping arrangement and calculation of SC
structure and cleat & lead
principle, winding radial force withstand by clamping
arrangement: Adequacy has
& axial support system, structure. been validated by the
cleats & lead support 2. Winding drawing with axial and
simulation software…..
arrangement] radial support details, lead exit
details
*To be made part of short circuit test report document

(For design to be similar every criteria specified above should match)
Result: The reference transformer was found/not found to be similar to the offered transformer. Design review
of offered transformer can be carried out by comparison with reference transformer as per the process given in
IEC 60076-5.
Manufacturer Signature Purchaser’s Signature
Representative Coil assembly reference Winding Arrangement
The detail comparison of technical parameters of typical offered & reference short circuit tested
transformer is given below. The data is for reference and guidance purpose only.
Technical parameter of Offered & Short circuit tested Transformer

Sr. Technical Parameters Short Circuit Tested Unit Rating Offered Transformer
No
1.00 Contract Ref. ……… ………
1.01 Package & Substation ……… ………
2.00 Rating
2.01 HV / LV 315 MVA 500 MVA
2.02 TV 105 MVA 167 MVA
2.03 Cooling ONAN/ONAF/ODAF ONAN/ONAF/ODAF
2.04 Rating at Different cooling 189/252/315MVA (60%/80%/100%) 300/400/500MVA (60%/80%/100%)
2.05 Voltage ratio 400/220/33 kV 400/220/33 kV
2.06 Voltage / Turn 200 280
2.07 Frequency 50 Hz 50 Hz
2.08 Phases 3 3
Max. Partial discharge at 1.58
2.09 <100 pC <100 pC
Um/3
2.10 Design of Power Frequency Level 570 kVrms 570 kVrms
2.11 Noise Level 80 dB 80 dB
No
2.12 Neutral (Solidly Earthed) Solidly Earthed Solidly Earthed
2.13 Service Outdoor Outdoor
2.14 Duty Continuous Continuous
2.15 Overload capacity As per IEC 60076-7 As per IEC 60076-7
3.00 Impedance with Tolerance

3.01 HV - LV
3.02 Normal tap Designed/Guaranteed/Measured Designed/Guaranteed
3.03 Max Voltage tap 12.10%/12.5% ± IEC Tol/12.4% 12.4%/12.5% ± IEC Tol
3.04 Min Voltage tap 9.8%/-/10.12% 9.8%/10.3% ± IEC Tol
3.05 HV - TV 16.8%/-/16.29% 16.1%/15.4% ± IEC Tol
3.06 Normal tap
3.07 Max Voltage tap 67%/60% Min/69.36% 64%/60% Min
3.08 Min Voltage tap 59%/-/60.81% 56%
3.09 LV-TV 79%/-/80.94% 75%
Temp. rise over an ambient of 50

4.00
Deg C
4.01 Top Oil 35 Deg C 45 Deg C
No
4.02 Winding 40 Deg C 50 Deg C
4.03 Winding hot spot rise 66 Deg C 61 Deg C
4.04 Core hot spot rise 61 Deg C 55 Deg C
Guaranteed losses at Principle tap,

rated voltage & frequency
5.00 Guaranteed/Measured/Designed Designed/Guaranteed
(Mentioned measured values in DSC
tested unit)
5.01 Load Loss, kW 444.5/425.78/429.39 495/500
5.02 No Load loss, kW 104.5/84.27/84.18 88.4/90
5.03 Aux Loss, kW 8.5/6.76/8.28 15/15
6.00 System Fault Level (HV / IV / LV)
If System fault level is higher than
SC tested T/F please submit
6.01 50/40/-kA 63/50/-kA
calculation of short circuit
impedance variation.
7.00 Winding connection (HV/IV/LV) Auto Star/Delta Auto Star/Delta
8.00 Insulation (HV/IV/LV) Graded/Graded/Uniform Graded/Graded/Uniform
1300kVp/1430kVp/1050kVp/570kVrms 1300kVp/1430kVp/1050kVp/570kVrms
8.01 HV (LI/LIC/SI/PF/AC)
/38kVrms /38kVrms
950kVp/1045kVp/750kVp/395kVrms/3 950kVp/1045kVp/750kVp/395kVrms/3
8.02 IV (LI/LIC/SI/PF/AC) 8kVrms 8kVrms
No
8.03 LV (LI/LIC/AC) 250kVp/275kVp/95kVrms 250kVp/275kVp/95kVrms
8.04 N (LI/AC) 170kVp/38kVrms 170kVp/38kVrms
9.00 Bushing Ratings
9.01 HV 420kV/2000A, OIP Condenser 420kV/1250A, RIP Condenser
9.02 LV 245kV/1250A, OIP Condenser 245kV/2000A, RIP Condenser
9.03 TV 72.5kV/3150A, OIP Condenser 52kV/3150A, RIP Condenser
9.04 Neutral 36kV/2000A, Oil Communicating 36kV/2000A, Oil Communicating
9.05 Impulse level (HV/IV/LV/N) 1425kVp/1050kVp/250kVp/170kVp 1425kVp/1050kVp/250kVp/170kVp
9.06 Switching impulse level (HV/IV) 1050kVp/850kVp 1050kVp/850kVp
Power Frequency (Dry) 695kVrms/505kVrms/105kVrms/77 695kVrms/505kVrms/105kVrms/77
9.07
(HV/IV/LV/N) kVrns kVrns
10.0
CORE
0
10.0
Flux Density at Rated Voltage 1.722 T 1.72 T
1
10.0 Core Construction
3 Main Limbs / 2 Return Limbs 3 Main Limbs / 2 Return Limbs
2 [main limb / return limb]
Cross-section ratio -
10.0 100% & 53% 100% & 53%
Main & Return limb
3 100% & 53% 100% & 53%
Main limb & Yoke
No
10.0
Core Diameter 815 1015
4
10.0 Window Height (top of Bottom yoke
2500 2400
5 to bottom of top yoke)
10.0
Phase center /Phase - Return limb 2315 / 1420 2610/1650
6
10.0
Grade HP Grade HP Grade
7
10.0
Building factor 1.17 1.18
8
10.0
Weight 67500 kgs Approx. 108500 kgs Approx.
9
11.0
Winding
0
11.0 Winding arrangement sequence Core - LV - Reg. - Common - Series Core - LV - Reg. - Common - Series
1 (Core - LV - Reg. - Common - Series)
11.0
Winding Type & Material
2
11.0
LV Helical, Electrolytic Copper Helical, Electrolytic Copper
3
11.0
REG Multi Helical, Electrolytic Copper (Tap) Multi Helical, Electrolytic Copper (Tap)
4
No
11.0
IV Disc, Electrolytic Copper Disc, Electrolytic Copper
5
11.0
HV Shielded disc, Electrolytic Copper Shielded disc, Electrolytic Copper
6
12.0 Conductor Type / dimension /

0 Insulation
12.0 Epoxy Bonded CTC, 1.5 x 7.8//23, 0.5 Epoxy Bonded CTC, 2|| (1.3 x 5.4//31),
LV
1 PI 0.5 PI
Epoxy Bonded CTC, 1.25 x 4.8//25, 1.5 Epoxy Bonded CTC, 1.36 x 6.5//27, 1.5
12.0
REG PI PI
2 (ZNO elements used) (ZNO elements used)
12.0 Epoxy Bonded CTC, 1.4x 6.45//23, 1.1 Epoxy Bonded CTC, 2|| (1.1 x 6.4//25),
IV
3 PI 1.1 PI
12.0 Epoxy Bonded CTC, 2 X (1.4 x 5.5//17), Epoxy Bonded CTC, 2 X (1.1 x 5.7//35),
HV
4 1.5 PI 1.5 PI
13.0
Proof Stress Value in Mpa
0
13.0
LV 180 200
1
13.0
REG 160 200
2
13.0
IV 200 200
3
No
13.0
HV 160 200
4
13.0
ID / OD / Height
0
13.0
LV 875/955/1900 1075/1160/1780
1
13.0
REG 1115/1155/1780 1320/1365/1700
2
13.0
IV 1305/1575/1950 1515/1845/1790
3
13.0
HV 1755/2100/1950 2069/2430/1790
4
14.0 No of Turns (Max / Nor / Min)

0 Voltage Tap
14.0
LV 165 115
1
14.0
REG 112/0/112 80/0/80
2
14.0
IV 635 450
3
14.0
HV 520 368
4
No
15.0
Winding weight Bare Copper Bare Copper
0
15.0
LV 3440 kg 4300 kg
1
15.0
REG 2100 kg 2300 kg
2
15.0
IV 16450 kg 20700 kg
3
15.0
HV 22400 kg 27500 kg
4
16.0 Current Density (Max / Nor / Min)

0 Voltage Tap (A/mm²)
16.0
LV 4.02 3.99
1
16.0
REG 2.85/3.14/3.49 2.81/3.1/3.44
2
16.0
IV 2.03/1.83/1.58 1.92/1.73/1.49
3
16.0
HV 1.62/1.78/1.98 1.54/1.7/1.89
4
17.0 Loss at Max / Nor / Min Voltage

0 Tap (kW)
No
17.0
I2R 385 / 344 / 415 441 / 394 / 471
1
17.0
Stray 39/ 45 / 56 47 / 54 / 117
2
17.0
Eddy 30/ 37 / 55 37 / 47 / 67
3
17.0
Stray+Eddy 69 / 82 / 111 84 / 101 / 184
4
17.0
Total Load Loss 454 / 426 / 526 525 / 495 / 655
5
17.0
% (Stray+Eddy) of Load loss 15.2 / 19.3 / 21 16 / 20.5 / 28
6
17.0
Core loss 84.5 88.4
7
18.0
GAP (mm)
0
18.0
CORE - LV or CORE-TV 30 30
1
18.0
LV - REG 80 80
2
18.0
REG - IV 75 75
3
18.0
IV-HV 90 112
4
No
18.0
PH - PH 175 177
5
18.0
PH - RETURN LIMB 160 166
6
19.0
Spacers / Circle (Nos. x Width)
0
19.0
LV 24 x 35W 36 X 30W
1
19.0
REG 24 x 45W 36 X 40W
2
19.0
IV 36 X 40W 36 X 45W
3
19.0
HV 36 X 50W 36 X 60W
4
Supporting Area
20.0
((No of spacer x width) *100/Mean
0
dia)
20.0
LV 29.20% 31.0%
1
20.0
REG 30.3% 34.1%
2
20.0
IV 32.0% 31.0%
3
20.0
HV 30.0% 30.5%
4
No
21.0
Top Ring Thickness & Material 100 mm & Laminated Press Board 130 mm & Laminated Press Board
0
22.0
Bottom Ring Thickness & Material 80 mm & Laminated Press Board 90 mm & Laminated Press Board
0
23.0
Oil Quantity during first filling 100 kL 115 kL
0
24.0
Tank Thickness
0
24.0
Side 12 mm 12 mm
1
24.0
Top 25 mm 25 mm
2
24.0
Bottom 20 mm + Box Stiffener 20 mm + Box Stiffener
3
Change of Solid Insulation & Oil

25.0 Similar/No change w.r.t short circuit
duct for above GAP (Sr. No – 18.0) -
0 tested unit.
YES / NO
Active Part arrangement

(Core & Coil Assembly) Change -
0 tested unit.
YES / NO
No
Internal clearance in oil (Active part
- Tank) -
0 tested unit.
Change (Yes / No)
Cooling System (Radiator, Fans,
Pumps)
28.0 Same / Fans & pumps are suitably
Change (Yes / No), If yes, submit -
0 considered to dissipate total losses
detailed design calculation for
supporting documents)
DOC No : ______________
Comparison Table - Forces & Electric Field Stress Summary
REV : _________________
Sr. Technical Parameters 315MVA, 400/220/33 kV 500MVA, 400/220/33 kV
No Short Circuit Tested Offered Transformer
1.0 NOA Ref No. ----- -----
1.1 Package & Substation ----- -----
Radial Forces (Actual / Permissible)
2.0
(N/mm2 or Mpa)
2.1 LV 57.05/180 Mpa 47.5/200 Mpa
2.2 Regulating 56.06/160 MPa 75.16/200 Mpa
2.3 IV 61.93/200 Mpa 69.56/200 Mpa
2.4 HV 86.14/160 Mpa 100.25/200 Mpa

Axial Tilting Forces (Actual /
3.0
Permissible) ( kN)
3.1 LV 3954/37207 kN 485/105686 kN
3.2 Regulating 296/6764 kN 398/3164 kN
3.3 IV 1436/129384 kN 1819/111123 kN
3.4 HV 1105/56222 kN 2405/349302 kN
4.0 Axial Yoke Clamp Force in Winding (kN) 1912 kN 1723 kN

Compressive Force in Winding
5.0
(Actual / Permissible) (kN)
5.1 LV 3954/9845 kN 485/1421 kN
5.2 Regulating 296/432 kN 398/796 kN
5.3 IV 1436/2585 kN 1819/4075 kN
5.3 HV 1105/3591 kN 2405/4642 kN

Tengential (Spiralling) Force in LV
6.0 310.36/979.24 18.29/61.6
Winding (Actual / Permissible) (kN)
Dielectric Stresses (Actual /
7.0
Permissible) (kVrms/mm)
7.1 Oil Stress (Core - LV) < 6.5 kVrms/mm
7.2 Oil Stress (LV - Regulating) < 6.5 kVrms/mm
7.3 Oil Stress (Regulating- IV) < 6.5 kVrms/mm
7.4 Oil Stress (IV- HV) < 6.5 kVrms/mm
7.5 Max Oil Stress Location & Value IV - HV winding < 6.5 kVrms/mm
7.6 Creep Stress in LV Winding < 3 kVrms/mm
7.7 Creep Stress in Regulating Winding < 3 kVrms/mm
7.8 Creep Stress in IV Winding < 3 kVrms/mm
7.9 Creep Stress in HV Winding < 3 kVrms/mm
7.10 Paper Stress < 16 kVrms/mm
7.11 Stress at Normal Service condition Less than half of above values
Comparison of forces and stresses of 500MVA,400/220/33kV,3-Phase Auto Transformer with SC tested Doc. No: _________________;
315MVA,400/220/33kV, 3-Phase Auto Transformer as per IEC-60076-5 Rev_________
Type of Tertiary Winding Tap Winding Common Winding Series Winding

force/
Stress
Actu Referen Allowa Critic Actua Referen Allowa Critic Actu Referen Allowa Critic Actu Referen Allowa Critic
al ce ble al l ce ble al al ce ble al al ce ble al
Mean
hoop
tensile
stress
on disc-,
Not Applicable 16.41 10.99 160 - 21.95 14.18 200 - 100.25 86.14 200 -
helical-,
and layer
type
windings
(Mpa)
Mean
hoop
compressi
ve
stress on
disc, 47.5 57.05 160 - 75.16 56.06 160 69.56 61.93 200 Not Applicable
helical,
single
layer type
windings
(Mpa)
Equivalent Not applicable
mean hoop
compressi
ve stress
on multi
layer type
windings
(Mpa)
Stress due
to radial
bending of
conductor
s between 70.5 642 211.5 - 69.6 14.63 123.8 - 201.9 22.66 278.6 - -
axial
sticks and
spacers
(Mpa)
Stress
due to
axial
bending
of
305.44 1375 1460 - 177.8 134.8 1146.8 - 2574.08 1114 8597.4 - 2336.2 5160 11120.4 -
conductor
s between
radial
spacers
(Mpa)
Thrust
force
acting on
the
low
18.29 310.36 61.6 - Not Applicable Not Applicable Not Applicable
voltage
winding
lead
exists
(kN)
Maximum
axial
compressi
on
force on 485 3954 1421 - 398 296 796 - 1819 1436 4075 - 2405 1105 4642 -
each
physical
winding
(kN)
Maximum
axial
compressi
on
force on
winding 485 3954 - 105686 398 296 - 3164 1819 1436 - 111123 2405 1105 - 349302
compared
to crit.
Force for
tilting
(kN)
Maximum
end
thrust
force on
201/ 2429/ 101/ 572/ 531/ 785/ 732/
physical - - 82/59 - - - - - -
165 3316 97 744 508 877 750
winding :
- UP (kN)
- DOWN
(kN)
Compress
ive stress
on
conductor
paper
11.25 20.1 80 - 17.66 16.77 80 - 8.78 12.56 80 - 10.55 5.78 80 -
Insulatio
n and
radial
spacers
(Mpa)
Compress
ive stress
on end
stack
4.66 12.35 80 - 4.48 4.64 80 - 2.76 4.63 80 - 3.44 3.83 80 -
insulation
structure
s and end
ring (Mpa)
Actual Reference Allowable Critical
Compress
ive stress
on
common 59.21 60.27 80 -
press
rings
(Mpa)
Tensile
stress on
Not Applicable Not Applicable Not Applicable Not Applicable
tie rods
(Mpa)
Clamping
force per 1723 1912 -
limb (kN)
Annexure-K
PAINTING PROCEDURE
PAINTING Surface Primer Intermedi Finish Total Colour

preparatio coat ate coat Dry shade
n undercoat Film
Thick-
ness
(DFT)
Main Shot Blast Epoxy Epoxy high Aliphatic Minimu RAL
tank, cleaning base build polyureth m 7035
pipes, Sa 2 ½* Zinc Micaceous ane (PU) 155m
conservat primer iron oxide (Minimum
or tank, (30- (HB MIO) 50m)
oil storage 40m) (75m)
tank &
Driving
Mechanis
m (DM)
Box etc.
(external
surfaces)
Main Shot Blast Hot oil -- -- Minimu Glossy
tank, cleaning resistan m 30m white for
pipes Sa 2 ½* t, non- paint
(above 80 corrosiv
NB), e paint,
conservat low
or tank, viscosit
oil storage y
tank & varnish
DM Box or
etc. epoxy
(Internal
surfaces)
Radiator Chemical / Epoxy Epoxy PU paint Minimu Matching
(external Shot Blast base base Zinc (Minimum m shade of
surfaces) cleaning Zinc primer 50m) 100m tank/
Sa 2 ½* primer (30-40m) different
(30- shade
40m) aesthetic
ally
matching
to tank
Manufacturer may also offer Radiators with hot dip galvanised
(in place of painting) with minimum thickness of 40m (min)
Radiator Chemical Hot oil -- -- -- --
and pipes cleaning, if proof,
up to 80 required low
NB viscosit
(Internal y
surfaces) varnish
or Hot
oil
resistan
t, non-
corrosiv
e Paint
Digital Seven tank Zinc -- EPOXY Minimu RAL
RTCC process as chroma paint with m 80m 7035
Panel per te PU top / for shade
IS:3618 & primer coat or powder for
IS:6005 (two POWDER coated exterior
coats) coated minimu and
m 100m Glossy
white for
interior
Control cabinet / Marshalling Box - No painting is required.
Note:
(*) indicates Sa 2 ½ as per Swedish Standard SIS 055900 of ISO 8501 Part-1.
NB: Nominal Bore
Annexure–L
I. UNUSED INHIBITED HIGH GRADE INSULATING OIL PARAMETERS
Sl. Property Test Method Limits

No.
A Function
1a. Kinematic IS 1448 Part 25 or ISO 12 mm2/s (Max.)
Viscosity at 40 °C 3104 or ASTM D7042
1b. Kinematic 1800 mm2/s (Max.)
Viscosity at -30
°C
2. Appearance A representative The oil shall be clear and
sample of the oil shall bright, transparent and free
be examined in a 100 from suspended matter or
mm thick layer, at sediment
ambient temperature
3. Pour point IS 1448 Part 10/Sec 2 -40 °C (Max.)
or ISO 3016
4. Water content IEC 60814
a) for bulk supply 30 mg/kg (Max.)
b) for delivery in 40 mg/kg (Max.)
drums
5. Electric strength IS 6792 or IEC 60156 Minimum 30 kV (new
(breakdown unfiltered oil) / 70 kV (after
voltage) treatment)
6. Density at 20 °C IS 1448 Part 16 or ISO 895 kg/m3 (Max.)
12185 or ISO 3675 or
ASTM D7042
7. Dielectric IS 16086 or IEC 60247 0.0025 (Max.)
dissipation factor or IEC 61620
(tan delta) at 90
°C
8. Negative impulse ASTM D3300 145 (Min.)
testing KVp @ 25
°C
9. Carbon type IEC 60590 and IS Maximum Aromatic : 4 to12
composition (% of 13155 or ASTM %
Aromatic, D2140 Paraffins : <50%
Paraffins and & balance shall be
Naphthenic Naphthenic compounds.
compounds )
B Refining/Stability
1. Colour ISO 2049 L0.5 (less than 0.5)
Annexure-L: Unused inhibited/uninhibited insulating oil parameters Page 1 of 6

2. Appearance – Clear, free from sediment
and suspended matter
3. Neutralization IEC 62021-1 or IEC 0.01 mg KOH/g (Max.)
Value (Total 62021-2
Acidity)
4. Interfacial tension IEC 62961 or ASTM 0.043 N/m (Min.)
at 27°C D971
5. Total sulphur ISO 14596 or ISO 0.05 % (Max.)
content 8754 (before oxidation test)
6. Corrosive sulphur DIN 51353 Not Corrosive
7. Potentially IEC 62535 Not Corrosive

corrosive sulphur
8. Presence of IS 13631 or IEC 0.08% (Min.) to 0.4% (Max.)

oxidation 60666
inhibitor
9. DBDS IEC 62697-1 Not detectable (<5 mg/kg)
10. Metal passivator IEC 60666 Not detectable (<5 mg/kg)
additives
11. 2-Furfural and IS 15668 or IEC Not detectable (<0.05
related compound 61198 mg/kg) for each individual
content compound
12. Stray gassing Procedure in Clause Non stray gassing:
under thermo- A.4 of IEC 60296- < 50 µl/l of hydrogen (H2)
oxidative stress 2020 and < 50 µl/l methane (CH4)
(oil saturated with air) and < 50 µl/l ethane (C2H6)
in the presence of
copper
C Performance
1. Oxidation IEC 61125 (method c)
stability Test duration: 500
hours
-Total acidity* 4.8.4 of IEC 0.3 mg KOH/g (Max.)
61125:2018
-Sludge* 4.8.1 of IEC 0.05 % (Max.)
61125:2018
-Dielectric 4.8.5 of IEC 0.05 (Max.)
Dissipation 61125:2018
Factor* (tan delta)
at 90 °C
*values at the end of oxidation stability test

D Health, safety and environment (HSE)

1. Flash point IS 1448 Part 21 or ISO 135 °C(Min.)
2719
2. Poly Cyclic IP 346 <3%
Aromatic (PCA)
content
3. Poly Chlorinated IS 16082 or IEC Not detectable (< 2 mg/kg)
Biphenyl (PCB) 61619
content
Note: Supplier shall declare the chemical family and function of all additives
and the concentrations in the cases of inhibitors, antioxidants and passivators.
II. UNUSED UNINHIBITED INSULATING OIL PARAMETERS
Sl. Property Test Method Limits

No.
A Function
1a. Kinematic IS 1448 Part 25 or ISO 12 mm2/s (Max.)
Viscosity at 40 °C 3104 or ASTM D7042
1b. Kinematic 1800 mm2/s (Max.)
Viscosity at -30
°C
2. Appearance A representative The oil shall be clear and
sample of the oil shall bright, transparent and free
be examined in a 100 from suspended matter or
mm thick layer, at sediment
ambient temperature
3. Pour point IS 1448 Part 10/Sec 2 -40 °C (Max.)
or ISO 3016
4. Water content IEC 60814
a) for bulk supply 30 mg/kg (Max.)
b) for delivery in 40 mg/kg (Max.)
drums
5. Electric strength IS 6792 or IEC 60156 Minimum 30 kV (new
(breakdown unfiltered oil) / 70 kV (after
voltage) treatment)
6. Density at 20 °C IS 1448 Part 16 or ISO 895 kg/m3 (Max.)
12185 or ISO 3675 or
ASTM D7042
7. Dielectric IS 16086 or IEC 60247 0.0025 (Max.)
dissipation factor or IEC 61620
(tan delta) at 90
°C

8. Negative impulse ASTM D3300 145 (Min.)
testing KVp @ 25
°C
B Refining/Stability
1. Colour ISO 2049 Max. 1.5
2. Appearance – Clear, free from sediment
and suspended matter
3. Neutralization IEC 62021-1 or IEC 0.01 mg KOH/g (Max.)
Value (Total 62021-2
Acidity)
4. Interfacial IEC 62961 or ASTM 0.04 N/m (Min.)
tension at 27°C D971
5. Corrosive DIN 51353 Non-Corrosive on copper
sulphur and paper
6. Potentially IEC 62535 Non-Corrosive
corrosive
sulphur
7. Presence of IS 13631 or IEC 60666 Not detectable (<0.01%)
oxidation
inhibitor
8. DBDS IEC 62697-1 Not detectable (<5 mg/kg)
9. Metal passivator IEC 60666 Not detectable (<5 mg/kg)
additives
10. 2-Furfural and IS 15668 or IEC 61198 Not detectable (<0.05
related mg/kg) for each individual
compound compound
content
C Performance
1. Oxidation IEC 61125 (method c)
stability Test duration: 164
hours
-Total acidity* 4.8.4 of IEC 1.2 mg KOH/g (Max.)

61125:2018
-Sludge* 4.8.1 of IEC 0.8 % (Max.)
61125:2018
-Dielectric 4.8.5 of IEC 0.5 (Max.)
Dissipation 61125:2018
Factor* (tan
delta) at 90 °C
*values at the end of oxidation stability test

D Health, safety and environment (HSE)

1. Flash point IS 1448 Part 21 or ISO 135 °C(Min.)
2719
2. Poly Cyclic IP 346 <3%
Aromatic (PCA)
content
3. Poly Chlorinated IS 16082 or IEC 61619 Not detectable (< 2 mg/kg)
Biphenyl (PCB)
content
Note: Supplier shall declare the chemical family and function of all additives
and the concentrations in the cases of inhibitors, antioxidants and passivators.
III. Oil used for first filling, testing and impregnation of active parts at
manufacturer's works shall meet parameters as mentioned below
1 Break Down voltage (BDV) - 70kV (Min.)

2 Moisture content - 5 ppm (Max.)
3 Tan-delta at 90°C - 0.005 (Max.)
4 Interfacial tension - 0.04 N/m (Min.)
IV. Each lot of the oil shall be tested prior to filling in main tank at site
for the following:
1 Break Down voltage (BDV) - 70 kV (Min.)

2 Moisture content - 5 ppm (Max.)
V. After filtration & settling and prior to energization at site oil shall
be tested for following:
1 Break Down voltage (BDV) - 70 kV (Min.)

2 Moisture content at hot - 5 ppm (Max.)
condition
5 *Oxidation Stability -
a) Acidity 0.3 (mg KOH /g) (Max.)-For
Inhibited Oil
1.2 mg KOH/g (Max.)-For
Uninhibited Oil
b) Sludge - 0.05 % (Max.) - For Inhibited Oil
0.8 % (Max.) - For Uninhibited Oil

c) Tan delta at 90 °C - 0.05 (Max.) - For Inhibited Oil
0.5 (Max.) - For Uninhibited Oil
6 Total PCB content* Not detectable (< 2 mg/kg)
* Separate oil sample shall be taken and test results shall be submitted
within 45 days after commissioning for approval of the utility

Annexure-M
STANDARD DIMENSIONS FOR CONDENSER BUSHINGS

(For 420 kV and below voltage class Bushings)
Symbol Description
L2 Length between bottom seat of flange and bottom of the oil end shield/ stress relieving
electrode/ oil end terminal whichever is the longest
L6 Length for accommodating Bushing Current Transformer (BCT)
D2 Maximum diameter of oil immersed end
D3 Outside diameter of fixing flange
D4 Pitch Circle Diameter of fixing holes of flange
D5 Diameter of fixing hole
N Number of fixing holes
D6 Maximum diameter of oil end shield/stress relieving electrode
L11 Horizontal Distance between holes for bushing bottom connection for 4 hole connection
L12 Vertical Distance between holes for bushing bottom connection for 4 hole connection
L13 Vertical Distance between holes for bushing bottom connection for 2 hole connection
D7 Diameter of hole for bushing bottom connection for 2 hole connection
D8 Diameter of hole for bushing bottom connection for 4 hole connection
Annexure-M : Standard dimensions for condenser bushings Page 1 of 3
Annexure-M
Voltage Rating 420 245 145 72.5 52

(kV)
BIL kVp 1425 1050 650 325 250
Creepage 13020 7595 4495 2248 1612
Distance (mm)
(min.)
Current Rating 1250 1250 2000 1250 2000 800 2000 1250
(A)
Type of lead Solid SS SS SS SS SS SS
Stem
(SS)
L2 ±5 1640 1130 1230 800 1030 695 450
L6 (min.) 400 300 300 300 300 100

D2 (max.) 350 270 165 180 115 165 115
D3±2 720 450 335 335 225 335 225
D4±1 (PCD) 660 400 290 290 185 290 185
D5xN 24x12 20x12 15x12 15 x12 15x6 15x12 15x6
D6 (max.) 350 270 180 115 115
L11 - - 45 - 45 - 55 -
L12 - - 40 - 40 - 40 -
L13 40 40 - 40 - 40 - 40
D7 14 14 14 14 14 14 14
D8 - -  14 - - - - -
Length & 125 & 125 & 125 & 125 & 125 & 125 & 125 & 125 &
Diameter of Air 60 60 60 60 60 60 60 60
End Terminal
Annexure-M
Notes:
1. All dimensions are in mm.
2. No positive tolerance where maximum dimension specified and no negative tolerance where minimum dimension
is specified.
3. For other details of oil end terminal for 2000 A (145 kV/245 kV) solid stem type bushing, refer Fig 4 of IS 12676.
4. For other details of oil end terminal for 2000 A, 72.5 kV solid stem type bushing, refer Fig 3B of IS 12676.
5. For other details of oil end terminal for 800 A and 1250 A (52kV/72.5 kV/145 kV/245 kV/420 kV) solid stem
type bushing, refer Fig 3A of IS 12676.

Annexure-N
PHYSICAL INTERCHANGEABILITY OF TRANSFORMERS OF DIFFERENT

MAKE
1.0 One of the objectives of standardization is to achieve physical

interchangeability of transformers of different makes, procured by utility
(ies), by standardizing the minimum foundation loading to be considered
for civil foundation design of transformers. In case of failure of any
transformer, outage time to replace a failed unit by a spare unit/new unit
of different make would be minimized as it can be accommodated in the
same space without/minor modification in existing foundation.
2.0 In general, the foundation layout & design of transformer depends on

weight of the transformer (with oil and all fittings & accessories), design of
soak pit (with or without remote oil collecting pit) with trans rack/grating
& gravels and free space to be kept below the transformer to accommodate
oil and water in case of fire. The number of rails, number & location of
jacking pads of transformers are also equally important.
3.0 The foundation design should take into account the following points:
The foundations of transformer should be of block type foundation.

Minimum reinforcement should be governed by IS: 456.
a) Transformer can be placed on foundation either directly or on roller
assembly (with suitable locking arrangement) along with suitable anti
Earthquake Clamping Device as specified in Chapter-2.
b) The plinth height of transformer foundation may be kept from 300

mm to 500 mm above finished ground level of the
substation/switchyard depending upon the size of the transformer.
Pulling blocks should be provided for shifting of transformer for
maintenance purposes.
c) The pedestal support should be provided for supporting the cooler

bank, firefighting system etc. The RCC Rail-cum-road system
integrated with the transformer foundation may be provided to enable
installation and the replacement of any failed unit. The transfer track
system should be suitable to permit the movement of any failed unit
fully assembled (including OLTC, bushings) with oil. This system
should enable the removal of any failed unit from its foundation to the
nearest road. If trench/drain crossings are required, then suitable
Annexure-N: Physical interchangeability of transformer and reactor of different make

R.C.C. culverts should be provided in accordance with I.R.C.
standard/relevant IS.
d) Foundation of each transformer including oil conservator tank and

cooler banks etc. should be placed in a self-sufficient pit surrounded
by RCC retaining walls (Pit walls). The retaining wall of the pit from
the transformer should be such that no part of transformer/reactor
is outside the periphery of retaining wall.
e) An oil soak pit of adequate capacity should be provided below each oil
filled transformer to accommodate at least 150% of full quantity of oil
contained in the transformer and minimum 300 mm thick layer of
gravels/pebbles of approximately 40 mm size (spread over a steel iron
grating/trans rack) providing free space below the grating.
Alternatively, an oil soak pit should be provided below each
transformer/reactor to accommodate 1/3rd of total quantity of oil
contained in the transformer and minimum 300 mm thick layer of
gravels/pebbles of approximately 40 mm size (spread over a steel iron
grating/trans rack) providing free space below the grating provided a
common remote oil collecting pit of capacity at least equal to oil
quantity in the largest size transformer/reactor is provided for a group
of transformers. Bottom of the soak pit below the transformer/reactor
should be connected to the common oil collecting pit with drain pipe
(two or more Hume/concrete pipes) of minimum 150 mm diameter
with a slope not less than 1/96 for fast draining of oil and water
through gravity from soak pit to the burnt oil collecting pit, which is
generally located away from transformers/reactors.
f) Every soak pit below a transformer should be suitably designed to

contain oil dropping from any part of the transformer.
g) The common remote oil collecting pit and soak pit (when remote oil
collecting pit is not provided) should be provided with suitable
automatic pumping facility, to always keep the pit empty and
available for an emergency.
h) The disposal of transformer oil should be carried out in an

environmental friendly manner.
i) The minimum height of the retaining walls of pit should be 150mm to

200mm above the finished ground level to avoid outside water pouring
inside the pit. The bottom of the pit is generally made of PCC M15
grade and should have a uniform slope towards the sump pit. While
designing the oil collection pit, the movement of the transformer must
be taken into account.

j) The grating shall be made of MS flat of size 30 mm x 5 mm at spacing
of 30 mm and MS bar of 6 mm dia at spacing of 150 mm at right angle
to each other. Maximum length & width of grating should be 2000
mm & 500 mm respectively. The gratings, supported on ISMB 150
mm, should be placed at the formation level and will be covered with
300 mm thick layer of stone aggregate having size 40 mm
(approximate). All steel work used for grating and supports should be
painted with epoxy based zinc phosphate primer (two packs)
confirming to IS: 13238-1991, thereafter with two or more coat of
bituminous paint of approved quality should be applied.
k) In case of transformers with separately mounted cooler / radiator

bank, the position of the cooler / radiator bank has been
recommended on the left side of the transformer when viewing from
HV side. However, transformer shall be designed in such a way that
cooler / radiator bank can be positioned on either side of the main
tank. Similarly the conservator shall be on the left side of the tank
while viewing from HV side.
l) The separation wall(s) or fire barrier wall(s) of four hours fire

withstand rating shall be provided between the transformers and
reactors or between the transformer(s) & the adjacent wall of a
building if wall of the building do not have the capability to withstand
fire for a duration of four (4) hours as per Central Electricity Authority
(Measures relating to Safety and Electric Supply) Regulations.
m) Other requirement related to civil construction of foundation may be

specified by the utility in line with relevant BIS standards and best
practices.
4.0 It is a fact that maximum weight of transformer (with oil and all fittings &
accessories) and outline dimension do not vary much from manufacturer
to manufacturer for same rating. Hence a common foundation layout plan
with soak pit (with oil and all fittings & accessories) with loading details
would facilitate the interchangeability of transformers/reactors of different
make of similar/same ratings. The utilities shall strive to standardize the
foundation plan for different rating of transformers so that transformers
of different makes could be accommodated in the same space with minor
modification / without any modification in the existing foundation
resulting in reduction in the outage time of replacement of old transformer
or reactor.
5.0 The rail track gauge shall be 1676 mm. All voltage class transformers shall
have two (2) rails..

6.0 The manufacturers have different arrangement of jacking and different
spacing between jacking pads. Hence, it is difficult to standardize the civil
foundation drawing based on jacking pad locations / arrangement. Design
of block foundation based on weight of transformer for a particular MVA
rating along with no. of rails as mentioned above and provision of suitable
size of portable metal plate for jacking [(400 mm x 400 mm x 32 mm thick)
/ (300 mm x 300 mm x 30 mm thick)] would facilitate the physical
interchangeability of transformers/reactors of different make on same
foundation block. One set of metal plates for jacking of Transformer shall
be provided by OEM / contractor. Minimum size of metal plates for jacking
and minimum weight of transformer to be considered for design of
foundation block shall be as follows:
Rating of Transformer (MVA, Voltage Weight of transformer (in Minimum

ratio, no. of Phases) metric Tons) size of
removable
metal
plates for
Jacking of
transformer
315MVA, 400/33kV, 3-Phase 400 mm x
Transformer with two LV winding To be indicated by 400 mm x
manufacturer / utility 32 mm
thick
250MVA, 400/33kV, 3-Phase 400 mm x
Transformer with two LV winding -do- 400 mm x
32 mm
thick
160MVA, 400/33kV, 3-Phase 400 mm x
32 mm
thick
125MVA, 400/33kV, 3-Phase 400 mm x
32 mm
thick
160MVA, 220 (or 230)/33kV, 3-Phase 400 mm x
Power Transformer -do- 400 mm x

32 mm
thick
32 mm
thick
32 mm
thick
100MVA/75MVA, 132 (or 110)/33kV, 400 mm x
3-Phase Power Transformer -do- 400 mm x
32 mm
thick
50MVA / 31.5MVA, 132(or 110)/33kV, 300 mm x
3-Phase Power Transformer -do- 300 mm x
30 mm
thick

Annexure - O
1100 V GRADE POWER & CONTROL CABLES
1.1 Separate cables shall be used for AC & DC.
1.2 Separate cables shall be used for DC1 & DC2.
1.3 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.
1.4 The Aluminium/Copper conductors used for manufacturing the cables

shall be true circular in shape before stranding; shall be of good quality,
free from defects and shall conform to IS 8130.
1.5 The fillers and inner sheath shall be of non-hygroscopic, fire retardant
material, shall be softer than insulation and outer sheath shall be suitable
for the operating temperature of the cable.
1.6 Progressive sequential marking of the length of cable in metres at every

one metre shall be provided on the outer sheath of all cables.
1.7 Strip wire armouring method (a) mentioned in Table 5, Page-6 of IS: 1554
(Part 1) – 1988 shall not be accepted for any of the cables. For control
cables only round wire armouring shall be used.
1.8 The cables shall have outer sheath of a material with an oxygen index of
not less than 29 and a temperature index of not less than 250°C.
1.9 All the cables shall conform to fire resistance test as per IS: 1554 (Part -
I).
1.10 The normal current rating of all PVC insulated cables shall be as per IS:
3961.
1.11 Repaired cables shall not be accepted.
1.12 Allowable tolerance on the overall diameter of the cables shall be ± 2 mm.
1.13 PVC Power Cables
1.13.1 The PVC insulated 1100V grade power cables shall be of Fire Retardant
Low Smoke Halogen (FRLSH) type, C2 category, conforming to IS: 1554
Annexure-O: 1100 V Grade power and control cable Page 1 of 2

(Part-I) and its amendments read along with this specification and shall be
suitable for a steady conductor temperature of 85°C. The conductor shall
be stranded aluminium of H2 grade conforming to IS 8130. The insulation
shall be extruded PVC of type-C of IS: 5831. A distinct inner sheath shall
be provided in all multi core cables. For multi core armoured cables, the
inner sheath shall be of extruded PVC. The outer sheath shall be extruded
PVC of Type ST-2 of IS: 5831 for all cables. The copper cable of required
size can also be used.
1.14 PVC Control Cables
1.14.1 The 1100V grade control cables shall be of FRLSH type, C2 category
conforming to IS: 1554 (Part-1) and its amendments, read along with this
specification. The conductor shall be stranded copper. The insulation shall
be extruded PVC of type A of IS: 5831. A distinct inner sheath shall be
provided in all cables whether armoured or not. The outer sheath shall be
extruded PVC of type ST-1 of IS: 5831 and shall be grey in colour except
where specifically advised by the purchaser to be black.
1.14.2 Cores shall be identified as per IS: 1554 (Part-1) for the cables up to five
(5) cores and for cables with more than five (5) cores the identification of
cores shall be done by printing legible Hindu Arabic Numerals on all cores
as per clause 10.3 of IS : 1554 (Part - 1).
Annexure-O: 1100 V Grade power and control cable Page 2 of 2

ANNEXURE – P
LIST OF CODES/STANDARDS/REGULATIONS/PUBLICATIONS
A list of Codes/Standards/Regulations/Publications which shall be used for

design review, manufacturing, testing, erection, transportation etc. has been
given below. In case of revision/amendment of these, revised/amended
versions shall be followed.
IS 2026: Part 1 : 2011 - Power transformers: Part 1 General

(Reaffirmed Year : 2016)
IS 2026: Part 2 : 2010 - Power transformers Part 2 Temperature-rise

IS 2026: Part 3 : 2018 - Power Transformers Part 3 Insulation

Levels, Dielectric Tests and External
Clearances in Air ( Fourth Revision )
IS 2026: Part 4 : 1977 - Power transformers: Part 4 Terminal

(Reaffirmed Year : 2016) marking, tappings and connections
IS 2026 : Part 5 : 2011 - Power Transformers Part 5 Ability to

(Reaffirmed Year : 2016) Withstand Short Circuit
IS 2026 : Part 6 : 2017 - Power Transformers Part 6 Reactors
IS 2026 : PART 7 : 2009 - Power Transformers Part 7 Loading Guide

(Reaffirmed Year : 2019) for Oil-Immersed Power Transformers
IS 2026 : Part 8 : 2009 - Power Transformers : Part 8 Applications

(Reaffirmed Year : 2019) guide
IS 2026 : Part 10 : 2009 - Power Transformers : Part 10 Determination

(Reaffirmed Year : 2019) of sound levels
IS 2026 : Part 10 : Sec 1 : - Power Transformers part 10 Determination

2018 of Sound Levels Section 1 Application guide
IS 2026 : Part 14 : 2018 - Power Transformers Part 14 Liquid-

Immersed Power Transformers Using High-
Temperature Insulation Materials
IS 2026 : Part 18 : 2018 - Power Transformers Part 18 Measurement of

Frequency Response
Annexure-P: List of Codes/Standards/Regulations/Publications Page 1 of 7

IS 3024 : 2015 - Grain Oriented Electrical Steel Sheet and
Strip ( Third Revision )
IEC / IEEE 60214- Tap-changers - Part 2: Application

2:2019 guidelines
IS 649 : 1997 - Methods for testing steel sheets for magnetic

(Reaffirmed Year : 2018) circuits of power electrical apparatus
IS-10028 (Part 1, 2 & 3) - Code of practice for selection, installation &

maintenance of transformer
IS 3639 : 1966 - Fittings and Accessories for Power

(Reaffirmed Year : 2016) Transformers
IS 3637 : 1966 - Gas Operated Relays

IS 335 : 2018 - New Insulating Oils — Specification (Fifth

Revision)
IEC 60296-2020 - Fluids for electrotechnical applications –

Mineral insulating oils for electrical
equipment
IEC 60422 : 2013 - Mineral insulating oils in electrical

equipment - Supervision and maintenance
guidance
IS 6792 : 2017 - Insulating Liquids - Determination of the

Breakdown Voltage at Power Frequency -
Test Method (Second Revision)
IS 8468 : Part 1 : 2018 - Tap - Changers Part 1 Performance

IEC 60214-1 : 2014 Requirements and Test Methods (First
Revision)
IS 8478 : 1977 - Application guide for on-load tap changers

IS/IEC 60137 : 2017 - Bushings for alternating voltages above

1000 Volts
IS 12676 : 1989 - Oil Impregnated Paper Insulated Condenser
(Reaffirmed Year : 2016) Bushings - Dimensions and Requirements
Annexure-W: List of Codes/Standards/Regulations/Publications Page 2 of 7

IS 4257 : Part 1 : 1981 - Dimensions for Clamping Arrangements for
(Reaffirmed Year : 2019) Porcelain Transformer Bushings - Part I :
For 12 kV to 36 kV Bushings
IS 4257 : Part 2 : 1986 - Dimensions for clamping arrangements for

(Reaffirmed Year : 2019) porcelain transformer bushings: Part 2 For
72.5 kV and 123 kV bushings
IS 8603 : 2008 - Dimensions for porcelain transformers

(Reaffirmed Year : 2019) bushings for use in heavily polluted
atmospheres 12/17.5kV, 24kV and 36kV
IS 8603 : Part 4 : 2003 - Dimensions for Porcelain Transformer

(Reaffirmed Year : 2019) Bushings for Use in Heavily Polluted
Atmospheres - Part 4 : 52 kV Bushings
ANSI-C57.12.80 - General requirements for Distribution,

Power and Regulating Transformers
ANSI-C57.12.90 - Test Code for Distribution, Power and

Regulation Transformers
NEMA-TR-1 - Transformers, Step Voltage Regulators and

Reactors
IS 1747 : 1972 - Nitrogen

IS-5: 2007 - Colours for Ready Mixed Paints and

Enamels
IS 3043 : 2018 - Code of Practice for Earthing
IS 8263 : 2018 - Radio Interference Test on High -Voltage

Insulators (First Revision)
IS 8269 : 1976 - Methods for switching impulse tests on high

(Reaffirmed Year : 2014) voltage insulators
- High-voltage Test Techniques Part 1 General

IS 2071 : Part 1 : 2016
Definitions and Test Requirements ( Third
Revision)
IS 16803 : 2018 - High Voltage Test Techniques -

Measurement of Partial Discharges by
Electromagnetic and Acoustic Methods

IS/IEC 60270 : 2000 - High — Voltage Test Techniques — Partial
(Reaffirmed Year : 2016) Discharge Measurements
IS 13235 : Part 1 : 2019 - Short-Circuit Currents — Calculation of

Effects Part 1 Definitions and Calculation
Methods ( First Revision)
IS 13235 : Part 2 : 2019 -

Short-Circuit Currents — Calculation of
Effects Part 2 Examples of Calculation (First
Revision )
IS 16227 : Part 1 : 2016 - Instrument Transformers: Part 1 General
requirements
IEC 61869-2 : 2007
IS 16227 : Part 2 : 2016 - Instrument Transformers Part 2 Additional

Requirements for Current Transformers
IEC 61869-2 : 2012
IS 16227 : Part 100 : - Instrument Transformers Part 100

2018 Guidance for Application of Current
Transformers in Power System Protection
IS/IEC 60529 : 2001 - Degrees of protection provided by enclosures

(Reaffirmed Year : 2019) (IP CODE)
IS/IEC-60947 - Low voltage switchgear and control gear
IS 2062 : 2011 - Hot Rolled Medium and High Tensile

(Reaffirmed Year : 2016) Structural Steel
IS 9595 : 1996 - Metal arc welding of carbon and carbon

(Reaffirmed Year : 2019) manganese steels - Recommendations
IS 10801 : 1984 - Recommended procedure for heat treatment

(Reaffirmed Year : 2016) of welded fabrications
IS 4253 : Part 1 & 2 : - Cork Composition Sheets

2008 (Reaffirmed Year
: 2019)
IS 11149 : 1984 - Rubber Gaskets

IS 12444 : 1988 - Continuously cast and rolled electrolytic

(Reaffirmed Year : 2015) copper wire rods for electrical conductors
IS 513 : 2016 - Cold Reduced Carbon Steel Sheet and Strip
IS 12615 : 2018 - Line Operated Three Phase A.C. Motors ( IE

CODE ) "Efficiency Classes and Performance
Specification" ( Third Revision )
IS/IEC 60034 : PART 5 : - Rotating electrical machines : Part 5
2000 (Reaffirmed Year Degrees of protection provided by the
: 2018) integral design of rotating electrical
machines (IP CODE) - Classification
IS 5561 : 2018 - Electric Power Connectors- Specification
IS 2932 : Part 1 : 2013 - Enamel, Synthetic, Exterior : (a)

(Reaffirmed Year : 2018) Undercoating (b) Finishing - Specification :
Part 1 for Domestic and Decorative
Applications
IS 2074 : Part 1 : 2015 - Ready Mixed Paint, Air Drying, Red Oxide -
Zinc Chrome, Priming - Specification
IS 3400 - Methods of Test for Vulcanized Rubber
IS 456 : 2000 - Plain and Reinforced Concrete - Code of

(Reaffirmed Year : 2016) Practice (Including Amendment 1, 2, 3,& 4)
IS 13238 : 1991 - Epoxy Based Zinc Phosphate Primer (two

(Reaffirmed Year : 2017) Pack)
IS 2848 : 1986 - Industrial Platinum Resistance

(Reaffirmed Year : 2016) Thermometer Sensors
IS/IEC 61850 - Communication Networks and Systems for

Power Utility Automation
IS 16683 : Part 1, 2 & 3 : - Selection and Dimensioning of High Voltage

2018 Insulators Intended for Use in Polluted
Conditions
IEEE 1538-2000 Guide for determination of maximum

winding temperature rise in liquid filled

transformers
IEEE Standard C57.156- Guide for tank rupture mitigation of oil

2016 immersed transformers
IEEE Standard C57.150- Guide for Transformer Transportation

2012
IEEE Standard C57.149- Guide for the application and interpretation

2012 of Frequency Response Analysis of oil
immersed transformers
IEEE Standard C57.104- Guide for the Interpretation of Gases
2019 Generated in Mineral Oil-Immersed
Transformers
IEC 60599-2015 Mineral oil-filled electrical equipment in

service - Guidance on the interpretation of
dissolved and free gases analysis
IEEE Std. C57.12.10 - Standard requirements for liquid immersed

2017 power transformers
IEEE Std. 57.104-2019 Guide for the Interpretation of Gases

Generated in Mineral Oil-Immersed
Transformers
IEC 60599 Mineral oil-filled electrical equipment in
service – Guidance on the interpretation of
dissolved and free gases analysis
IEEE Std. 62-1995 Guide for Diagnostic Field Testing of Electric
Power Apparatus - Part 1: Oil Filled Power
Transformers, Regulators, and Reactors
CIGRE Technical Guide lines for conducting design reviews

Brochure No. 529 -2013 for Power Transformers
CIGRE Technical Guide on Transformer Transportation

Brochure No. 673-2016
CIGRE Technical Guide for conducting factory capability

Brochure No. 530-2013 assessment for Power Transformers
CIGRE TB 209 Short Circuit Performance of Power

Transformers
CIGRE TB 436 Experiences in service with new insulating
liquids
Central Electricity Authority (Measures Relating to Safety and Electric
Supply) Regulations

Central Electricity Authority (Technical Standard for Construction of
Electrical Plants and Electric Lines) Regulations
Central Electricity Authority (Installation and Operation of Meters)

Regulations
CBIP Manual on Transformers (Publication No. 317)
ISO 9001: Quality System – Model for Quality Assurance in

Design/Development.
ISO-14001 (Environmental Management System)
OHSAS 18001 (Occupational Health and Safety Management System)

Invitation of Comments Solar Park Transformer-1

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Chapter-1

TECHNICAL SPECIFICATIONS OF POWER TRANSFORMERS FOR

1.1 This chapter covers specification for design, engineering, manufacture,

1.2 For transportation, erection, testing and commissioning and condition

1.5 Components having identical rating shall be interchangeable.

2.0 STANDARD RATINGS OF TRANSFORMER

Standard ratings of transformer for Solar Park pooling stations shall be

Sr. No. MVA Line Voltage Phase No. of

2. 250 MVA 400/33 kV Three Phase Two

Chapter-1:Technical Specification for Power Transformers for Solar parks Page 1

4. 125 MVA 400/33 kV Three Phase One

5. 160 MVA 220/33 kV Three Phase One

Note: The transformers of 400/33kV, 160MVA & 125MVA rating

It is desirable that Transformers of above ratings are only procured by

3.0 SPECIFIC TECHNICAL REQUIREMENTS

The technical parameters of these transformers are detailed in

4.0 GUARANTEED AND OTHER TECHNICAL PARTICULARS

5.1 Transformers shall be capable of operating under natural cooled

5.2 In case of ONAN/ONAF cooling and ONAN/ONAF/ODAF (or OFAF)

5.3 The transformer shall be free from any Electrostatic Charging

5.4 The transformers shall be capable of operating continuously at the

Chapter-1:Technical Specification for Power Transformers for Solar parks Page 3

400kV system - 63 kA for 1 sec (sym, rms, 3 phase fault)

However, for transformer design purpose, the through fault current

Chapter-1:Technical Specification for Power Transformers for Solar parks Page 4

5.12 Transformers shall withstand, without damage, heating due to the

The air core reactance of HV winding of transformer shall not be

5.13 Tertiary Windings (if applicable as per Annexure - A)

The tertiary winding shall be avoided for transformers designed with

5.14 Radio Interference and Noise Level

The transformer shall be designed with particular attention to the

The noise level of transformer, when energised at normal voltage and

6.0 MAXIMUM LOSSES

S. Differential of specified losses vs RATE

3 Auxiliary Losses Rs. 8,00,000/KW

7.0 DYNAMIC SHORT CIRCUIT TEST REQUIREMENT AND VALIDITY

The transformer, the design of which is similar to the offered

A format (forms part of Annexure-J) filled with data of a typical sample

8.0 TYPE TESTS REQUIREMENT AND VALIDITY

The offered transformer or the transformer, the design of which is

Chapter-1:Technical Specification for Power Transformers for Solar parks Page 6

Central Electricity Authority’s “Guidelines for the validity period

9.0 DESIGN REVIEW

9.1 The transformer shall be designed, manufactured and tested in

9.2 Design reviews shall be conducted by the purchaser or by an appointed

9.3 The design review shall be finalised before commencement of

9.4 The manufacturer shall provide all necessary information and

9.5 The manufacturer will be required to demonstrate the use of

Chapter-1:Technical Specification for Power Transformers for Solar parks Page 7

10.0 SERVICE CONDITION

The transformer shall be designed for the following service conditions

Sr. Description Parameters

In addition to the above, utilities may specify additional site

11.0 CONSTRUCTION DETAILS

Chapter-1:Technical Specification for Power Transformers for Solar parks Page 8

11.1 Tank & tank cover

Length of tank (m) Minimum plate thickness

11.1.5 Tank shall be capable of withstanding, without damage, severe strains

Chapter-1:Technical Specification for Power Transformers for Solar parks Page 9

11.1.9 Tank MS plates of thickness >12 mm should undergo Ultrasonic