Bhartiya City Bengaluru

Bhartiya City, Thanisandra MainRoad,

Bengaluru-560064.
PH.: +91 80 6742 3333
Email: [email protected]

TECHNICAL SPECIFICATIONS
FOR 31.5 MVA, 66/11KV POWER
TRANSFORMERS

MEPF CONSULTANTS

EPG Consultants Pvt. Ltd.

#209, 2nd Floor, Panchajanya,
4th Cross, 2nd Main, 2nd Stage. 12th Block, Nagarabhavi.
Bengaluru – 560 072, Karnataka, India
[email protected]
9483522509 / 9972408312 / 9980882164
 TECHNICAL SPECIFICATIONS FOR 66/11 kV POWER TRANSFORMER

TABLE OF CONTENTS

TABLE OF CONTENTS .....................................................................................................2

TECHNICAL SPECIFICATIONS FOR 31.5MVA, 66/11KV POWER TRANSFORMERS. ..........3
1.0 SCOPE ...................................................................................................................3
2.0 STANDARDS ..........................................................................................................3
3.0 CLIMATIC CONDITION ...........................................................................................5
4.0 CLEARANCES ........................................................................................................5
5.0 AUXILIARY POWER SUPPLY ..................................................................................6
6.0 PRINCIPAL PARAMETERS .....................................................................................6
7.0 DUTY REQUIREMENTS ..........................................................................................7
8.0 GUARANTEED LOSS ............................................................................................ 10
9.0 CONSTRUCTION DETAILS ................................................................................... 11
10.0 PROTECTION ....................................................................................................... 62
11.0 QUALITY ASSURANCE PLAN ............................................................................... 63
12.0 INSPECTION ........................................................................................................ 64
13.0 NITROGEN REQUIREMENT .................................................................................. 82
14.0 MINIMUM EXPERIENCE FOR QUALIFYING AS A BIDDER ...................................... 82
15.0 PERFORMANCE GUARANTEE .............................................................................. 82
16.0 REJECTION.......................................................................................................... 83
17.0 DOCUMENTATION ............................................................................................... 83
18.0 PACKING AND TRANSPORTATION ...................................................................... 86
19.0 TRAINING ............................................................................................................ 87
20.0 TESTING AND COMMISSIONING .......................................................................... 89
21.0 GENERAL ............................................................................................................ 89
22.0 NITROGEN INJECTION FIRE PROTECTION .......................................................... 90
23.0 DEVIATION FROM TECHNICAL SPECIFICATION .................................................. 90

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 TECHNICAL SPECIFICATIONS FOR 66/11 kV POWER TRANSFORMER

TECHNICAL SPECIFICATIONS FOR 31.5MVA, 66/11KV POWER TRANSFORMERS.

1.0 SCOPE

1.01 This specification covers design, manufacture, shop testing, supply, delivery, supervision
of erection, testing and commissioning of 31.5MVA, 66/11KV two winding Transformer
with air forced cooling complete and with all fittings and accessories, Nitrogen Fire
Protection System, OLTC, RTCC, FCC, parallel operating equipments, first filling of oil and
10% spare oil in non-returnable drums at KPTCL 66/11 stations in Bhartiya City campus.
The power transformers thus offered shall be designed for satisfactory parallel operation
with the power transformers to be installed in future, the transformer/s sharing the load in
proportion to the rating of the winding.

The power transformer shall be SCADA compatible.

1.02 It is not the intent to specify completely herein all details of the design and construction of
equipments. However, the equipment shall conform in all respects to standards of
engineering, design and workmanship listed in clause No. 2 and shall be capable of
performing in continuous commercial operation up to the supplier’s guarantee in a manner
acceptable to the purchaser, who will interpret the meanings of drawings and
specification and shall have the power to reject any work or material which, in his
judgment, is not in accordance therewith. The equipments offered shall be complete with
all components necessary for effective and trouble free operation such component shall
be deemed to be within the scope of supplier’s supply, irrespective of whether those are
specifically brought out in this specification and or / the commercial order or not.

1.03 The transformers shall conform in all respects to high standards of engineering, design,
workmanship and latest revisions of relevant standards at the time of offer and purchaser
shall have the power to reject any work or material which, in his judgment, is not in full
accordance therewith.

2.0 STANDARDS

2.01 The transformers, accessories and associated equipment shall generally conform to the
latest revision and amendments of standards as given below, except to the extent explicitly
modified in the Specifications,

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 TECHNICAL SPECIFICATIONS FOR 66/11 kV POWER TRANSFORMER

International and
Indian Standard Title Internationally
recognized Standard
IS-325 Three Phase Induction Motors IEC – 60034
IS-335 Insulating oils for Transformers and Switchgear IEC-60296, BS-148
Gun metal gate, globe and check-valves for
IS-778
general purpose.
Code of practice for Electrical maintenance
IS-1866-2000 and supervision of mineral insulating oil in
equipment.
IS-1886 Code of practice for installation and
maintenance of transformers
IS-2026 Power Transformers IEC-60076
Bushings for alternating or AC voltage above
IS-2099 IEC-60137,BS-223
1000V
Degrees of Protection provided by enclosures
IS-2147
for low voltage switchgear and control gear
IS-2705 Current Transformers IEC-61869
Code of practice of climatic proofing of
IS-3203
electrical equipments.
IS-3347 Dimension for porcelain Transformer Bushings
IS-3401 Silica gel
IS-3637 Gas operated relays
IS-3639 Fittings & Accessories for Power transformers
IS-4253 Cork and rubber
IS-5561 Electric Power connector
IS-5578 Marking and arrangements for switchgear
:bus bars, Main connections and auxiliary
IS-11353
wiring.
IS-6272 Industrial cooling fans
IS-6600 Guide for loading of oil immersed transformers IEC-354
IS-8468 On load tap changer IEC-60214
IS-8478 Application guide for OLTC IEC-60542
Guide for sampling and analysis of dissolved
IS-9434
gas in oil filled equipments.
Oil impregnated paper-insulated condenser
IS-12676
Bushing Dimension and requirements.
Insulation Co-ordination, Indian Electricity
IEC-60071
Rules 1956
High voltage test techniques
IEMA Standard Publication- Transformer-I IEC-60060
CBIP Manual on power transformers

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 TECHNICAL SPECIFICATIONS FOR 66/11 kV POWER TRANSFORMER

2. 02. The standards mentioned above are available from:

Standard Name and Address

BUREAU OF INDIAN STANDARDS, Manak Bhawan, No. 9 Bahadur

IS
Shah Zafar Marg, New Delhi-110 001, INDIA

INTERNATIONAL ELECTRO-TECHNICAL COMMISSION, bureau

IEC central de la Commission Electro Technique International, 1, Rue
deVerembe, Geneva, SWITZERLAND.

2.03 Equipment meeting with the requirements of other authoritative international standards
which ensure equal or better Performance than the standards mentioned above shall also
be considered. When the equipment offered by the supplier conforms to other standards,
salient points of difference between standards adopted and the standards specified in this
specification shall be clearly brought out in the offer. Two copies of such standards with
authentic translation in English shall be furnished along with the offer.

3.0 CLIMATIC CONDITION

The equipment to be supplied against this specification shall be suitable for satisfactory
continuous operation under the following tropical conditions.

a) Maximum ambient air temperature [Deg. C] - 50

b) Minimum ambient air temperature [Deg. C] - 5
c) Average daily ambient air temperature [Deg. C] - 30
d) Relative humidity [%] - 10-100
e) Average rainfall per annum [mm] - 3000 max.
f) Maximum altitude above mean sea level [Mtrs] - 1000
g) Maximum wind pressure [Kg. / Sq. M] - 150
h) Isoceraunic level [days / year] - 46
i] Seismic level [horizontal acceleration] - 0.3g
Moderately hot and humid tropical climate, conducive to rust and fungus growth.

4.0 CLEARANCES

4. 01 The overall dimensions of the transformer shall allow for sufficient clearances for
installation:

In 66KV Yard with bay width of 7600mm boom height of 8500mm, the phase to phase and
phase to earth clearance of 66KV Bay is 2000 mm and 1800 mm. However, the overall
length of transformer is to be limited to 6500mm and the maximum length of the
transformer from centre line of transformer to the longest side shall be less than 3500mm.

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4.02 RAIL GAUGE: Rail gauges to be available at the station are indicated below: For 31.5MVA
Transformer:

a) In the direction parallel to the line of 66KV bushing -1676mm.

b) In the direction perpendicular to the line of 66KV bushing -1676mm.

5.0 AUXILIARY POWER SUPPLY

Auxiliary electrical equipment shall be suitable for operation on the following supply
system: -

415V, 3Ph, 4Wire, 50Hz, neutral grounded AC

a) Power Devices like drive motors etc.
supply

b) AC Control & Protective devices

240V, Single Phase, 50 Hz, neutral ground AC
supply

220V, DC, 2Wire un-grounded DC supply from

c) DC for Alarm, Control & protective batteries and battery charger. The ripple
devices content in the DC supply from the charger will
be less than 2%

Each of the foregoing supplies shall be made available by the purchaser at the terminal
point for each transformer for operation of accessories and auxiliary equipment.
Supplier’s scope includes supply of interconnecting cables, terminal boxes etc. the above
supply voltage may vary as below, and all devices shall be suitable for continuous
operation over entire range of voltages.

i) AC Supply : Voltage +10% to –20%, Frequency + or –5%

ii) DC Supply : +10% to – 20%

6.0 PRINCIPAL PARAMETERS

6.01 The transformer shall be of core type construction, 3 Ph oil immersed, oil natural, forced
air cooled and forced oil cooled with external radiator and shall be suitable for outdoor
service. The transformer shall conform to the principal technical parameters indicated in
Annexure - A.

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7.0 DUTY REQUIREMENTS

7.01 The interconnecting transformers would be used for Bi-directional flow of rated power.

7.02 The 66/11KV Transformer shall operate satisfactorily in parallel with each other of similar
voltage between HV and IV Bus bars.

7.03 The transformer and all its accessories like bushing CT's shall be designed to withstand
without injury, the thermal and mechanical effects of any external short circuit to earth and
of short circuits at the terminals of any winding for a period of 3 sec. The short circuit level
of the HV system to which the subject transformer will be connected is 40KA [Sym, rms, 3
phase fault]. The accessories of the transformer like bushings CTs etc., shall be designed
to withstand short time current rating of 40KA.

7.04 The transformer shall be capable of being loaded in accordance with IS: 6600 / IEC-354 up
to loads of 150%. There shall be no limitation imposed by bushings, tap changer etc. or any
other associated equipments.

7.05 The transformer shall be capable of being operated without danger on any tapping at the
rated KVA with voltage variation of ± 10% corresponding to the voltage of that tapping.

7.06 Noise Level i) The noise level of Transformer, when energized at normal voltage and
frequency with fans and pumps running shall not exceed 83db, when measured under
standard conditions, as per Table 01 of NEMA, TR - 1.

7.07 Transformer shall be capable of withstanding thermal and mechanical stress caused by
symmetrical or asymmetrical faults on any winding.

The thermal ability to withstand short circuit for duration of 3 secs. shall be demonstrated
by theoretical evaluation of the ability to withstand a short circuit event by manufacturer’s
experiences supported by IEC guidelines as per IEC 60076-5, 2006 ( 3rd edition or the
latest version)/ IS 2026-5, 2011(or latest version). The calculation of dynamic ability to
withstand short circuit shall be submitted before drawing approval along with thermal
stability calculations.

The windings shall be capable of withstanding axial and radial forces during fault
conditions. The detailed calculation towards the above should be furnished before
drawing approval.

The short circuit temperature rise should not exceed the limits, fixed as per IS: 2026. The
calculation towards the above for 66kV & 11kV primary & secondary respectively
windings shall be furnished before drawing approval.

7.08 Transformer shall withstand, without injurious heating, combined voltage and frequency
fluctuation, which produces the following over fluxing condition:

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 TECHNICAL SPECIFICATIONS FOR 66/11 kV POWER TRANSFORMER

i) 115% continuously: for all transformers where base voltage & frequency refers to those
mentioned in 3 & 4 of Annexure - A.

125% for 1 minute: for all transformers where base voltage & frequency refers to those
mentioned in 3 & 4 of Annexure - A.

140% for 5 seconds: for all transformers where base voltage & frequency refers to those
mentioned in 3 & 4 of Annexure - A.

ii) The Bidder shall indicate 150% and 170% over voltage withstand time. But the normal
flux density should be limited to 1.60 Tesla. Suitable over flux relay will be provided by the
purchaser for protection with adjustable setting taking into account the above capability
of the transformer.

iii) Over fluxing withstand characteristics up to 170% of V/f shall be submitted along with
the tender where base voltage and frequency refers to those mentioned in 3 & 4 of
Annexure – A.

7.09 Transformer shall be capable of operating under the natural cooled ONAN condition up to
the specified load. The forced cooling equipment shall come into operation by pre-set
contacts of winding temperature indicator and the transformer shall operate as a forced
cooled unit, initially as ONAF up to specified load and then as OFAF. Cooling shall be so
designed that during total failure of power supply to cooling fans and oil pumps, the
transformer shall be able to operate at full load for at least ten (10) minutes without the
calculated winding hot spot temperature exceeding 140° C, also stopping up to one cooling
fans in each bank should not have any effect on the cooling system, Transformers fitted
with two cooler banks, each capable of dissipating 50 per cent of the heat loss at
continuous maximum rating, shall be capable of operating for 20 minutes in the event of
failure of the oil circulating pump or blowers associated with one cooler, without the
calculated winding hot spot temperature exceeding 140°C at continuous maximum rating.

7.10 DGA of oil shall be periodically monitored by the employer and the interpretation of DGA
results will be as per IEC 599.

7.00 Design review (for 66/11kV Transformer):

The transformers 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 with respect to thermal,
mechanical, dielectric and electrical stress etc. shall be maintained during design,
selection of raw material, manufacturing process etc so that the transformer provides long
life with least maintenance.

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 TECHNICAL SPECIFICATIONS FOR 66/11 kV POWER TRANSFORMER

Design reviews shall be conducted by Owner or an appointed Consultant at different

stages of the procurement process for transformer, however the entire responsibility of
design shall be with the manufacturer.

NOTE: If design review is conducted by appointing an external Consultant by KPTCL, the

cost of consultancy charges shall be borne by the bidder.

Owner may visit to the manufacturers works to inspect design, manufacturing and test
facilities.

The design review will commence after placement of award with successful bidder and
shall be finalised before commencement of manufacturing activity. These design reviews
shall be carried out in detail to the specific design with reference of the transformer under
scope of this specification.

The manufacturer shall provide all necessary information and calculations during design
review to demonstrate that the transformer meets the requirements for short circuit
strength and durability. The latest recommendations of IEC 60076-5/2006/ IS 2026-
5/2011 and Cigre SC 12 shall be applied for short circuit withstand evaluation.

The manufacturer will be required to demonstrate the use of adequate safety margin for
thermal, mechanical, dielectric and vibration etc. design to take into the account the
uncertainties of his design and manufacturing processes.

The scope of such a design review shall at least include the following:

1. Core and magnetic design

2. Winding, tapping and insulation design

3. Short-circuit withstand capability

4. Thermal design including review of localized potentially hot area.
5. Cooling design
6. Overload capability

7. Eddy current losses

8. Seismic design, as applicable
9. Insulation co-ordination

10.Tank and accessories

10.1 Bushings and barrier design
10.2 Tap changers
10.3 Protective devices
10.4 Fans, pumps and radiators

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10.5 Sensors and protective devices – its location, fitment, securing and level of
redundancy
10.6 Oil and oil preservation system
11.Corrosion protection
12.Electrical and physical Interfaces with substation
13.Earthing

14.Processing and assembly

15.Testing capabilities
16.Inspection and test plan
17.Transport and storage

18.Sensitivity of design to specified parameters

19.Acoustic Noise
20.Spares, inter-changeability and standardization

21.Maintainability
22.Electrical clearances between windings to core (both axially & radially) between
windings, outer windings and tank, etc.
23.Any other design aspect, as deal necessary.

8.0 GUARANTEED LOSS

i) The bidder while quoting should clearly indicate the guaranteed value of the losses
which shall be firm and without any tolerance limit in respect of under mentioned losses at
normal tap, as required in GTP.

(a) No load loss at rated voltage and rated frequency.

(b) Load losses at rated output, rated voltage and rated frequency.
(c) I2R Loss at rated output, rated voltage and rated frequency.
(d)Auxiliary losses at rated output.

ii)The guaranteed values of the losses quoted by the bidder will be used as the basis for
evaluation of tenders, or for variation of the Contract Price in accordance with the
capitalized cost of losses specified.

iii)For the purpose of evaluation of the offer, the lowest aggregate of figure of loss for the
transformer, quoted by any Bidder shall be taken as the basis and that quoted by other
Bidders will be computed to arrive at the differential price to be applied for each of the bid.

iv)The Maximum permissible losses (No load loss, I2R loss, auxiliary loss and load loss) at
rated voltage/current (at 75 deg C) have been specified in technical

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 TECHNICAL SPECIFICATIONS FOR 66/11 kV POWER TRANSFORMER

particulars/parameters. 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 technical
particulars/parameters, 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 technical particulars/parameters.

Sl. No. Differential of specified losses vs Measured losses RATE (in INR per KW)

1 No Load Loss Rs. 10,00,000/KW

I2R Losses/Load Losses

2 (Differential of whichever loss is higher shall be Rs. 8,00,000/KW
considered for penalty)

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

Note: For a fraction of a kW, the penalty shall be applied on pro rata basis.

9.0 CONSTRUCTION DETAILS

The features and construction details of power transformer shall be in accordance with
the requirements stated here under.

9.01.01

CORE

9.01.02

(a) The cores shall be built up with high grade non aging cold rolled super grain-oriented
silicon steel laminations especially suitable for transformer cores. The conventional
grain oriented (CGO) core of grade M4 or better shall be used.

(b) The manufacturer of transformer shall directly import CRGO either from the
manufacturer or through their accredited marketing organization of repute or through
authorized dealer. In support of this requirement the manufacturer of transformer
should submit an undertaking in the form of an affidavit on Rs.100/- stamp paper, duly
notarized, in the specified format.

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9.01.03

After being sheared, the lamination shall be treated to remove all burrs and shall be re-
annealed to remove all residual stresses. At least one side of each lamination shall be
coated with and durable carlite Lamination coating, which shall, be inert to the action of
hot transformer oil. Paper and varnish insulation will not be accepted. The nature of
insulation shall be inorganic coating.

9.01.04

The core shall be provided with adequate lugs suitable for lifting the complete core and
coil assembly of the transformer.

9.01.05

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.

9.01.06

Core and winding shall be capable of withstanding the shock during transport, installation,
service (during short circuit) and adequate provision Shall be made to prevent movement
of core and winding relative to tank during these conditions. Necessary cooling ducts shall
be provided.

9.01.07

Each of the core bolts and parts of the core clamping frame work which are likely to form
a closed circulation path shall be insulated from the core laminations and tested after
completion of the core assembly to withstand, a voltage of 2500V, rms 50Hz, for a duration
of one minute.

9.01.08

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

9.01.09

When bell type tank construction is offered, suitable projecting guides shall be provided
on core-assembly to facilitate removal of tank.

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9.01.10

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

9.01.11

The maximum flux density in any part of the core and yoke at rated MVA, voltage and
frequency at any tap shall not exceed 1.60 tesla.

9.01.11

Bidder should have in house core cutting facility for proper monitoring and control on
quality and also to avoid any possibility of mixing of prime material with defective / second
grade material.

9.02.01

WINDINGS:

9.02.02

The tenderer shall ensure that winding of all EHV class transformer is made in dust proof,
atmosphere, preferably in an enclosure or room where higher air pressure is maintained
so that no dust can enter the premises. The Bidder shall furnish the facilities available in
this regard at their works along with the tender.

9.02.03

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

9.02.04

The windings shall be so designed that all coil assemblies of identical voltage rating shall
be interchangeable and field repairs to the windings can be made readily, without special
equipments. The coil shall be supported between adjacent sections by insulating spacers
and barriers, Bracing’s and other insulating materials used in the assembly of the windings
shall be so arranged to ensure a free circulation of the oil and to reduce hot spots in the
windings. The high, medium and tertiary windings on each leg shall be so assembled as to
admit their being placed on or removed from core leg as complete units.

9.02.05

The insulation of the coils shall be treated with suitable insulating varnish or equivalent
compound to develop the full electrical strength of the windings. All materials used in the
insulation and assembly of the windings shall be insoluble non-catalytic and chemically

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inactive with the hot transformer oil and shall not soften or otherwise be adversely affected
under the operating conditions. Class 'A' insulation shall be used throughout.

9.02.06

All threaded connections shall be provided with locking facilities. All leads from the
winding to the terminal Board and bushings shall be rigidly supported to prevent injury
from vibration. Guide shall be used where practicable.

9.02.07

The winding shall be clamped securely in place so that they will not be displaced or
deformed during short circuits. The assembled cores and windings shall be vacuum dried
and suitably impregnated before removal from the treating tank. The copper conductors,
used in the coil structure shall be best suited to the requirements and all permanent
current carrying joints in the windings and leads shall be welded or brazed.

9.02.08

All-star connected windings of 66KV and above shall have graded insulation as per
relevant India or International Standard. The Power Transformer shall withstand the
power frequency and impulse test voltage specified. The windings shall be designed to
reduce to minimum out of balance forces in the transformer at all voltage variations. The
conductor shall be transposed at intervals to reduce eddy currents and equalize currents
and temperature distribution along the windings.

9.02.09

The stacks of windings shall receive adequate shrinkage treatment before and after final
assembly. Adjustable devices if necessary, shall be provided for taking up possible
shrinkage of coils if any, in service, The provision made in this respect shall be clearly
brought out in the Tender.

9.02.10

Power transformer should be designed for the short circuit current of 100/z times the rated
primary current of transformer for 3 secs where ‘Z’ is the percentage impedance of
transformer, The high voltage and medium voltage winding shall be capable of
withstanding this fault current. The supplier would furnish the detailed calculation to prove
the short circuit strength of power transformer.

9.02.11

The tertiary winding which is meant for stabilizing purpose shall be capable of
withstanding the over currents resulting from different forms of system faults that can

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arise in service, associated with system earthing conditions which is solidly grounded
system, Suitable cross section and current density of tertiary winding may be provided,
taking in to account, the source impedance specified. The duration of the fault current
shall be as per IS depending upon the inter winding impedance. The excess section
provided shall take care of the mechanical stresses also during system short circuit. In
the tender the calculation to prove the short circuit strength of the winding should be
furnished.

The short circuit MVA capacity of the tertiary winding shall be 25% extra over the
calculated and designed short circuit MVA. Detailed short circuit calculations of the
transformer shall be furnished along with the offer.

9.02.12

The maximum current density in any winding shall not exceed 3 Amps / sq. mm at all taps.

9.02.13

The conductors shall be transposed at suitable intervals in order to minimize eddy current
and to equalize the distribution of current and temperature along the windings.

9.02.14

Fibre optic Sensors shall be embedded in each phase of the winding. The sensors shall
be located where the Temperature is the highest.

9.02.15

SUPPRESSION OF HARMONICS: The transformer shall be designed with particular

attention to the suppression of harmonic voltages, especially the 3rd and 5th so as to
eliminate wave form distortion and any possibility of high frequency disturbances,
inductive effected or of circulating currents between neutral points of different
transformer stations reaching such a magnitude as to cause interference with
communication circuits.

9.03.00

TANK AND TANK ACCESSORIES:

9.03.01

TANK:

a) The transformer tank and cover shall be fabricated from tested grade low carbon steel
suitable for welding. For 31.5 MVA transformer, the thickness shall be not less than
8mm for sides, 10mm for bottom and top cover and for 150 MVA transformer, the

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thickness shall be not less than 10mm for sides, 20mm for bottom and top cover. The
tank shall be of welded construction. (Please Consider 31.5 MVA in this case)

b) All seams and those joints not required to be opened at site shall be factory welded
and wherever possible they shall be double welded. After completion of tank
construction and before painting, dye penetration test shall be carried out on welded
parts of jacking bosses, lifting lugs and all load bearing members. The requirement of
post weld heat treatment for tank / stress relieving parts shall be based on
recommendation of BS 5500 table 4.4.3.1

c) The completely fabricated tank shall be subjected to oil leakage test, vacuum test and
pressure test as specified in the clause 17.3.1 and 17.3.2 section A of revised 1987
CBIP manual. The tank cover shall be bolted to the tank and the transformer design
shall be such that the tank will not be split between lower and upper cooler connection
for un-tanking. The tank shall also be designed to withstand (a) Mechanical shocks
during transportation (b) short circuit forces (c) Vacuum filling of oil d). Continuous
internal pressure of 35kN/m2 over normal hydrostatic pressure of oil.

d) Tank stiffeners shall be provided for general rigidity, and these shall be designed to
prevent retention of water.

e) The transformer of rating 100MVA and above shall be of bell type tank construction
with the joint at about 500 mm above the bottom of the tank. In case the joint is welded
it should be provided with flanges suitable for repeated welding. The joint shall be
provided with suitable gasket to prevent weld splatter inside the tank. Proper tank
shielding shall be done to prevent excessive temperature rise of the joint. In bell tank
construction, suitable projecting guides shall be provided on core assembly to
facilitate removal of tank.

f) Suitable guides shall be provided for positioning the various parts (core and coil
assembly) during assembly or dismantling. Adequate space shall be provided
between the cores and windings and the bottom of the tank for collection of any
sediment.

g) Lifting eyes or lugs shall be provided on all parts of the transformer requiring
independent handling during assembly or dismantling. In addition, the transformer
tank shall be provided with lifting lugs and bosses properly secured to the sides of the
tank for lifting the transformer either by crane or by jacks. Suitable haulage holes shall
also be provided.

h) The design of the tank, the lifting lugs and bosses shall be such that the complete
transformer assembly filled with oil can be lifted with the use of these lugs without any
damage or distortions.

i) The tank shall be provided with two suitable copper alloy lugs for the purpose of
grounding.

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j) Each tank shall be equipped with the following valves with standard screw connection
for external piping.

1. One drain valve - 100 mm (4") flanged at the bottom of the tank to completely drain
the tank. At the option of the purchaser, a large valve may be furnished with an
eccentric reducer. This valve shall be equipped with a small sampling cock. Also,
another sampling cock shall be provided at the top of the tank.
2. One filter valve located at the bottom of the tank. The filter valve shall be 50 mm (2")
flanged to seat 40 mm (1½ ”) male threaded adopter, for the filter pipe connection.
3. One filter valve located at the top of the tank. The filter valve shall be 50mm (2")
flanged to seat 40 min (1 ½ “) male threaded adopter, for the filter pipe. The opening
of the valve shall be baffled to prevent aeration of the oil.

k) Wherever possible the transformer tank and its accessories shall be designed without
pockets wherein gas may collect. Where pockets cannot be avoided, pipes shall be
provided to vent the gas into the main expansion pipes.

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

m) Tank shields shall be such that no magnetic/ fields shall exist outside the tank. They
shall be of magnetically permeable material. If required impermeable shields shall be
provided at the coil ends. Tank shield shall not resonate when excited at the natural
frequency of the equipment. Bidder may confirm use of tank shields in the schedule of
additional information.

9.03.02

TANK COVER:

iii) The tank cover shall preferably be sloped to prevent retention of rain water and
shall not distort when lifted.

b) At least two adequately sized inspection openings, one at each end of the tank shall
be provided for easy access to bushings and earth connections. The inspection
covers shall not weigh more than 25 Kg. The inspection covers shall be provided with
two handles to facilitate shifting/lifting.

c) The tank covers shall be fitted with pockets at the position of Maximum oil temperature
of MCR (Maximum Continuous Rating) for RTD sensor / thermometer and bulbs of oil
and winding temperature indicators. It shall be possible to remove these bulbs without
lowering the oil in the tank. Protection shall be provided where ever necessary for
each capillary tube.

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d) Bushings, turrets, covers of inspection Openings, thermometer, pockets etc., shall be

designed to prevent ingress of water into or leakage of oil from the tank,

e) All bolted connections shall be fitted with weatherproof, hot oil resistant gasket in
between, for complete oil tightness. Special attention shall be given to the methods of
marking the hot oil tight joints between the tank and cover as also between the cover
and the bushings and other outlets to ensure that the joints can be remade
satisfactorily and with ease, with the help of semi-skilled labour. If gasket is
compressible, metallic stops shall be provided to prevent over-compression.

9.03.04

AXLES AND WHEELS:

a) The transformer tank shall be supported on a structural steel base equipped with
forged steel or cast steel, flanged bi- directional wheels and axles suitable for moving
the transformer completely fitted with oil. These shall be so designed as not to deflect
excessively to interfere with the movement of the transformer. Wheels shall be
provided with suitable bearings which shall be rust and corrosion resistant. Fittings
for lubrication shall also be provided.

b) Suitable locking arrangement along with foundation bolts shall be provided for the
wheels to prevent accidental movement of transformer.

c) The wheels are required to swivel, and they shall be arranged so that they can be
turned through an angle of 90º when tank is jacked up to clear of rails. Means shall be
provided for locking the swivel movements in positions parallel to and at right angles
to the longitudinal axis of the tank.

d) The gauge of the wheels when the transformer is moved on the common track shall be
1676 mm. The gauge of wheels when the transformer is moved on its own foundation
plinth which will be at right angles to the direction of the common track shall be 2982
mm for 100MVA and above transformer and 1676 mm for 31.5MVA Transformer.

e) A minimum of four jacking pads in accessible position at 500 mm height to enable the
transformer to complete with oil, to be raised or lowered using hydraulic or screw
jacks.

f) Suitable haulage holes shall be provided to facilitate moving the transformers and they
shall be suitably braced in a vertical direction so that bending does not occur when
the pull has a vertical component. Suitable jacks for lifting the transformer for
changing the plane of rotation of the wheels shall be supplied.

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9.03.05

ANTI- EARTHQUAKE CLAMPING DEVICE:

To prevent transformer movement during earthquake, clamping device shall be provided

for fixing transformer to the foundation. The supplier shall supply necessary bolts for
embedding in the concrete foundation. The arrangements shall be such that the
transformer can be fixed to or -unfastened from these bolts as desired. The fixing of the
transformers to the foundation shall be designed to withstand seismic events to the extent
that a static coefficient of 0.3g, applied in the direction of least resistance to that loading
will not cause the transformer or clamping devices as well as bolts to be over stressed.

The details of the device used and its adequacy shall be brought out in the additional
information schedule.

9.03.06

CONSERVATOR TANK:

a) The conservator tank shall have adequate capacity between highest and lowest
visible levels to meet the requirement of expansion of the total cold oil volume in the
transformer and cooling equipment from minimum ambient temperature to 100º C.

Conservator shall be with volumetric capacity at least 7 ½ % of a total volume of oil in

the main tank of the transformer. The conservator tank shall be above the level of the
bushing flanges.

b) The conservator tank shall be bolted into position so that it can be removed for
cleaning purposes. Suitable provision shall be kept replacing air cell wherever
applicable.

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

The conservator shall be fitted with magnetic oil level gauge with low level electrically
insulated alarm contact.

d) Conservator shall be provided in such a position as not to obstruct the electrical

connections to the transformer.

e) OLTC shall have separate conventional type conservator (without air cell) with
magnetic oil level gauge with potential free oil level alarm contact and prismatic oil
level gauge.

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Separate conservator tank/ compartment in the main conservator shall be provided

for OLTC.

f) The conservator tank shall have two filter valves one at the bottom at one end, the
other at the top, opposite end, in addition to the valve specified in the accessories for
the main tank. The conservator shall also have shut-off valve and a sump with a small
drain valve and sampling cock, the latter so arranged as not to interfere with oil lines.

g) 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

9.03.07

PRESSURE RELIEF DEVICE:

Adequate number of pressure relief devices shall be provided at suitable locations which
shall be of sufficient size for rapid release of any pressure that may be generated in the
tank and which may result in damage to the equipment. The device shall operate at a static
pressure of less than the hydraulic test pressure of transformer tank. It shall be mounted
direct on the tank. One set of electrically insulated contacts shall be provided for
instantaneous tripping along with the recommended settings. If required discharge of PRD
shall be properly taken through pipes and directed away from the Transformer / other
equipments and this shall be prevented from spraying on the tank. Following routine test
shall be conducted on PRD:

a) Air pressure test

b) Liquid pressure test

c) Leakage Test
d) Contact Test
e) Dielectric Test

9.03.08

BUCHHOLZ RELAY:

A Double float type Buchholz relay shall be provided. All the gases evolved in the
transformer shall collect 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
or stainless-steel tube shall be connected from the gas collector to a valve located about
1200 mm above ground level to facilitate sampling, with the transformer in service. The
device shall be provided with two electrically independent ungrounded contacts, one for
alarm on gas accumulation and the other for tripping on sudden rise of pressure. It shall
be provided with shut off valves and flange coupling to permit easy removal without
lowering oil level in the main tank.

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9.03.09

TEMPERATURE INDICATORS:

A) OIL TEMPERATURE INDICATOR (OTI ):

iv) All transformers shall be provided with a 150 mm dial type thermometer for top
oil temperature indication. The thermometer shall have adjustable, electrically
independent un-grounded alarm and trip contacts, maximum reading pointer
and resetting device mounted in the cooler control cabinet. Temperature.
sensing element suitably located in a pocket of top oil to read the hottest part of
the oil shall be provided. This shall be connected to the OTI by means of capillary
tubing. Accuracy class of OTI shall be 1.5% or better.
ii. Remote Oil temperature indicator. It shall be suitable for flush mounting on
RTCC panel. The difference between local and remote OTI indication at any
given time shall not exceed 1 degree C.

B) WINDING TEMPERATURE INDICATOR (WTI)

A device for measuring the hot spot temperature of each of the (HV, IV & LV) windings shall
be provided. It shall comprise of the following:

i. Temperature sensing element with three hot spot winding temperature

elements one each located in the HV windings, IV windings and LV windings.
ii. Image coil.
iii. Auxiliary CTs, if required to match the image coil, shall be furnished and
mounted in the cooler control cabinet,150mm diameter local indicating
instrument with maximum reading pointer mounted in cooler control cabinet
and with two adjustable electrically independent ungrounded contacts
(besides that required for control of cooling equipment), one for high winding
temperature alarm and one for trip. The cooling equipments (Fan / Pump
Motor) shall be switched on when the winding attains respective present high
temperature and switch it off when the temperature drops by an established
differential (so as to avoid too frequent on and off operation of the switch).
iv. Calibration device.
vi. In addition to the above, the following indication equipment shall be provided
for each winding.

a) Remote winding temperature indicator. It shall be suitable for flush mounting

on RTCC panel. The difference between local and remote WTI indication at any
given time shall not exceed 1 degree C. One RWTI shall be provided for each
winding in the middle phase (HV, IV / LV).

vii) The winding temperature detector relay shall be indicating and responsive to
the combination of top oil temperature and winding current, calibrated to
follow the hottest spot temperature of the transformer winding. The winding

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temperature detector shall operate remote alarm in the event of the hottest
spot temperature approaching a dangerous value and it shall automatically
actuate.

viii) Auxiliary supply if required, at owner's panel, for RWTI, shall be 220 V DC
only.

ix) Accuracy class of WTI shall be 1.5% or better.

x) Any special cables required for shielding purpose for connection between
cooler control cabinet and remote winding Temperature Indicator control
circuit shall be in supplier's scope of work.

xi) Suppliers should supply reputed make winding temperature indicator. The
make shall be indicated in his offer and the purchaser reserves the right to
suggest different make in the event of an order. The earlier performance shall
be indicated in the offer.

C)SIGNAL TRANSMITTER FOR EACH WINDING:

Signal transmitter shall have additional facility to transmit signal for recording winding
temperature at Owners data acquisition system, for which a duplex platinum RTD with
nominal resistance of 100 Ohms at zero degree centigrade shall be supplied. The RTD
shall be suitable for 3 wire under grounded system . The calibration shall be as per SAMA
(USA) standard. The RTD may be placed in the pocket containing temperature sensing
element and image coil for WTI system which will be used for both remote WTI and DAS.
Necessary equipment for sending the signal to remote WTI and DAS shall be provided in
lieu, separate RTD for each of the functions shall be provided.

D)REMOTE WINDING TEMPERATURE INDICATOR

It shall be suitable for flush mounting on Owner’s panel. This shall not be repeater dial of
local WTI and will operate by signal transmitter.

Any special cable required for shielding purpose for connection between cooler control
cabinet and remote WTI control circuit, shall be in the scope of contractor. One RWTI shall
be provided for each winding of HV, IV and LV. Auxiliary supply for RWTI, if required, will
be 220DC only. Drawing showing dimensional details of RWTI shall be submitted to the
Owner within two months from the date of award of contract.

E) Temperature Indicator:

Temperature measurement of Oil and windings shall be done using Fiber optic sensors,
meeting following criteria:

1. System shall be of proven and rugged technology. The temperature sensing tip along
with the fibre optic cable shall be of an already type tested design. Details of the relevant

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tests conducted shall be submitted along with the offer. The probes shall be directly
installed in each phase/winding of power transformer to measure the winding hot spot
and at the top (inside) of the transformer to measure top oil temperature. There shall be
minimum eight probes inside the transformer, out of which one probe should be installed
in top of the transformer for detection of top oil temperature.

2. The remaining Fibre optic probes shall be installed in core and each phase /
winding at the hottest spots of each of the phase windings. The locations of the probes
shall be proposed by the Manufacturer by identifying the hot spots with necessary
supporting calculations/documents and shall be finalized by agreement of the
Purchaser.

3. Probes shall be able to be completely immersed in hot transformer oil; they shall
withstand exposure to hot Kerosene vapor during the transformer insulation drying
process (VPD). The probes shall meet the requirement to eliminate the possibility of
partial discharge in high electrical stress areas in the transformer.

4. Temperature range of the system should be -30°C to 200°C & accuracy of ± 2°C with
no recalibration required. The probes shall not get damaged/affected during filtration
of the transformer.

5. Probes shall be all Silica, Double Teflon jacketed fibre with perforations/slits in the
outer jacket to allow complete oil filling.

The fibre with Teflon jacket shall be strong enough to withstand the severe conditions
prevailing inside an EHV transformer.

6. The microprocessor-based Fibre optic temperature monitoring system using Fibre

optic probes shall confirm the following features:

i. The Microprocessor based Fibre optic TMS shall read & display temperature of
each Fibre optic sensor measurement channel. The system shall work in
independent mode and failure of one channel should not affect the performance
of the other healthy channels.

ii. The logic for each relay should not consider the temperature channels for which
probe error is detected and the out-put should return to normal state
immediately after the probe error is detected.

7. A Microprocessor based monitoring & recording unit shall be a part of the system.
System should include analog outputs for each measurement channel. Temperature
resolution of the analog outputs shall be ±0.1°C and the systems shall offer a user
programmable temperature alarm outputs with 8 relays, alarm lamps (LED) and
controller system status indicators. All inputs and outputs of the system shall meet
the requirements of surge test of IEEE C37.90.1-2002 in which a 4000 V surge is

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applied to all the inputs and outputs without permanent damage to the instrument. The
microprocessor-based unit shall be of an already type tested design & details of type
tests conducted shall be submitted with the offer. The device shall be communicable
type & the protocol shall be IEC 61850 compliant. Provision for Time Synchronization
with GPS shall be made.

The temperature monitoring system shall be direct measurement non-calibrating

type. It shall read & display temperature of each Fibre Optic sensor measurement
channel. The system shall work in independent mode and failure of one channel should
not affect the performance of the other healthy channels.

8. The system shall be capable of retaining temperature data of 90 days at one (1)
reading/ minute and should retain maximum temperature of each channel until reset.

9. The manufacturer should submit data showing that the probes are located in the
hottest point of the winding, while submitting drawings for approval.

10. The fiber optic cables are to be brought out of the main tank through the tank wall
penetrator feed through plate. The Feed through plate shall be welded on the Tank
such that no oil leakage/moisture ingress will occur. The external fibre optic extension
cable shall then be run to main control cabinet, routed inside the conduits with large
bend radiuses.

11. The controller shall be housed in the cooler control cubicle or in a separate box of IP56
class mounted on the transformer tank. The position shall be clearly indicated in the
GA drawings.

12. Temperature rise test measurements shall be made with the FO Thermometers. The
equipment shall be operational during temperature rise tests and demonstrated
during these tests. During probe verification, the hottest spot for each phase shall
be identified, and temperature data for all probes recorded and reported in the test
report.

13. For remote indications on RTCC panel output of 4 to 20 mA shall be made available

9.03.10

EARTHING TERMINALS:

i)Two (2) earthing pads [each complete with two (2) Nos. tapped holes, M 10 bolts, plain
and spring washers] suitable for connection to 50 x 8 galvanized steel flat shall be provided
each at position close to the two (2) diagonally bottom corners of tank. Earthing strip up to
the ground level shall be provided by the Bidder.

ii)Two earthing terminals suitable connection to 50 x 8 mm galvanized steel flat also be

provided on cooler, marshalling box and any other equipment mounted separately.

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9.04.00

INTERNAL EARTHING ARRANGEMENTS:

9.04.01

GENERAL:

All metal parts of the transformer with the exception of the individual core- laminations,
core bolts and associated individual clamping plates shall be maintained at some fixed
potential.

9.04.02

EARTHING OF CORE CLAMPING STRUCTURE:

The top main core clamping structure shall be connected to the tank body by a copper
strap. The bottom clamping structure shall be earthed by one or more of the following
methods.

a) By connection through vertical tie rods to the top structure.

b) By direct metal - to - metal contact with the tank base maintained by the weight of
the core and windings.

c) By a connection to the top structure on the same side of the core as the main earth
connection to the tank.

9.04.03

EARTHING OF MAGNETIC CIRCUIT:

The magnetic circuit shall be earthed to the clamping structure at one point only through
a link placed in an accessible position beneath an inspection opening in the tank cover.
The connection to the link shall be on the same side of the core as the main earth
connection.

9.04.04

Magnetic circuit having an insulated sectional construction shall be provided with a

separate link for each individual section. Where oil ducts or insulating barriers parallel to
the plane of the laminations divide the magnetic circuit into two or more electrically
separate parts, the ducts or barriers shall be bridged (where the magnetic circuit is
divided into pockets by cooling ducts parallel to the plane of the laminations or by
insulating material above 0.25 mm thick tinned copper strips bridging pieces shall be
inserted to maintain electrical continuity between pockets) and the magnetic circuit shall
not be regarded as being of sectional construction.

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9.04.05

EARTHING OF CLAMPING RINGS:

Where coil clamping rings are of metal at earth potential, earth ring shall be connected to
the adjacent core clamping structure on the same side of transformer as the main earth
connections.

9.04.06

SIZE OF EARTHING CONNECTIONS:

All earthing connections with the exception of those from the individual coil clamping rings
shall have a cross sectional area of not less than 0.8 sq. cm. Connections inserted between
laminations of different sections of core as per Clause 9.04.04 shall have a cross sectional
area of not less than 0.2 sq. cm.

9.05.00

INSULATING OIL:

9.05.01

a) Uninhibited Mineral insulating oil shall be used & shall comply with IEC-60296- 2012
(Latest version).

Supplier shall furnish type test certificate complying to IEC-60296-2012 (latest version)
from any NABL accredited oil testing laboratory.

For 100MVA & 150MVA transformer: The oil shall be got tested by R&D section, KPTCL
before filling and after filling into the transformer (before energizing) as per relevant
standards. -Not applicable for this project

For 31.5MVA transformer: The oil shall be got tested by R&D section, KPTCL after filling
into the transformer (before energizing) as per relevant standards.

b) Sufficient quantity of oil necessary for first filling of all tanks, coolers and radiator at the
proper level along with 10% extra oil for topping up shall be supplied in non-returnable
containers suitable for outdoor storage.

c)For 100MVA & 150MVA transformer, the supplier shall dispatch the transformer filled
with an atmosphere of Nitrogen. The Bidder shall take care of the weight limitation on
transport and handling facility at site. Necessary arrangement shall be ensured by the
supplier to take care of pressure drop of nitrogen during transit and storage till completion
of oil filling during erection. A gas pressure testing valve with necessary pressure gauge
and adapter valve shall be provided.

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9.05.02

At manufacturers works oil sample shall be drawn before and after heat run test and shall
be tested for following:

a)BDV-60KV (min)

b)Moisture content – 10 PPM (Max.)

c)Dissolved gas analysis - samples for DGA shall be taken from sampling device with
24 hrs prior to commencement of temperature test and immediately after this
test. The acceptance norms with reference to various gas generation rates
during the temperature rise test shall be as per IS 10593(based on IEC 599)

Values of DGA test conducted before & after heat run test shall be furnished, as base value
for future test

9.06.00

OIL PRESERVING EQUIPMENT:

9.06.01.

For 245 KV class transformers Bidder shall offer diaphragm type oil sealing in conservator
to prevent oxidation and contamination of oil due to contact with atmospheric air. In this
type of oil preservation system conservator shall be fitted with a dehydrating filter
breather. It shall be so designed that :

i) Passage of air is through a dust filter and silicagel.

ii) Silicagel is isolated from atmosphere by an oil seal.
iii) Moisture absorption indicated by a change in colour of the tinted crystals can
be easily observed from a distance.
iv) Breather is mounted not more than 1400 mm above rail top level.
v) To minimize the ingress of moisture following shall be provided:
a) Three breathers (of identical sizes) shall be connected in series for main tank
conservator.
b) Two breathers (each of 2.5ltrs min volume) shall be connected in series for
OLTC tank conservator

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9.06.02

DIAPHRAGM SEAL TYPE CONSTANT OIL PRESSURE SYSTEM: (Air Cell System)

The bidder shall furnish his experience list for diaphragm type oil sealing system. The
requirement of the system is given below:

a) In this system contact of the oil with atmosphere shall be prohibited by using a flexible
air cell of nitrite rubber reinforced with nylon cloth.

b) Diaphragm used shall be suitable for continuous operation in an atmosphere of

100deg.C to which transformer oil is likely to rise.

c) The connection of the air cell to the top of the reservoir shall be by an air proof seal
permitting entrance of air into the cell only.

d) The diaphragm of the conservator shall withstand the vacuum during installation and
maintenance period. Otherwise, provision shall be made to isolate the conservator
from main tank during vacuum by providing vacuum scaling valve in the pipe
connecting main tank with the conservator.

9.07.00

BUSHINGS:

a) The electrical and mechanical characteristic of bushings shall be in accordance with

IS: 2099 and IS: 3347 (Part - III/Section-I). Dimensions and requirements of oil filled
condenser bushings shall be in accordance with IS : 12676-1989/ CBIP manual, IEC-
60137 section ‘P’ (Revised). Dimension and requirement of solid bushing or oil
communicating bushing shall conform to IS 3347,
Part-IV.

b) 72.5 KV bushings shall be oil filled condenser type.

36KV bushings shall be either oil communicating or solid porcelain type. The oil used
for the oil filled type shall be the same as that used in the transformer. No arcing horns
shall be provided on any bushing. -36 kV rating is not applicable in this project. Please
consider only for 66kV (or 72.5kV)

Bushings shall be as per technical particulars furnished. The bushings shall have high
factor of safety against leakage to ground and shall be so located as to provide adequate
electrical clearances between bushings and between the bushings and grounded parts.
Bushings of the identical voltage rating shall be interchangeable. All the bushings shall be
equipped with suitable terminals of approved type and size and all external current
carrying contact surfaces shall be silver plated adequately. The insulation class of the high
voltage neutral bushings shall be properly coordinated with the insulation class of the
neutral of the high Voltage winding. The supplier shall furnish (i) Impulse flash over, (ii) Dry
flash-over characteristic for bushing spark gap set at difference of separation. The bidder

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shall also furnish the impulse voltage characteristic of the transformer winding and
bushing to enable the purchaser to obtain effective insulation co-ordination between the
transformer lightning arrester and the rest of the station equipment.

c) All main windings and neutral leads shall be brought out through outdoor type
bushings, which shall be so located that the full flash over strength will be utilized, and
the adequate phase clearance be realised.

d) Each bushing shall be so co-ordinated with the transformer insulation, that all flash-
over will occur outside the tank.

e) Condenser type bushings shall be provided with -

i. Non-breathing oil expansion chamber made of toughened amber glass to filter

all light rays which may cause the oil to sludge. Prismatic type of gauge shall be
provided to indicate the oil level.

ii. Oil filling plug and drain valve if not hermetically sealed;

iii The dielectric power factor shall not be more than 3.5% at 40 deg C.

iv. Tap for capacitance and tan delta test.

When bushings have an under -oil end of re-entrant form, the pull – through lead shall
be fitted with the a gas bubble deflector.

f) Bushing of identical rating shall be interchangeable. The length for bushing current
transformer accommodation (L6 - as per CBIP manual) shall be minimum of 300mm.
Where turret type current transformers are specified, the bushings shall be
removable without disturbing the current transformer.

g) Porcelain used in bushing manufacture shall be homogenous, free from laminations,

cavities and other flaws or imperfections that might affect the mechanical or dielectric
quality and shall be thoroughly vitrified tough and impervious to moisture.

h) Glazing of porcelain bushing shall be of uniform brown colour free from blisters, and
burrs.

i) Special precaution shall be taken to eliminate moisture from paper insulation during
manufacture, assembly, transport and erection.

j) Bushing turrets shall be provided with vent pipes which shall be connected to route
any gas collection through the Buchholz relay.

k) All bushings shall have puncture strength greater than the dry flash over value.

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l) Main terminals shall be soldering less terminals and shall be of the type and size
specified in the schedule of requirements of drawings.

m) The spacing between the bushings must be adequate to prevent flash over between
phases under all conditions of operation.

n) No arcing horn shall be provided on bushing.

o) Suitable insulating cap (Preferably Raychem sleeve) shall be provided on the terminal
of bushing of tertiary winding to avoid accidental external short circuit.

9.08.00

TERMINAL CONNECTORS:

9.08.01

a) The 245, 123 and 72.5 KV bushing shall be provided with bimetallic type connectors
and of universal type. The connectors shall be suitable for ACSR conductor diameter
of 28.14 mm for 220 and 110KV and 2x28.14mm (Twin drake) for 66KV side. For
31.5MVA Transformer the connector on 66KV side shall be suitable for ACSR
conductor of diameter of 28.14mm. The connector shall be designed to prevent
corrosion due to bimetallic action.

The 36KV bushings shall be provided with terminal connectors.-Not applicable

The neutral bushings on 220, 110 & 66 KV side shall be provided with suitable
connectors for connection to strip type copper bus bars for ground connections. -
Please consider for 66kV

c) In case of 11 KV bushing side of 31.5 MVA, 66/11kV transformer, the transformer shall
be provided with connectors to which copper flat of size suitable for continuous
current of 2000A are to be connected. The copper flat is to be extended up to
Aluminium U.G. Cable of 12 runs (4 runs/ph) of 1000 Sq.mm Aluminium U.G. Cable. The
copper flats to be provided with suitable spaces between lams aeration.
The bus bars shall be coated with non-inflammable bus bar paints. The material of bus
bars shall be EC grade copper conforming to VDE 0201 Code-ECUF30, IS-8084. The
support insulators shall be suitable for voltage class of 33 KV.

d) Terminal connectors must have been successfully type tested strictly as per IS : 5561.
Connectors shall be of electrolytic grade copper forged and silver plated / tinned for
10microns.

e) No part of a clamp shall be less than 12.5mm thick.

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Non-magnetic, hot dip galvanized / electro-galvanized nuts, bolts and washers shall be
used. Nuts and bolts shall have hexagonal head with threads as per IS and shall be fully
threaded type. Also instead of spring washers, check / lock nuts shall be provided.

The connectors shall be designed for minimum 120% of the maximum current carrying
capacity of the ACSR conductor and the temperature rise under these conditions shall not
be more than 50% of that of the main conductor.

9.08.02 –

A BUSHING CURRENT TRANSFORMERS:

a). Current transformers shall comply with IS: 2705, IEC: 61869

b). It shall be possible to remove turret mounted CTs from the transformer tank without
removing the tank cover. Necessary precaution shall be taken to minimize the eddy
currents and local heat generated in the turret.

c). All secondary leads shall be brought to a terminal box near each bushing. These
terminals shall be wired up to the Cooler Control Cabinet using separate cables for
each core/phase.

d). Bushing CT parameters indicated in the specification are tentative and liable to
change within reasonable limits. The Bidder shall obtain the Purchaser’s approval
before proceeding with design of Bushing CTs.

9.08.02-

B TERMINAL MARKING:

The terminal marking and their physical position shall be in accordance with IS : 2026
unless otherwise specified.

9.09.00

EARTHING ARRANGEMENTS:

9.09.01

TERTIARY WINDING EARTHING ARRANGEMENT:

a) The open delta terminals of the tertiary windings shall be brought out and shorted by
using a copper link of adequate size and connected to earth. The earthing of the open
delta terminals shall be brought to the ground level by a copper flat of minimum size
100 x 12 mm which shall be supported from the tank by porcelain insulators of highest
system voltage of 36kV.

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b) The end of the copper flat bar shall be brought to the ground level, at a convenient
point, for connection to purchaser’s ground network through 50 x 8 mm galvanised
steel flats. The connection shall be made by using two (2) bolted grounding terminals
with necessary accessories.

9.09.02

NEUTRAL EARTHING ARRANGEMENT:

a) The neutral terminal of the star connected winding shall be brought to the ground
through externally installed NCT (which is in the purchasers scope) by a copper flat of
size minimum 2x50 /75 x 10 mm which shall be supported on mounting structure of
NCT, by porcelain insulators of highest system voltage of 36kV. The NCT will be
installed at a distance of about 2Mtrs. from the transformer and the live point of the
NCT will be the same as that of Neutral bushing.

b) The end of the copper flat bar shall be brought to the ground level, at a convenient
point, for connection to purchasers ground network through 50 x 8 mm galvanised
steel flats. The connection shall be made by using two (2) bolted grounding terminals
with necessary accessories.

c) Suitable flexible copper strip connection of adequate size shall be provided for
connecting to Neutral Bushing terminals to avoid tensile load on the
Bushings.

9.10.00-

AUXILIARY POWER SUPPLY FOR OLTC, COOLER CONTROL AND POWER CIRCUIT

9.10.00-

Auxiliary Power Supplies shall be as indicated in clause 3.0 and will be provided by the
purchaser at any one place for OLTC Control and Cooler Control.

9.10.00.

All loads shall be fed by one of the two feeders through an electrically interlocked
automatic changeover scheme housed in any one of the local control cabinets for tap
changer control and cooler circuits.

9.10.00.

Design features of the changeover scheme shall include the following:

i) Provision for the selection of one of the feeders as normal source and the
other as standby.

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ii) Upon failure of the normal source, the loads shall be automatically
transferred, after an adjustable time delay, to the standby source.

ii) Indication for ‘failure of normal source’ and for ‘transfer to standby source’ and
also for ‘failure to transfer’ shall be provided in the local cubicle as well as in
RTCC panel.

iii) Automatic re-transfers to normal source with an adjustable time delay following
re-energization of the normal source.

iv) Both the transfer and the re-transfer shall be ‘dead transfers’ and AC feeders
shall not be paralled at any time.

v) Necessary isolating switches, MCCB’ s and other components for the above
power supply transfer arrangement shall be provided by the supplier.

vi) MCCB’s shall be provided for Incoming AC supply ie., both Main & Standby AC
supply.

9.10.00-

B TAP CHANGING EQUIPMENT

9.10.01

TAP CHANGE SWITCH (GENERAL REQUIREMENT)

a) The on load tap changer shall be of the In Tank ,Hi speed ,Transient resistance type
and same shall be provided neutral end of the HV winding and shall permit constant
voltage on secondary side.

b) OLTC gear shall be motor operated for local as well as remote operation. An external
hand wheel / handle shall be provided for local manual operation. The OLTC shall be
suitable for power flow on either direction. The transformer shall give full load out put
on taps.

c) Arrangement shall be made for securing and padlocking the tap changer wheel in any
of the working positions and it shall not be possible for setting or padlocking the wheel
in any intermediate position. The arrangement shall be such that no padlock key can
be inserted unless all contacts are correctly engaged, and switch set in a position
where no open or short circuit is possible. An indicating device shall be provided to
show the tap in use.

d) On load tap changer shall be sourced from reputed manufacturer and it should be
type tested as per relevant IEC 60214 including switching and transient resistance
test of the relevant switch and test methods shall be in full conformance to the
procedures indicated in IEC 60214.

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9.10.02

ON LOAD TAP CHANGING GEAR (OLTC) SHALL BE SCADA COMPATIBLE

The details of the method of diversion of the load current during tap changing, the
mechanical construction of the gear and the control features for OLTC gear shall be
submitted with the bid. Information regarding the service experience on the gear and a list
of important users shall be furnished, the tap changer shall change the effective
transformation ratio without producing phase displacement.

a) The current diverting contacts shall be housed in a separate oil chamber not
communicating with the oil in main tank of the transformer. The chamber shall be
provided with a means of releasing the gas produced by the arcing.

b) The contacts shall be accessible for inspection without lowering oil level in the main
tank and the contact tips shall be replaceable.

c) For reduction of make and break arcing voltage due to overloads and short circuits,
the arcing switch or arc suppressing tap selector shall be provided with reactors or
resistors. Necessary tools and tackles shall be furnished for maintenance of OLTC
gear.

OR

The supplier shall indicate the safeguards provided in order to avoid arcing at the current
diverting contacts in the event of operation of the OLTC gear under over-load
conditions of the transformer.

d) The OLTC oil chamber shall have oil filling and drain plug, oil sampling valve, relief
vent and level glass, It shall also be fitted with a Buchholz relay the outlet of which
shall be connected to a separate conservator tank. A dial type indicating thermometer
of rolrest pattern shall be provided for OLTC and mounted in the side of transformer
at convenient height to read the temperature in the hottest part of the oil fitted with
alarm and trip contacts.

e) The diverter switch or arcing switch shall be so designed 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 equipments.

f) Tap changer shall be so mounted that bell cover of transformer can be lifted without
removing connections between windings and tap changer.

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i) Drive mechanism chamber shall be mounted on the tank in accessible position,

It should be adequately ventilated and provided with anti-condensation metal
clad heaters. All contactors, relay coils and other parts shall be protected
against corrosion, deterioration due to condensation, fungi. Pad locking
arrangement for hinged door of the cubicle and cable glands for all incoming
cables, etc shall be provided.

ii) The tap change driving motor shall be suitable for operation with 415 V, 3 phase,
50 Hz external power supply.

g) Each transformer unit shall be provided with a local OLTC control cabinet and a
remote OLTC control panel. The control feature shall provide following.

i)Local remote selector switch mounted in the local control cubicle shall switch
control of OLTC in the following manner:

When the selector switch is in LOCAL position, it shall be possible to operate the RAISE-
LOWER control switches specified in section (ii) below. Remote control of RAISE-LOWER
functions shall be prevented.

When the selector switch is in REMOTE the local control cubicle mounted RAISE - LOWER
switches specified in section (ii) shall be inoperative, Remote control of the raise - lower
function shall be possible from the remote control panel. The LOCAL - REMOTE selector
switch shall have at least two spare contacts per position which are closed in that position
but open in the other position.

ii). A RAISE-LOWER CONTROL SWITCH shall be provided in the Local Control Cubicle.
The switch shall be spring loaded to return to the center 'OFF' position and shall
require movement to the RIGHT to raise the voltage of the transformer.
Movement to the left shall lower the voltage.

This switch shall be operative only when 'local remote', selector switch is in local
position.

‘Step by step' operation to ensure only one tap change takes place even if the
tap change control switch is stuck or held in the operated position. Seal in
circuits to ensure positive completion of a tap change impulse once initiated.

Interlock to prevent an impulse being give to reverse the tap change direction
while a tap change operation is already under progress, until the mechanism
comes to rest and resets the circuits for fresh operation .

iii) Operating mechanism for on load tap changer shall be designed to go through
one step or tap change per command. Subsequent tap changes shall be

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initiated only on receipt of a new or repeat command. This should be

ensured through Snap Action Mechanism in the Drive Mechanism

iv). On load tap changer shall be equipped with a time delay for 'INCOMPLETE
STEP’ in alarm consisting of a normally open contact which closes, if the tap
changer fails to make a complete tap change. The alarm shall not operate for
momentary loss of auxiliary power.

iv) The OLTC load tap changer shall be equipped with a fixed resistor network
capable of providing discrete voltage steps for input to the supervisory
system.
v) The resistor based potentiometric unit shall be installed in the local OLTC
control cabinet to provide tap position indication for the transformer. The
supplier shall also provide a spare set of instruments as per clause for tap
position indication on the RTCC panel in the control room. Complete
mounting details shall be included with approved diagram.

vi) Limit switches shall be provided to prevent over running of the mechanism and
shall be directly connected in the circuit of the operating motor. In addition, a
mechanical stop shall be provided to prevent over - running of the mechanism
under any condition. Limit switches may be connected in the control circuit of
the operating motor provided that a mechanism-de-clutching mechanism is
incorporated.

j). Thermal device or other means shall be provided to protect the motor and control
circuit. All relays, switches, MCCB / MCB etc. shall be mounted in the drive mechanism
chamber and shall be clearly marked for the purpose of identification.

k) A permanently legible lubrication chart shall be fitted within the driving mechanism
chamber.

l) A five-digit counter shall be fitted to the tap changing equipment to indicate the
number of operations completed.

m) All relays and operating devices shall operate correctly at any voltage between the
limits specified.

n) It shall not be possible to operate the electric drive when the manual operating gear
is in use.

o) It shall not be possible for any two controls to (i.e., manual, local electrical and remote)
be in operation at the same time.

p) The equipment shall be suitable for supervisory control & indication with make before
break multi-way switch, having one potential free contact for each tap position. This

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switch shall be provided in addition to any other switch/ switches, which may be
required for remote tap position.

q) All electrical control switches and the local operating gear shall be clearly labeled in
a suitable manner to indicate the direction of tap changing.

r) OLTC Shall have a mechanical fuse incorporated in the design to ensure the
protection of divertor switch in the event of an undue mechanical stress on Tap
Changer.

s) The Tap Selector Contacts shall not be of the threaded type to ensure positive, full
face and firm contact from Transformer leads to Tap Changer.

t) No continuity break shall be allowed during changeover between any two taps. The
OLTC shall be tested for the same by ensuring that there is no open circuit showing
while changing two taps.

u) OLTC design should have been seismic tested and qualified.

v) OLTC Routine Tests:

OLTC manufacturer shall conduct the following routine tests fully in compliance with IEC
60214 on every unit as given below before dispatch to assure the quality of the product.

Sl. No. IEC Reference Test description Acceptance level

Mechanical Minimum 1000
1 60214 Cl No. 5.3.1
Endurance Test operations
Switching operation
2 60214 Cl No. 5.3.2 Sequence Test with timing less than
50m sec.
10 PSI (0.7kg per
3 60214 Cl No. 5.3.4 Pressure Test Sq.cm.) for 8 hrs. at
room temp.
Vacuum (Helium) Vacuum level of 6x 10(-
4 60214 Cl No. 5.3.4
Test 5)
Should withstand 2KV
Auxiliary circuit
5 60214 Cl No. 5.3.3 relative to earth for 1
insulation tests
min
Helium based or any
6 Special Test Gas Tightness Test other mutually agreed
method
Contact resistance
7 Special Test <2 miliohms
Test
Physical & As per approved
8 Special Test
Dimensional Checks drawing

All the relevant test reports shall be submitted along with the test report of Transformer
for KPTCL approval.

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w) The Tap Changer shall be suitably protected through Oil Surge Relay and it shall be
of reed magnetic switch type. This surge relay shall be tested for an Oil flow
velocity of 1.20 +/- 0.20 m/s.

9.10.03

MANUAL CONTROL:

The cranking device for manual operation of the OLTC gear shall be removable and
suitable for operation by a man standing on ground level. The mechanism shall be
complete with the following:

v) Mechanical tap position indicator which shall be clearly visible from near the
transformer.
vi) A mechanical operation counters.
vii) Mechanical stops to prevent over cranking of the mechanism beyond the
extreme tap positions.
iv) The manual control considered as back up to the motor operated on load tap
changer control shall be interlocked with the motor to block motor -start-up
during manual operation. The manual operating mechanism shall be labeled to
show the direction of operation for raising the primary and vice-versa.

9.10.04

a)ELECTRICAL CONTROL:

This includes the following

i) Local Electrical control.

ii)Electrical remote control from remote control panel.

b) REMOTE ELECTRICAL GROUP CONTROL:

The OLTC control scheme offered shall have provision of remote electrical group control
during parallel operation of transformers. This is in addition to independent control of
OLTC. It shall be possible to operate 4 No. of transformers by group control of OLTC. For
this, a flexible circuit arrangement shall be provided for addition of transformers at a later
date.

viii) A four position selector switch having MASTER, FOLLOWER, INDEPENDENT

and OFF position shall be provided in the remote OLTC control panel for each
transformer. This shall be wired to enable operator to select operation of OLTC
in either Master, follower or independent mode.
ix) Out of step relays with timer contacts shall also be provided to give alarm and
indication in case of tap positions in all the transformers under group control
being not in identical position. There should be an automatic lock out of the

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combined control when any one of the units fails to fall in steps, due to mal
operation of its gear.
x) Under abnormal condition such as may occur if the contactor controlling one
tap changer sticks, the arrangement must be such as to switch off supply to the
motor so that an out of step condition is limited to one tap difference between
the units.
xi) Master position:

If the selector switch is in MASTER position, it shall be possible to control the OLTC units
in the FOLLOWER MODE by operating the controls of the MASTER UNIT. Independent
operation of the units under FOLLOWER mode shall have to be prevented. However, the
units under independent mode will be controlled independently.

xii) FOLLOWER POSITION.

If the selector switch is in follower mode, control of OLTC shall be possible only
from MASTER panel.

xiii) INDEPENDENT POSITION

In this position of selector switch, control of OLTC of individual unit only shall
be possible.

xiv) PARALLELING INTERLOCK:

An interlock shall be incorporated in the electrical control circuit of the ON load
tap change gear to prevent electrical closing of the circuit breaker on the low
voltage side of non-operation transformer with those already in operation, when
:

a) Its ON load tap change gear is not in the same position as those already in operation.

b) The auxiliary AC supply to its on load tap change motor is not switched before hand.

viii. The ON load tap changer scheme drawing for parallel operation, shall be as per
section N of CBIP manual (revised).

9.10.05

MAKE OF OLTC:

The make of OLTC shall be an approved vendor with KPTCL

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9.11.00

COOLING EQUIPMENT AND ITS CONTROLS:

9.11.01

COOLING EQUIPMENT:

a) Tank mounted radiator Bank shall be provided for 31.5MVA, 66/11KV

Transformer.

b) Each radiator bank shall have its own cooling fans, oil pumps, oil flow indicator, shut
off valves, lifting lugs, top and bottom oil filling valves, air release plug, a drain valve,
grounding terminals and thermometer pocket fitted with captive screw cap on the inlet
and outlet. Heat exchangers, fans and oil pumps shall be completely interchangeable.

c) Cooler unit shall be connected to the tank by machined steel flanges welded to the
cooler unit and to the tank and provided with gaskets. At each cooler unit connection,
there shall be provided on the tank an indicating shut off valve which can be fastened
in either open or closed position. A separate oil tight blank flange shall be provided
for each tank connection for use when the cooler is detached.

d) One stand by fan for at least 20% capacity shall also be provided and identified with
each radiator bank.

e) Cooling fans shall not be directly mounted on radiator bank which may cause undue
vibration. Fans shall be so located that they are readily accessible for inspection and
repair.

f) The Exhaust air flow from cooling fan shall not be directed towards the main tank in
any case.

g) Cooling fans for each radiator bank shall be located so as to prevent ingress of
rainwater. Each fan shall be suitably protected by galvanised wire guard.

ii) The cooler and its accessories shall be hot painted with corrosion resistant paint

h) Two (2), 100% centrifugal oil pumps (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. Under failure of main oil pump, the
changeover from main to standby oil pump shall be automatic.

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i) Motor and oil pump shall be enclosed in an oil tight container with motor leads brought
through a hermetically sealed bushing. Each cooler unit shall be arranged for
detaching from the transformer without disturbing the oil in the transformer tank.
Moving parts of the motor and pump shall be readily removable with dismantling the
cooler and with minimum spillage of oil.

j) Cooling fans and oil pump motors shall be suitable for operation from 415 volts, three
phase 50Hz power supply and shall confirm to IS : 325.

k) An oil flow indicator shall be provided for the confirmation of the oil pump operating in
a normal state. A provision shall be made in the flow indicator to indicate reverse flow
of oil/loss of oil flow.

l) Suitable mechanical interlock should be provided for proper mounting of the pump
and motor, so that oil flow is ensured in the required direction only.

m) Cooler shall be so designed as to be accessible for cleaning and painting, to prevent

accumulation of water on the outer surface, to completely drain oil the tank and to
ensure against formation of gas pockets when the tank is being filled. The cooler and
its accessories shall be hot painted with corrosion resistant paint.

n) Each cooling fan and oil pump motor shall be provided with starter, thermal overload
and short circuit protection.

o) Each radiator shall be provided with :

• One shut-off valve at the top (80 mm size)

• One shut -off valve at the bottom (80 mm size)
• Air release device at the top.
• Main and sampling device at the bottom.
• Lifting lugs.
• Expansion joints, one each on top and bottom cooler pipe connections.
• Air release device and oil plug on oil pipe connections,

p) The radiator bank and cooler pipe arrangement should be such that it does not hinder
the movement of the transformer.

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9.11.02

COOLING EQUIPMENT CONTROL (ONAN/ONAF/OFAF) :

a) Cooler units shall be suitable for operating with a 415 volts, 3 phase, 50 Hz, 4 wire
external AC power supply.

b) Control equipment for oil pump and fan motors shall be mounted in a weather and
vermin proof marshalling cabinet adjacent to the transformer and shall include the
necessary contactors with automatic control and annunciator equipment and
provision for manual control.

c) Automatic operation control (Switching in and out) of fans/ pumps shall be provided
(with temperature change) from contacts of winding temperature indicator. The
supplier shall recommend the setting of WTI for automatic change over of cooler
control from ONAN to ONAF to OFAF. The setting shall be such that hunting i.e.,
frequent start stops operations for small temperature differential do not occur.

d) Suitable manual control facility for cooler fans and oil pumps with manual / automatic
selector switches and push buttons shall be provided.

e) Each motor or group of motors shall be provided with a three pole electrically
operated contactor and with control gear of suitable design both for starting and
stopping the motor manually and also automatically from the Contacts on the winding
temperature indicating device. Additional terminal for remote/manual electrical
control of' motors shall be provided.

f) Where small motors are connected in groups the group protection shall be arranged
so that it operates satisfactorily in the event of a fault occurring on single motor.

g) Where blowers and oil pumps are provided the connections shall be arranged as to
allow the motors or group of motors to be started up and shut down, either collectively
or individually.

h) All motor contactors and their associated apparatus shall be capable of holding in and
operating satisfactorily and without over heating for a period of 10 minutes if the
supply voltage falls for a small period to 75% of normal voltage at normal frequency.
The motor contactors and associated apparatus shall be capable of normal operation
with supply voltage at 85% of normal values and at normal frequency.

i) All contacts and other parts, which may require renewal, adjusting or inspection, shall
be readily accessible.

j) The contact arrangements are to be designed as to prevent the simultaneous starting

of motors of a total rating of more than 20 HP.

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k) Alarm indication for failure of group of fans and oil pump shall be provided. Alarm
indication for failure of' power supply shall also be furnished.

l) The Bidder shall specify the loading of the transformer in case of failure of one or more
set of fans.

NOTE: In addition to the above details, the clause No. 9.18 -Specification for control cabinet
for tap change driving motor unit is applicable, wherever necessary.

9.11.03

COOLER CONTROL CABINET:

a) Each transformer unit shall be provided with a cooler control cabinet.

b) Control equipment for oil pump and fan motors shall be mounted in a weather and
vermin proof marshalling cabinet adjacent to the transformer and shall include the
necessary contactors with automatic control and annunciator equipment and
provision for manual control.

c) The cooler control cabinet shall have all necessary devices meant for cooler control
and local temperature indicators. All the contacts of various protective devices
mounted on the transformer shall also be wired up to the terminal board in the cooler
control cabinet. All the secondary terminals of the CT's shall also be wired up to the
terminal board at the cooler control cabinet.

d) The cooler control cabinet shall have two (2) sections. One section shall have the
control equipment exclusively meant for cooler control The other section shall house
the temperature indicators, auxiliary CT’s and the terminal boards meant for
termination of various alarm and trip contacts as well as various CT secondaries. The
initiating device and contacts for alarm and trip function for the following shall be
terminated to the terminal block which will be wired up to the purchaser's control and
relay panel. Buchholz trip / alarm, oil temperature high alarm, oil temperature very
high trip, oil low level (MOG) alarm, winding temperature high alarm, winding
temperature very high trip, OLTC surge relay trip, pressure relief device trip main and
OLTC. Alternatively, the two sections may be provided as two separate panels
depending on the standard practices of the supplier.

e) The temperature indicators shall be so mounted that the deals are not more than 1600
mm from ground level. Glazed door of suitable size shall be provided for convenience
of reading.

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9.11.04

VALVES:

a) All valves up to and including 100 mm size shall be of gun metal or of cast steel/cast iron.
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
clockwise when facing the hand wheel.
b) Suitable means shall be provided for locking the valves in the open and close position.
Provision is not required for locking individual radiator valves
c) Each valve shall be provided with the indicator to show clearly the position of the valve.
d) All valve flanges shall have machined faces.
e) All valves in oil line shall be suitable for continuous operation with transformer oil at
100ºC
f) The oil sampling point for main tank shall have two identical valves to be put in series. Oil
sampling valve shall have provision to fix rubber hose of 10mm size to facilitate oil
sampling.
g) A valve or other suitable means shall be provided to fix the on line dissolved gas monitoring
system to facilitate continuous dissolved gas analysis. The location and size of the
same shall be finalized during detail engineering stage.
h) Suitable valves shall be provided to take sample of oil from the OLTC chamber during
operation of the transformer.
i) 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 conforming to IS:2074
followed by two coats of fully glossy finishing paint.
j) All hardware used shall be cadmium plated/electro galvanized.

9.11.05

REMOTE OLTC / COOLER CONTROL PANEL (RTCC PANEL):

The auxiliary devices for remote electrical control of the OLTC and cooler shall be housed
in a separate panel to be placed in the control room. The panel shall be made of sheet steel
of not less than 3mm and it shall be duly finished with stove enamel paint. The size of the
control cubic panel to be supplied by the supplier shall be 610 mm depth and 2312 mm
height2313mm(H) x 610mm(D) x 800mm (W). The width of the cubicle to be as per suppliers
practice. The colour of the finishing paint shall be opaline Siemens grey green
corresponding to shade No. 275 RAL 7032,of IS : 5, for panel exterior.

Control and signal devices required to be mounted in the RTCC Panel shall comprise of the
following:

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 TECHNICAL SPECIFICATIONS FOR 66/11 kV POWER TRANSFORMER

1. Local - Remote maintained contact selector switch for OLTC

2. Actuating switch/push button for electrical raise / lower control,

3. Remote tap position indicator with tap nos. and corresponding rated voltage marked
on the instrument. The tap position indicators shall be digital type.

4. One potential free contact per tap for tele- transmission of tap position from
switchyard and control room to load dispatch center shall be provided.

5. A four-position selector switch having master follower, independent and off position.

6. Repeater dial of transformer winding temperature indictor.

7. Name plate for each component.

8. Initiating devices and contacts for alarm as well as for indications for discordance in
the tap changer in any of the parallel operating transformers

9. Cubicle lamp actuated by door switch, space heater, power sockets etc shall be
provided inside RTCC panel.

10. The OLTC shall be suitable for supervisory control and indication with make before
break multiway switch having one potential free contact for each tap position. This
switch shall be provided in addition to any other switch/switches which may be
required for remote tap position indication.

11. Annunciator (facia type) scheme complete with accessories for the following:

i) Tap change incomplete/Motor stuck up.

ii) Tap changer out of step
xv) Tap changer motor trip.
iv) Failure of AC supply to the OLTC local control Kiosk.
xvi) OLTC control supply failure
xvii) Running Fan failure of each group
vii) Stand by fan failure of each group.

xviii) Running Pump failure of each group.

ix) Stand by pump failure of each group.
x) 415V cooler control supply failure.
xi) No flow / reverse flow of oil in oil pump of each group.
xii) 415V Cooler Main Supply fail.
xiii) 415V Cooler Stand by Supply fail.
12. Signal lamps for:

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 TECHNICAL SPECIFICATIONS FOR 66/11 kV POWER TRANSFORMER

i) Fan 'ON' for each group / each fan.

ii) Pump 'ON' for each pump.

iii) Standby fan 'ON' for each group.
v) Cooling system on Local manual / local auto
vi) Cooling system on Remote manual/ Remote auto
vii) 415 Volts cooler Supply 'ON',
viii) 415 volts cooler supply auto change over from Main to Stand by.
ix) 415 Volts cooler supply-A ‘ON’
x) 415 volts cooler supply-B ‘ON’
xi) Cooler control supply ‘ON’
xi) 415 Volts OLTC supply ' ON '.

xii) Tap changer upper limit reached.

xiii) Tap changer lower limit reached

xiv) Tap changer in local mode

xv) Tap changer in Remote RTCC/ITCS/SAS mode

xvi) Tap change in progress

xvii) Tap changer in Independent/Master/follower mode
9.11.05-

Microprocessor based Numerical RTCC Unit for Tap changer Control & Transformer
Monitoring

Microprocessor based technology has been envisaged for the control of forced cooling
equipment, condition monitoring and OLTC control of transformers.

Tenderers shall provide full description of the control system offered and details of
deviations from specified requirement shall be brought out in the offer along with
necessary justifications.

The intent of this section is to describe the desired functional and environmental
requirements in respect of microprocessor based Intelligent Transformer Control
System (ITCS) without limiting the additional features that the tenderer may be able to
include in the offer. The TCS should provide facilities such as SCADA/ SAS links,
transformer cooler control and data logging, control of the OLTC, remote OLTC tap
position indication in digital form at local and the remote temperature indications for
windings and top oil, temperature alarms and trip, marshalling of other control and
alarm functions, emergency overload control, recording of accumulated “use of life” local
display of status of control and alarm functions and selection of local and remote
control etc.

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 TECHNICAL SPECIFICATIONS FOR 66/11 kV POWER TRANSFORMER

The ITCS equipment (other than HMI and microprocessor unit) shall be located within
the auxiliary marshalling cubicle and the Man Machine Interfacing (MMI) unit in the
transformer RTC control panel in the control room.

a) FUNCTIONS:

i) Monitoring:

The ITCS shall be capable of monitoring the analogue data and status signals of the
following:

Transformer LV load, voltage, tap changer status including tap position, tap changing in
progress, tap changer control supply fail, 415V OLTC supply fail, tap changer incomplete,
tap changer out of step, OLTC upper limit reached, OLTC lower limit reached, status of
control switches with respect to OLTC and cooling, OLTC motor current, OLTC motor trip,
temperature difference between OLTC compartment and main tank. Temperature and
condition of the transformer cooler status including top oil temperature, ambient
temperature, winding hot spot temperature, run status of cooler fans and / or pumps, fan
and / or pump trip, Alarm and Trip status of all the transformer mounted relays, Interface
with the fibre optic thermometer where fibre optics probe have been specified. This
data shall be available for display, data logging and remote communication. For each
analog value the TCS shall display the present and minimum and maximum value reached
since the last time that the minima and maxima were reset to the current values. Sufficient
number of Binary Inputs (Min. 48 Nos.), Binary outputs (Min. 10 Nos.) and Analog inputs
(Min. 14 Nos.) shall be provided for monitoring the analog data & status signal.

ii) Cooling Control:

The TCS shall be capable of controlling all cooling systems of the transformer including
pumps, fans. The control function shall operate in such a way as to keep the transformer
temperature within the limit set by the Purchaser.

The TCS shall be capable of: Predictive mode to turn on the cooling system based on
predicted top oil and winding hot spot temperatures in addition to normal control based
on actual temperatures. This should work in the event of a sudden sustained increase in
load current, before the temperatures had risen to normal control settings, so as to keep
the transformer cooler longer. Predicted temperature shall be based on a thermal
model of each specific transformer ( based on actual heat run tests), ambient
temperature and load.

Periodic automatic testing:

It shall be possible to automatically exercise testing of the cooler system at preset

intervals to ensure that they are still functional, with an alarm if the test fails.

x)OLTC Control:

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The control shall include selection of the following operating modes and features as
applicable, by push buttons or keys at the controller or from SCADA/ SAS. Manual OLTC
control by pushbuttons or keys at the controller or from SCADA/ SAS. AVR (automatic
voltage regulation) Independent mode

Master or follower parallel mode

Circulating current parallel mode

VAR sharing parallel mode

Reverse reactance parallel mode

AVR time delay shall be settable with definite time, fast – tap – down and inverse-time
modes. AVR shall have the option of Line Drop Compensation (“LDC”).

AVR shall be blocked, if the voltage drops below the under voltage set points, to
prevent false operation in the event of supply line faults, VT fuse failure etc.

OLTC operations shall be blocked if the current though the OLTC exceeds a preset
value.

xi) Performance Calculations and Prediction:

The TCS shall be capable of calculating –

Watts and VARs

Accumulated number of tap changers from each tap position (discrete counter for each
position) and total number of tap changers.

Winding hot spot temperatures for each winding and maximum achieved.

Winding hot spot insulation ageing rate (per unit)

Accumulated insulation ageing (use of life) based on the winding hot spot (years) as per
the loading guide for oil immersed power transformer. The use of life calculations shall
also convey to the operator the amount of time available at the present over load rating
and the amount of overload available for two hours duration from the time in question.

Accumulated operating hours for each fan and pump group.

Accumulated number of starts for each fan and pump group.

xii) Alarms:

Alarms shall be extended to the SCADA/ SAS system for:

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 TECHNICAL SPECIFICATIONS FOR 66/11 kV POWER TRANSFORMER

Voltage out of range for too long (AVR mode only)

Voltage exceeds over-voltage alarm setting or is less than under-voltage alarm setting.

OLTC auxiliary power failure

OLTC fail (tap changed in progress too long or OLTC motor trip)

Temperature abnormalities such as high oil temperature and high winding temperature.

Top oil or winding hot spot temperature exceeds alarm settings.

Top oil or winding hot spot temperature exceeds trip or stage to alarm settings.

Cooler auxiliary power failure

Cooler fail (contactor failed to close when switched on, or motor trip, or oil flow failed)

All OLTC and temperature trip signals shall be provided by means of voltage free contacts
where the contacts have a rating of not less than 0.4A at 125 VDC resistive. All other trip
signals such as Buchholz, pressure relief and OLTC surge shall be provided directly
from the voltage free contacts of the respective device, not via the TCS. The alarms can
however be wired via the TCS.

xiii) Data Logging and Event Recording:

Monitored data shall be time and date stamped and logged in a format, which can be easily
imported to data analysis software such as MS Excel/Access. The local data storage
capability which can store all data at one-minute intervals shall be stated by the tenderer.

A separate event record is required to record the date and time (to nearest second)
when the status of any alarm changes. The number of events that can be stored shall be
stated by the tenderer.

xiv) Communication:

The TCS shall accept all Analogue / Digital quantities relevant to the control of the
transformer or as required by the purchaser. These quantities shall be able to be
interfaced to the purchaser’s SCADA/ SAS equipment. The ITCS shall be capable of down
loading data files via telephone line and GSM System. The protocol for communication
shall be as per IEC 60870-5-103 and IEC 61850.

xv) other capabilities:

Tenderers may also offer TCS which performs both Dissolved Gas Analysis and moisture
in oil condition monitoring.

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b) MAN, MACHINE INTERFACE:

Access to control variables within the TCS shall be available to the personnel as required
by the purchaser. The form of these interface should preferably be via a permanent front
panel that contains a display and keypad. The menu facilities shall be as simple and
intuitive as possible. Facilities to access the TCS via local RS-232 port and software
running on a laptop PC under the latest version of Windows shall also be provided. A
sample of the PC software shall be supplied to the purchaser for evaluation before
proceeding with that method. Software supplied to the purchaser is not returnable and
becomes the property of the purchaser.

c) ELECTRICAL ISOLATION AND TRANSIENT PERFORMANCE:

All equipment shall be type tested, tested during manufacture and after completion r
in accordance with latest IEC 60255 and IEC 60068.

d) POWER SUPPLIES:

The ITCS should be powered directly from the Sub-station battery bank.

e) INPUTS / OUTPUTS

f) DIGITAL INPUT AND OUTPUT MODULES

The “on” state of all digital inputs and outputs shall be indicated by Light Emitting Diodes
(LED) on the front of the modules. These LEDs shall be visible from the front panel on
which the TCS equipment is mounted. All inputs shall be electrically isolated from the
external circuit and capable of being driven from 42 V dc to 240 V dc.

All output shall be electrically isolated from external circuit and rated for switching 42 V
dc to 240 V dc and 0.5 Amp.

Sufficient number of DI and DO modules shall be provided to suit the scheme requirement
during drawing approval and during commissioning as per field condition. Additional 20%
spare DI’s and DO’s shall be provided for future use.

4-20mA analog inputs shall be provide for the following: Oil temperature, Core
temperature, HV- R phase, Y phase & B phase winding temperature, IV- R phase, Y phase
& B phase winding temperature, OLTC oil temperature, OLTC motor current, Ambient
temperature, all Dissolved gases 9Nos. in PPM, Water content in PPM in case on-line DGA
is provided. Additional 20% spare 4-20mA analog inputs shall be provided for future use.

g) COMMUNICATION PORTS:

Communication ports shall be provided for the following.

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Connection to a local computer for down loading data files, uploading settings, software
upgrade etc.

Communication with SCADA RTU/ SAS.

Connection to a dial-in modem for down loading data files uploading settings, software
upgrade etc.

Communication with sensors and other auxiliary equipment.

Serial communication with remote via a fibre optic links

Connection to LAN to WAN or Intranet.

h) SELF-MONITORING:

The TCS shall have a 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. In the event that the unit is unable to control the transformer, the device is to
revert to a fail-safe condition. Any monitoring system problem shall initiate an alarm.

i) MEMORY RETENTION:

The TCS shall be capable of retaining its information in the event of a power failure.

j) REAL TIME CLOCK:

There shall be real time clock for time stamping the data log and event records. A long
life battery shall be provided to keep the clock operating in the event of the power failure.
An alarm shall be generated if the battery fails. It shall also be possible to synchronize the
TCS clock with GPS system provided at the substations.

k) SECURITY:

Levels of security to limit access to authorized uses shall be provided for

Viewing data and downloading data files (no access control)

Changing control mode and manual control operations (password control)

Changing settings and configuration (password control)

Software upgrade (password control)

l) MOUNTING:

The TCS input/output modules /units shall be mounted within the auxiliary

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marshalling cubicle or in a separate cubicle with a similar construction located on the

transformer. The cubicle shall be rated to IP56. The cubicle shall be capable of protecting
the equipment contained within and always keep it in operational condition given the
conditions described in the environmental section. The Man Machine Interface (MMI) unit
will be mounted on the transformer Tap changer control panel in the control room.
Cabling between the MMI unit and input / output modules / unit shall be supplied by the
Purchaser. Any special cable if required, the details of the same shall be furnished. It
shall be possible to have a second MMI mounted in the transformer control cubicle if
required.

9.12.00

TERMINAL BLOCK:

xix) The terminal blocks to be provided shall be fully enclosed with removable covers
and made of moulded, non-inflammable plastic material with block and barriers
moulded integrally. Such block shall have washer and binding screws for
external circuit wire connections, a white marking strip for circuit identification
and moulded plastic cover. All terminals shall be clearly marked with
identification numbers or letters to facilitate connection to external wiring.
xx) All internal wiring to be connected to the external equipment shall be terminated
on terminal blocks, preferably vertically mounted on the side of each panel. The
terminal blocks shall be 1100 V grade and have 10 Amps continuous rating,
moulded piece, complete with insulated barriers, non dis-connecting stud type
terminals, washers, nuts and lock nuts, Terminal block design shall include a
white fiber marking strip with clear plastic, slip-on / clip-on terminal cover.
Markings on the terminal strips shall correspond to wire number and terminal
numbers on the wiring diagrams.
xxi) Terminal blocks for current transformer secondary leads shall be provided with
test links and isolating facilities. Also current transformer secondary leads shall
be provided with short-circuiting and earthing facilities.
iv) At least 20 % spare - terminals shall be provided on each panel and these spare
terminals shall be uniformly distributed on all terminal blocks.

v) Unless otherwise specified, terminal blocks shall be suitable for connecting

the following conductors on each side.

a) For all circuits except current transformer circuits minimum of two numbers of 2.5 sq. mm
copper.

b) For all CT circuits minimum of two numbers 4 sq. mm copper.

vi) There shall be a minimum edge to edge clearance of 250mm between the first
row of terminal block and the associated cable gland plate. Also the clearance
between two rows of terminal blocks shall be minimum of 150mm.

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vi) Arrangement of the terminal block assemblies and the wiring channel within the
enclosure shall be such that a row of terminal blocks is run parallel and in close
proximity along each side of the wiring duct to provide for convenient attachment of
internal panel wiring. The side of the terminal block opposite the wiring duct shall be
reserved for the owner's external cable connection. All adjacent terminal block shall
also share this field wiring corridor. A steel strip shall be connected between adjacent
terminal block rows at 450 mm intervals for support of incoming cables.
The number and size of the purchaser's multi-core incoming cable will be furnished to
the Bidder after placement of the order.

9.13.00

PAINTING:

9.13.01

Surface Preparation for Main tank, Pipes, Conservator tank etc.

All surfaces of transformer main tank, pipes, turrets, conservator tank etc. shall be
thoroughly blast cleaned with stand, shot or grit in accordance with ISO:8501 Part 1 or
Swedish standard SIS:055900 to a minimum standard of Sa 2½ to make the surface free
from visible oil, grease & dirt, mill, scale, rust, paint coatings and foreign matter, Machined
areas and threaded components etc are to be covered during blasting to prevent damage.

The Compressed air that is used for blasting should be dry and free from oil. The flanges
angles, tank curbs and other such areas shall be preferably blast cleaned prior to
fabrication and paint these with one coat of pre-fabrication primer prior to fabrication.
After adequate blast cleaning of each large surface where blasting time is more than three
hours an overall blast cleaning is to be done on the entire surface once more so that entire
surface areas is exposed as fresh for first coat of primer paint. The First coat of primer
paint should be applied not later than 3-4 hours after preparation of surface to avoid
oxidation.

9.13.02

Surface Preparation for radiator: -

All internal and external surfaces of radiator shall be thoroughly cleaned either by
chemical cleaning or by blast with stand, shot or grit in accordance with ISO: 8501 Part 1
or Swedish standard SIS 055900 to make the surface free from visible oil, grease & dirt,
mill scale, rust, paint coatings and foreign matter. Suitable chemical should be used for
chemical cleaning, if required. The compressed air that is used for blasting should be dry
and free from oil. After adequate surface cleaning, the first coat of primer paint /varnish
should be applied not later than 3-4 hours after preparation of surface to avoid oxidation.

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9.13.03. Painting –External & Internal surfaces:

Painting shall be carried out in closed and dust free area. The external surface shall be
coated with suitable layers of paint and to form an impermeable layer so that air and water
cannot reach the substrate. The paint selected shall be stable in outdoor condition such
as rain, sunlight, pollution etc. Paint used for primer, under coat and top or finish coat
should be from the same manufacturer and compatible to each other. In case in the rare
event, paint used for primer, under coat and finish coat are not from the same
manufacturer the compatibility test of the paint from different source shall be carried out.
Painting shall be applied as per the recommendation of the paint manufacturer. The
number of coats shall be such that the minimum dry film thickness (DFT) specified is
achieved. The DFT of painted surface shall be checked with a measuring gauge to ensure
specified DFT. Complete painting scheme for the transformer is tabulated below.

9.13.04

Painting –Transformer Main tank, pipes, conservator tank, radiator etc: -

Surface Primer Intermediate Total

Finish coat Colour shade
preparation coat Undercoat DFT
Main tank, Epoxy Light
Aliphatie
pipes, base Min grey,631 as
Blast Polyurethane
conservator Zinc Epoxy HB 155 per IS
cleaning (PU paint)
tank, etc. Primer M10 (75 um) micro 5/ KPTCL
Sa2 ½ (min 50
(External (30 – 40 m approved
micro-m)
surfaces) micro-m) drg..
Main tank, Min 30
Hot oil
pipes,
resistant
(above 80 Glossy white
Blast non
NB) paint/KPTCL
cleaning corrosive -- -- Micro
conservator approved
Sa2 ½ varnish m
tank, etc. drawings
or paint
(Internal
or epoxy
surfaces)
Matching
shade of
Epoxy Aliphatic tank/different
Chemical Epoxy base Min
Radiator base zinc Polyureth shade
blast zinc primer 110
(External primer ane (PU aesthetically
cleaning (30-40 micro
surfaces) (30-40 Paint) (in 50 matching to
(Sa 2 ½) micro-m) m
micro-m) micro m) tank/KPTCL
approved
drg.
Hot oil
Radiator proof low
and pipes Chemical viscosity KPTCL
up to 80 NB cleaning if varnish -- -- -- approved
(Internal required Flushing drawings
surfaces) with Trfr.
Oil

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9.13.05

Surface preparation for control cabinets/Marshalling Boxes: - Surface preparation for all
transformer Control cabinets/ Marshalling Boxes shall be carried out by Seven Tank
Process confirming to following Indian standard dust free area:

IS:3618 –1966: Degreasing by solvent wiping: Phosphate Treatment of Iron & steel for
Protection against corrosion.

IS: 6005-1970: Code of Practice for Phosphating of Iron & Steel Sequence of tanks with
required size suitable handle all transformer control cabinets/Marshalling Boxes shall be
as per following:

i) Degreasing tank plain welded M.S. tank with suitable supports of suspending the
jobs with overflow arrangement/scoop through to collect floating oils.

ii) De-rusting tank: PVC/FRP-lined mild steel tank.

iii) Phosphating tank: FRP lined mild steel tank

iv) Passivating tank: Mild steel tank.

vii) Rinse Tanks (3 Nos. – 1 No. each after Degreasing, De-rusting and phosphating)
mild steel tanks with overflow arrangement.
viii) Driers: Suitable air blowers.

Chemical: Suitable Chemicals should be used and concentration of chemicals /weight of

phosphate coating should be checked regularly as per recommendation of the chemical
manufacturer and applicable IS.

Inspection: The Surface for application of paint should be dry, free from oil, dirt, acid &
loose adhering powder and reasonably smooth in finish without uncovered areas, rusty
surfaces and roughness.

9.13.06 Painting-Control Cabinets/Marshalling Boxes - Painting scheme is tabulated below:

Intermediate
Primer coat Finish Coat Total DFT Colour Shade
Undercoat
Aliphatic Light grey, 631
Epoxy base Zinc
Epoxy HB MIO (75 Polyurethane (PU shade as per IS:5/
primer (30-40 Min 155 micro m
micro m) Paint min 50 KPTCL approved
micro m)
micro m) drg

9.14.00

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BOLTS AND NUTS:

All bolts and nuts exposed to weather shall be hot dip galvanized, Bolts and nuts below
M12 (half inch) size shall be electro-galvanized.

9.15.00

WIRING AND CABLING:

9.15.01

a) Cable box / sealing end shall be suitable for following types of cables: -

a) For 100 MVA and above transformer

1100-volt grade PVC insulated 1 X 4 core,
2.5 sq mm, stranded copper conductor cable
415volts power
b) For 31.5MVA Transformer, 1100 Volt grade PVC
insulated 1 x 4 Core, 2.5Sqmm. Standard copper
conductor cable.
a) In 100 MVA and above Transformer
1100-volt grade PVC insulated 7 x 19 core 2.5 sq mm
stranded copper conductor cable.
Control
b) For 31.5 MVA Transformer
1100-volt grade PVC insulated 4 x 19 core 2.5 sq mm
stranded copper conductor cable.

Signaling cable 1Px0.5Sq.mm screened cable for 4-20mA signals

Note: Consider for 31.5 MVA Transformer.

b) Compression type cable connector shall be provided for termination of power and
control cables.

c) All controls, alarms, indicating and relaying devices provided with the transformer
shall be wired up to the terminal blocks inside the local control cabinets (both cooler
and OLTC control cabinets).

d) All devices and terminal blocks with the cooler control cabinet shall be clearly
identified by symbols corresponding to those used on applicable schematic or wiring
diagrams.

e) Not more than 2 wires shall be connected to one terminal. Each terminal shall be
suitable for connecting two 2.5 sq. mm stranded copper conductor control cable from
each side.

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f) All internal wiring shall be securely supported, neatly arranged, readily accessible
and connected to equipment terminals and terminal blocks.

g) Engraved code identification plastic Alpha numeric ferrules marked to correspond

with schematic diagrams shall be fitted at both ends of wires. Alpha Numeric ferrules
shall fit tightly on wires and shall not fall off when the wire is disconnected from
terminal block.

9.16.00

FITTINGS & ACCESSORIES.

9.16.01

Following fittings shall be provided with each transformer covered in this specification.

a) Conservator for main tank, with oil filling hole and cap, isolating valves, drain valve
magnetic oil level gauge with low level alarm contacts and dehydrating breather,
diaphragm seal type constant oil pressure system (Air cell type).

b) Conservator for OLTC with drain valve, Buchholz relay (oil Surge) filling hole with cap,
prismatic oil level gauge and dehydrating breather.

c) Oil preservation equipment.

d) Pressure relief device with alarm / trip contacts.

e) Buchholz relay double float type with isolating valves on both sides, bleeding pipe with
pet cock at the end to collect gases and alarm and trip contacts
f) Air release plug.
g) Inspection openings and covers.

h) Bushing with metal parts and gaskets to suit the termination arrangement.
i) Winding temperature indicators for local and remote mounting. One RWTI for each of
the three windings (HV, IV&LV)
j) Oil temperature indicators.

k) Cover lifting eyes, transformer lifting lugs, jacking pads, towing holes and core and
winding lifting lugs.
l) Protected type mercury or Alcohol in glass thermometer.
m) Bottom and top filter valves with threaded male adapters, top, middle and bottom
sampling valves and drain valve. Sampling valves shall be provided with lap tap
arrangement with nozzle,
n) Rating and diagram plates on transformers and auxiliary apparatus.
o) Earthing terminals.

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p) Flanged bi-directional wheels.

q) Cooler control cabinet

r) On load tap changing equipment and OLTC control cabinet.
s) Drain valves / plugs shall be provided in order that each section of pipe work can be
drained independently.
t) Cooling equipment - Radiator complete with pumps, motors, fans etc.

u) Insulating oil.
v) Oil flow indicator
w) Terminal marking plate.
x) Jacking pads.

y) Lifting bollards

z) Haulage lugs.
aa) Cover lifting lugs

bb) Valve schedule plate

cc) RTCC panel

dd) Oil filling instruction plate of conservator

ee) Schematic diagram plate for operation of Tap changer Motor Drive Mechanism Box.

ff) The serial number of the transformer to be punched on the tank next to the rating
plate.
gg) Provision for fitting Nitrogen injection fire protection and extinguishing system.
hh) Bushing CT’s

ii) Temperature indicator compatible with SCADA.

jj) Fibre Optic based temperature measuring system complete.
kk) Transformer monitoring cum tap changer controller.
ll) Nitrogen Injection drain & stir method type fire extinguisher.

mm) On-line DGA (to be provided for 100MVA & 150MVA transformers).

nn) Hydraulic Jacks - one set per station.

NOTE: -

a. The fittings listed above are only indicative and any other fittings which generally are
required for satisfactory operation of the transformer are deemed to be included.

b) The accessories required with the transformer shall be SCADA/ SAS compatible.
Potential free contacts for Bucholtz relay, PRV,OSR, OTI, WTI, etc. need to provided.
Further for OTI, WTI, TPI, etc. dual output of 4-20mA shall be provided.

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c) The On-line DGA shall be provided for transformer with rating 100MVA and above.

d) All the microprocessor based IEDs such as Transformer monitoring cum tap-changer
controller, etc. shall be interfaced with the SAS of the sub-station in co-ordination with
the SAS supplier. Necessary files such as ICD, CID and PICS, MICS and PIXIT
documents shall be provided in soft copy for integration with third party HMI. In case
of sub-stations without SAS, the On-line DGA is to be interfaced with numerical tap-
changer controller (ITCS).

e) The required communication cables for the above is in the scope of the bidder/
supplier.

f) The auxiliary supply to all the IEDs shall be 220V, DC.

g) Warranty for the “Products and Solutions” for the IEDs as per International Standards
shall be furnished. Also, guarantee for the availability of spares and solutions for all
the IEDs for at least 10 years from the date of supply of products to be furnished.

h) KPTCL Engineers shall be trained for operation of ITCS and Fibre optic temperature
monitoring system.

9.16.02

The equipment and accessories furnished with the transformer shall be suitably mounted
on the Transformer for easy operation and inspection and maintenance and the mounting
details shall be subject to the approval of the purchaser. All valves shall be provided either
with blind companion flanges or with pipe plugs for protection.

9.16.03

Indication, alarm and relay equipment shall have contacts, suitable for operation with
220Volts DC supply. Any other accessories or appliances recommended by the
manufacturer for the satisfactory operation of the transformers together with their prices
shall be given in the tender.

9.17.00

LIMITS 0F TEMPERATURE RISE:

Refer Table No. 4 of IS-2026 (Part - II)

For purpose of standardization of limit of temperature rise of oil and winding, the following
ambient temperatures shall be considered.

1.Maximum ambient temperature 50º C

2.Maximum daily average ambient temperature 40º C

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3.Maximum yearly weighted average temperature 32º C

With the above ambient temperature, the temperature-rise shall be as follows:

1. Winding temperature rise - 55º C (when the

measured by oil circulation is natural
resistance method or forced and non-directed)

2. Top oil (temperature measured 50ºC

by thermometer)

9.18.00

SPECIFICATION FOR CONTROL CABINETS:

1. Control cabinet for the tap changer driving motors shall be housed in a local kiosk
mounted adjacent to or on the transformer.

2. Control cabinet of the operating mechanism shall be made out of 3mm thick sheet
steel. Hinged door with handle shall be provided with padlocking arrangement.
Sloping rain hood shall be provided to cover all sides 15 mm thick neoprene or better
type of gaskets shall be provided to ensure degree of protection of at-least IP55 as per
IS : 2147. The colour of paint shall be light gray in accordance with shade No. 631 of
IS-5.

3. Motors rated 1 KW and above being controlled from the control cabinet would be
suitable for operation on a 415V, 3 phase, 50Hz system. Fractional KW motors would
be suitable for operation on a 240 V, single phase, 50 Hz supply system,

4. Isolating switches shall be group operated units (3 pole for use on 3 phase supply
system and 2 pole for single phase supply systems) quick make and break type,
capable of breaking safely and without deterioration, the rated current of the
associated circuit. Switch handle shall have provision for locking, in both fully open
and fully closed positions,

5. Push button shall be rated for not less than 6 Amps, 415V AC or 2 Amps 220V DC and
shall be flush mounted on the cabinet door and provided with appropriate name
plates. Red, Green and Amber indicating lamps shall be flush mounted.

6. For motors up to 5 KW, contactors shall be direct-on-line, air break, single throw type
and shall be suitable for making and breaking the stalled current of the associated
motor which shall be assumed equal to 6.5 times the full load current of the motor at
0.2 pf. For motors above 5 KW, automatic star delta type starters shall be provided. 3
Pole contactors shall be furnished for 3 phase motors and 2 pole contactors for single
phase motors. Reversing contactors shall be provided with electrical interlocks
between forward and reverse contactors. If possible, mechanical interlocks shall also

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 TECHNICAL SPECIFICATIONS FOR 66/11 kV POWER TRANSFORMER

be provided. Contactors shall be suitable for uninterrupted duty and shall be of duty
category class AC4 as defined. in IS : 2959. The main contacts of the contactors shall
be silver plated and the insulation class for the coils shall be class E or better. The
dropout voltage of the contactors shall not exceed 70% of the rated voltage.

7. Contactors shall be provided with a three element, positive acting, ambient

temperature compensated time lagged, hand reset type thermal overload relay with
adjustable setting. Hand reset button shall be flush with The front door of the cabinet
and suitable for resetting with starter compartment door closed.

8. Single phasing preventer relay shall be provided for a 3-phase motors to provide
positive protection against single phasing.

9. Mini starter shall be provided with no volt coils whenever required.

10. Purchaser's power cables will be of 1100 Volts grade stranded copper conductor. All
necessary cable terminating accessories such as glands, crimp type tinned copper
lugs etc., for power as well as control Cables shall be included in bidder's scope of
supply. Suitable brass cable glands shall be provided for cable entry. The required
quantity of cable glands suitable for cable size of 19 X 2.5 sq. mm control cable shall
be provided. Dummy plates for cable glands shall be provided for purchaser's use if
necessary.

11. Wiring for all control circuits shall be carried out with 1100 Volts grade PVC insulated
tinned copper stranded conductors of sizes not smaller than 2.5 sq. mm. At least 20%
spare terminal blocks for control wire terminations shall be provided on each panel.
The terminal blocks shall be of non-disconnecting stud type. All terminals shall be
provided with ferrules indelibly marked or numbered and these identifications shall
correspond to the designations on the relevant wiring diagrams, The terminals shall
be rated for adequate capacity, which shall not be less than 10 Amps.

12. Separate terminal blocks shall be provided for terminating circuits of various voltage
classes. CT loads shall be terminated on a separate block and shall have provision for
short circuiting the CT secondary terminals.

13. Control cabinet shall be provided with 240V, 1-phase, 50Hz, 20W fluorescent light
fixture and a suitably rated 240V, 1-phase, 5 Amps, 3 pin socket for hand lamps. The 3
pin socket shall be provided with protective electrical and mechanical cover with
chain.

14. Strip heaters shall be provided inside each cabinet complete with thermostat
(preferably differential type) to prevent moisture condensation. Heaters shall be
controlled by suitably rated double pole miniature circuit breakers,

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15. Signal lamps provided shall be of neon screw type with series resistors, enclosed in
Bakelite body. Each signal lamp shall be provided with a fuse integrally mounted in the
lamp body.

16. Items inside the cabinet made of organic material shall be coated with a fungus
resistant varnish.

9.19.00

MOTORS:

Motors shall be 'squirrel cage' three phase induction motors of sufficient size capable of
satisfactory operation for the application and duty as required for the driven equipment.
Motors shall conform to IS : 325.

10.0 PROTECTION

10.01.00 The transformer shall have the following protection:

Detecting or actuating devices required which form part of the transformer construction
shall be provided by the transformer supplier.

a) Buchholz relay alarm and trip contact.

b) Oil temperature indicator with alarm and trip contact.

c) Winding temperature indicator for alarm, trip control of fans / motor contacts.

d) Magnetic oil gauge with low level alarm contact.

e) Oil surge protection for OLTC diverter tank with trip contact.

f) Pressure relief device with trip contact

g) Flow indicators and. alarms for the oil passages.

h) Nitrogen injection fire protection and extinguishing system

Protection to be provided by purchaser.

a) Circuit breaker on both primary and secondary sides.

b) High speed differential relay, restricted earth fault relay, over flux relay, and
back up over current and earth fault relay on both primary and secondary side.

c) Non directional over current relay for each phase on tertiary side.

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d) Lightning arrestors on both primary and secondary side.

10.02.00 PROTECTION AGAINST FIRE

Provision shall be made in the power transformers for fitting Nitrogen injection drain & stir
type of fire prevention and extinguishing system.

10.03.00 SPECIAL TOOLS AND TACKLES:

The bidder shall include in his proposal any special erection and maintenance tools
required according to the specialties of the Equipment. The list of such special tools shall
be given and price of these shall be included in the proposed price.

10.04.00 SPARE PARTS AND MAINTENANCE EQUIPMENT:

Bidder shall indicate in his proposal spares required for the trouble free operation of the
equipment for (5) five years.

11.0 QUALITY ASSURANCE PLAN

The Bidder shall invariably furnish the following information along with his offer, failing
which the offer shall be liable for rejection.

i. Statement giving list of important raw materials, names of sub-suppliers for the
raw materials, list of standards according to which the raw materials are tested,
list of tests normally carried out on raw materials in the presence of Bidder’s
representative, copies of test certificates.

ii. Information and copies of test certificates as in (i) above in respect of bought
out items. List of manufacturing facilities available.

iii. Level of automation achieved and list of areas where manual processing exists.

v. List of areas in manufacturing process, where stage inspection is normally

carried out for quality control and details of such tests and inspection.
vi. Special features provided in the equipment to make it maintenance free.
vii. List of testing equipment available with the Bidder for final testing of equipment
specified and test plant limitation, if any, vis-à-vis the type, special, acceptance
and routine tests specified in the relevant standards. These limitations shall be
very clearly brought out in ‘Schedule of Deviations’.

11.02.00

The supplier shall within 30 days of placement of order, submit the following information
to the purchaser.

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i. Name of the raw materials as well as bought out accessories and the names of sub-
suppliers selected from those furnished along with the offer.

ii. Type test certificates of the raw materials and bought out accessories.

iii. Quality Assurance Plan [QAP] withhold points for purchaser’s inspection. The QAP
and hold points shall be discussed between the purchaser and the supplier before
the QAP is finalized.

11.03.00

The supplier shall submit the routine test certificates of bought out items and raw materials
at the time of routing testing of the fully assembled equipment.

12.0 INSPECTION

i) The purchaser shall have access at all times to the works and other places of
manufacture where the transformers are being manufactured and the supplier
shall provide all facilities for unrestricted inspection of the suppliers works, raw
materials, manufacturer of all accessories and for conducting necessary test.

ii) The supplier shall keep the purchaser informed in advance of the time of starting
and of the progress of manufacture of equipment in its various stages so that
arrangements could be made for inspection.

iii) The manufacturer of transformer shall directly import CRGO either from the
manufacturer or through their accredited marketing organization of repute or
through authorized dealer. In support of this requirement the manufacturer of
transformer should submit an undertaking in the form of an affidavit on Rs.100/-
stamp paper, duly notarized, in the specified format.

Supplies shall offer the “CORE” for inspection and get approval by the purchaser
during the manufacturing stage. Suppliers call notice for the purpose should be
accompanied with the following documents as applicable, as a proof towards use of
Prime CORE material:

a) Invoice of the supplier

b) Mill's test Certificate
c)Packing List
d)Bill of lading
e) Bill of entry certificate by customs
iv) No material shall be dispatched from its point of manufacture unless the material
has been satisfactorily inspected and tested.

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v) The acceptance of any quantity of equipment shall in no way relieve the supplier
of his responsibility for meeting all the requirement of this specification and shall
not prevent subsequent rejection if such equipment are later found to be
defective.

vi) The supplier shall inform the purchaser at least thirty days in advance about the
manufacturing programme so that arrangement can be made for inspection, if
desired by the purchaser.

vii) The purchaser reserves the right to insist on witnessing the acceptance routine
testing of bought out items. The supplier shall communicate to the purchaser
the details of such testing programme at least three weeks in advance. The
testing shall not be postponed even if the purchaser is unable to depute his
representative for witnessing the testing.

12.1.1
Tank and Conservator

12.1.1.1
Certification of chemical analysis and material tests of plates.

12.1.1.2
Check for flatness.

12.1.1.3
Electrical interconnection of top and bottom by braided tinned copper flexible.

12.1.1.4
Welder's qualification and weld procedure.

12.1.1.5
Testing of electrodes for quality of base materials and coatings.

12.1.1.6
Inspection of major weld preparation.

12.1.1.7
Crack detection of major strength weld seams by dye penetration test.

12.1.1.8
Measurement of film thickness of:

i) Oil insoluble varnish.

ii) Zinc chromate paint.
iii) Finished coat.

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12.1.1.9
Check correct dimensions between wheels, demonstrate turning of wheels through 90øC
and further dimensional check.

12.1.1.10
Check for physical properties of materials for lifting lugs, jacking pads, etc. All load
bearing welds including lifting lug welds shall be subjected to NDT.

12.1.1.11
Leakage test of the conservator.

12.1.1.12
Certification of all test results.

12.1.2
Core

12.1.2.1
Sample testing of core materials for checking specific loss, bend properties,
magnetisation characteristics and thickness.

12.1.2.2
Check on the quality of varnish if used on the stampings:

i) Measurement of thickness and hardness of varnish on stampings.

ii) Solvent resistance test to check that varnish does not react in hot oil.
iii) Check overall quality of varnish by sampling to ensure uniform shining colour, no
bare spots, no over burnt varnish layer and no bubbles on varnished surface.

12.1.2.3
Check on the amount of burrs.

12.1.2.4
Bow check on stampings.

12.1.2.5
Check for the overlapping of stampings. Corners of the sheet are to be part.

12.1.2.6
Visual and dimensional check during assembly stage.

12.1.2.7
Check for interlaminar insulation between core sectors before and after pressing.

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12.1.2.8
Check on completed core for measurement of iron loss and check for any hot spot by
exciting the core so as to induce the designed value of flux density in the core.

12.1.2.9
Visual and dimensional checks for straightness and roundness of core,thickness of limbs
and suitability of clamps.

12.1.2.10
High voltage test (2 kV for one minute) between core and clamps.

12.1.2.11
Certification of all test results.

12.1.3
Insulation Material

12.1.3.1.
Sample check for physical properties of materials.

12.1.3.2
Check for dielectric strength.

12.1.3.3
Visual and dimensional checks.

12.1.3.4
Check for the reaction of hot oil on insulating materials.

12.1.3.5
Dimension stability test at high temperature for insulating material.

12.1.3.6
Tracking resistance test on insulating material

12.1.3.7
Certification of all test results.

12.1.4
Winding

12.1.4.1
Sample check on winding conductor for mechanical properties and electrical
conductivity.

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12.1.4.2
Visual and dimensional checks on conductor for scratches, dent marks etc.

12.1.4.3
Sample check on insulating paper for pH value, bursting strength and electric strength.

12.1.4.4
Check for the reaction of hot oil on insulating paper.

12.1.4.5
Check for the bonding of the insulating paper with conductor.

12.1.4.6
Check and ensure that physical condition of all materials taken for windings is satisfactory
and free of dust.

12.1.4.7
Check for absence of short circuit between parallel strands.

12.1.4.8
Check for brazed joints wherever applicable.

12.1.4.9
Measurement of voltage ratio to be carried out when core/yoke is completely restacked
and all connections are ready.

12.1.4.10
Conductor enamel test for checking of cracks, leakage and pin holes.

12.1.4.11
Conductor flexibility test

12.1.4.12
Heat shrink test for enamelled wire.

12.1.4.13
Certification of all test results.

12.1.5
Checks Before Drying Process

12.1.5.1
Check condition of insulation on the conductor and between the windings.

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12.1.5.2
Check insulation distance between high voltage connections, cables and earth and other
live parts.

12.1.5.3
Check insulating distances between low voltage connections and earth and other parts.

12.1.5.4
Insulation of core shall be tested at 2 kV/minute between core to bolts and core to clamp
plates.

12.1.5.5
Check for proper cleanliness and absence of dust etc.

12.1.5.6
Certification of all test results.

12.1.6
Checks During Drying Process

12.1.6.1
Measurement and recording of temperature, vacuum and drying time during vacuum
treatment.

12.1.6.2
Check for completeness of drying by periodic monitoring of IR and Tan delta.

12.1.6.3
Certification of all test results.

12.1.7
Assembled Transformer

12.1.7.1
Check completed transformer against approved outline drawings,provision for all fittings,
finish level etc.

12.1.7.2
Test to check effective shielding of the tank.

12.1.7.3
Jacking test with oil on all the assembled transformers.

12.1.7.4
Dye penetration test shall be carried out after the jacking test.

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12.1.8
Bought Out Items

12.1.8.1
The makes of all major bought out items shall be subject to Employer's approval.

12.1.8.2
The Contractor shall also prepare a comprehensive inspection and testing programme for
all bought out/sub-contracted items and shall submit the same to the Employer for
approval. Such programme shall include the following components:

a) Buchholz Relay.

b) Axles and wheels.

c) Winding temperature indicators for local and remote mounting.

d) Oil temperature indicators.

e) Bushings.

f) Bushing current transformers.

g) Cooler control cabinet.

h) Cooling equipment.

i) Oil pumps.

j) Fans/Air Blowers

k) Tap change gear.

l) Terminal connectors.

The above list is not exhaustive, and the Contractor shall also include other bought out
items in his programme.

12.2

Factory Tests

12.2.1

Routine Tests

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All standard routine tests in accordance with IS:2026 shall be carried out on each
transformer. Operation and dielectric testing of OLTC shall also be carried out as per
IS:2026 .

Following additional routine tests shall also be carried out on each transformer:

12.2.1.1 Magnetic Circuit Test

After assembly each core shall be tested for 1 minute at 2000 Volts between all bolts, side
plates and structural steel work.
12.2.1.2 Oil leakage test on transformer tank as per Clause 5.2.7.1 below.
12.2.1.3 Magnetic balance test
12.2.1.4 Measurement of no-load current with 415V, 50 Hz ac supply on LV side.

12.2.1.5 Frequency response analysis (FRA)

12.2.1.6 High voltage withstand test shall be performed on auxiliary equipment and wiring after
complete assembly.

12.2.2

Type Tests
12.2.2

(a) Type tested Transformer shall be offered. The type test reports shall not be older than
five (5) years as on the last date of submission of bid. The type tests are to be conducted
again without any extra cost to the owner in case the type test reports are older than five
(5) years as on the last date of submission of bid. The type test charges are to be indicated
in the schedule. The owner reserves right to insist for conducting all or a few type tests
even though the type tests are less than five (5) years old as on the last date of submission
of bid, the payment in such cases will be made as per the rates in the schedule.

a) For Transformers manufactured in India:

i. Type tests on indigenous equipment for which testing facility is available in

India, should have been conducted in any independent laboratories approved
by Government or accredited by National accreditation body of the country like
Central Power Research Institute (CPRI), Electrical Research and Development
Association (ERDA), etc.

ii. Type tests on indigenous equipment, for which testing facility is not available in
India, should have been conducted in a laboratory of foreign country accredited
by National accreditation body of that country.

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iii. The type tests conducted in-house by manufacturers shall also be acceptable
where the specific test facilities are not available in independent NABL
accredited laboratories provided the lab (manufacturer’s) is accredited by
National accreditation body of the country and the tests have been witnessed by
a representative of NABL accredited independent laboratory/Power utility.

b) For Transformer manufactured Abroad:

i. Type tests on imported equipment should have been conducted in an Indian

Laboratory or foreign laboratory accredited by National accreditation body of
respective country.

ii. Type tests conducted in-house by manufacturers shall also be acceptable

provided the laboratory is accredited by National accreditation body of the country
and the tests have been witnessed by a representative of accreditation
body/Power utility.

12.2.2

(b) However, following tests shall be conducted on one Transformer of each rating,
following type tests shall be conducted on one Transformer of each rating. while However
Temp Rise Test shall be carried out on all units:

12.2.2.

b. 1 Temp. Rise Test as per IS:2026 (Part-II)

Gas chromatographic analysis on oil shall also be conducted before and after this test and
the values shall be recorded in the test report. The sampling shall be in accordance with
IEC 567. For the evaluation of the gas analysis in temperature rise test the procedure shall
be as per IS:9434 (based on IEC:567) and results will be interpreted as per IS:10593 (based
on IEC -599).

The temperature rise test shall be conducted at a tap for the worst combination of loading
on he three windings of the transformer. The Contractor before carrying out such test shall
submit detailed calculations showing alternatives possible, 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.

12.2.2.b.2 Tank vacuum Test as per Cl.no.12.2.6.2 (i) below.

12.2.2.b.3 Tank pressure Test as per Cl.no. 12.2.6.2 (ii) below.

12.2.2.b.4 Pressure Relief Device Test

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The pressure relief device of each size shall be subjected to increase in oil pressure. It
shall operate before reaching the test pressure specified in ‘Tank tests’ subsequently in
this clause. The device shall seal off after the excess pressure has been released.

12.2.2.b.5

Measurement of capacitance and tan delta to determine capacitance between winding

and earth. The measurement shall be carried out before and after series of electric tests.

12.2.2.b.6

Lightning Impulse withstand test in all phases as per IS: 2026 (As type test, only for 220 kV
class & below)

12.2.3 Additional type tests

Following additional type tests other than type and routine tests shall also be carried out
on new unit of each type:

12.2.3.1 Measurement of zero Seq. reactance (As per IS:2026, for 3-phase transformer only.)

12.2.3.2 Measurement of acoustic noise level.

12.2.3.3 Measurement of power taken by fans and oil pumps.

12.2.3.4 Measurement of harmonic level in no load current.

12.2.3.5 Dynamic short circuit withstand test shall be carried out as per IEC 60076-5/ IS 2026-5.

Short circuit withstand test shall be conducted on one of each type and rating of
transformers to validate the design and quality unless such test has been conducted within
last five years on Transformer of same design. In case there is change in design before
five years, the new transformer design shall be validated by carrying out short circuit
withstand set.

Tests shall be conducted before and after short circuit test as per the relevant clauses of
IEC 60076-5/ IS 2026-5

Following shall also be conducted before and after Short Circuit test

i) Dissolved gas analysis

ii) Frequency response analysis

12.2.4

Routine tests on bushings

The following tests shall be conducted on bushings

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12.2.4.1

Test for leakage on internal fillings.

12.2.4.2

Measurement of creepage distance, dielectric dissipation factor and capacitance.

12.2.4.3

Dry power frequency test on terminal and tapping.

12.2.4.4

Partial discharge test followed by dielectric dissipation factor and capacitance

measurement.

12.2.5

Type Tests on fittings:

All the following fittings shall conform to type tests and the type test reports shall be
furnished by the contractor along with the drawings of equipment/fittings as per the clause
no. 9.2 of the Section – GTR. The list of fittings and the type test requirement is:

1. Bushing (Type Test as per IS: 2099/ IEC: 137)

2. Buchholz relay (Type Test as per IS: 3637 and IP-55 Test on terminal box)

3. OLTC (Temperature Rise of contact, Short circuit current test, Mechanical test
and Dielectric Test as per IEC:214 and IP-55 test on driving mechanism box)

4. Cooler Control cabinet (IP-55 test)

5. Pressure Relief device Test

The pressure Relief Device of each size shall be subjected to increase in oil
pressure. It shall operate before reaching the test pressure specified in
transformer tank pressure test at Cl. No. 5.2.7.2 (ii) below. The operating
pressure shall be recorded. The device shall seal off after excess pressure has
been released. The terminal box / boxes of PRD should conform to degree of
protection as per IP-55 of IS: 13947.

6. Magnetic Oil Level gauge & Terminal Box for IP-55 degree of protection.

7. 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.

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8. OTI & WTI – Switch setting & operation, Switch differential, Switch rating.

9. Oil pump – Vacuum Test at 250 torr maximum, oil pressure test at 1 kg/cm2 for
24 hrs.,

Temperature rise test by resistance method, IP-55 degree of protection for

terminal box.

10. Cooling fan and motor assembly – Free air delivery, Temperature rise, sound
level, running at reduced voltage, IP-55 degree of protection for terminal box.

12.2.6

Tank Tests

12.2.6.1

Routine Tests

Oil Leakage Test:

All tanks and oil filled compartments shall be tested for oil tightness by being completely
filled with air or oil of a viscosity not greater than that of insulating oil conforming to IS:335
at the ambient temperature and applying a pressure equal to the normal pressure plus 35
KN/Sq.m (5 psi) measured at the base of the tank. The pressure shall be maintained for a
period of not less than 12 hours for oil and one hour for air during which time no leak shall
occur.

12.2.6.2

Type Tests

(i) Vacuum Test

One transformer tank of each size shall be subjected to the specified vacuum.
The tank designed for full vacuum 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 Permanent deflection

of flat plate (in mm) (in mm)

-------------------------------------------------------------------------------------

Up to and including 750 5.0

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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

-------------------------------------------------------------------------------------

(ii) Pressure Test

One transformer tank of each size, its radiator, conservator vessel and other
fittings together or separately shall be subjected to a pressure corresponding
to twice the normal head of oil or to the normal pressure plus 35 KN/m2
whichever is lower measured at the base of the tank and maintained for one
hour. the permanent deflection of flat plates after the excess pressure has been
released shall not exceed the figure specified above for vacuum test.

12.2.7

Pre-Shipment Checks at Manufacturer's Works

12.2.7.1

Check for interchangeability of components of similar transformers for mounting

dimensions.

12.2.7.2

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

12.2.7.3

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

12.2.7.4

Gas tightness test to confirm tightness.

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12.2.7.5

Derivation of leakage rate and ensure the adequate reserve gas capacity.

12.3 Inspection and Testing at Site

The Contractor shall carry out a detailed inspection and testing programme for field
activities covering areas right from the receipt of material stage upto commissioning
stage. An indicative programme of inspection as envisaged by the Employer is given below
and in the document No.OS/T&C/Bay/95 (Pre commissioning Procedures and Formats for
substation bay equipment), which will be available in the respective sites and shall be
referred by the contractor. However, it is contractor's responsibility to draw up and carry
out such a programme duly approved by the Employer. Testing of oil sample at site shall
be carried out as per Cl.3.4 above.

12.3.1

Receipt and Storage Checks

12.3.1.1

Check and record condition of each package, visible parts of the transformer etc. for any
damage.

12.3.1.2

Check and record the gas pressure in the transformer tank as well as in the gas cylinder.

12.3.1.3

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

12.3.1.4

Check and record reading of impact recorder at receipt and verify the allowable limits as
per manufacturer's recommendations.

12.3.2

Installation Checks

12.3.2.1

Inspection and performance testing of accessories like tap changers, cooling fans, oil

pumps etc.

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 TECHNICAL SPECIFICATIONS FOR 66/11 kV POWER TRANSFORMER

12.3.2.2

(i) Check the direction of rotation of fans and pumps.

(ii) Check the bearing lubrication.

12.3.2.3 Check whole assembly for tightness, general appearance etc.

12.3.2.4 Oil leakage test

12.3.2.5 Capacitance and tan delta measurement of bushing before fixing/connecting to the
winding, contractor shall furnish these values for site reference.

12.3.2.6 Leakage test on bushing before erection.

12.3.2.7 Measure and record the dew point of nitrogen in the main tank before assembly.

12.3.3 Commissioning Checks

12.3.3.1 Check the colour of silica gel in silica gel breather.

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

12.3.3.3 Check the bushing for conformity of connection to the lines etc,

12.3.3.4 Check for correct operation of all protection devices and alarms :

(i) Buchholz relay.

(ii) Excessive winding temperature.

(iii) Excessive oil temperature.

(iv) Low oil flow.

(v) Low oil level indication.

(vi) Fan and pump failure protection.

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

12.3.3.6 Check resistance of all windings on all steps of the tap changer.

Insulation resistance measurement for the following:

(i) Control wiring.

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(ii) Cooling system motor and control.

(iii) Main windings.

(iv) Tap changer motor and control.

12.3.3.7 Check for cleanliness of the transformer and the surroundings.

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

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

12.3.3.10 Phase out and vector group test.

12.3.3.11 Ratio test on all taps.

12.3.3.12 Magnetising current test.

12.3.3.13 Capacitance and Tan delta measurement of winding and bushing.

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

12.3.3.15 Frequency response analysis (FRA).

12.3.3.16 Contractor shall prepare a comprehensive commissioning report including all

commissioning test results and forward to Employer for future record.

12.4 SEQUENCE OF TESTS:

The sequence of type tests, special tests (whenever applicable) and routine tests
required to be conducted on each transformer is as mentioned hereunder :

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 TECHNICAL SPECIFICATIONS FOR 66/11 kV POWER TRANSFORMER

Sl. No. TEST CATEGORY DESCRIPTION

1 Type Parameters as per drawings
Tank pressure test with measurement of
2 Type
deflection
Tank vacuum test with measurement of
3 Type
deflection
4 Type Pressure relief device test

Degree of protection IP55 for OLTC & Cooling

5 Type
control cabinets.

Magnetic circuit insulation test 2kV-1 minute.

6 Type Core to Yoke clamp, Core to flith plate, Core
bolt to yoke.

7 Type Oil DGA test (before & after HV & TR tests)

No load loss & current (before & after HV & TR

8 Type routine tests) at 90%, 100% & 110% of rated
voltage with 3W, 3A and 3V meters method.

9 Type Impulse test: One reduced full wave

One full wave
One reduced chopped wave
Two full chopped wave
Two full waves

Temperature rise test at ONAN, ONAF & OFAF

10 * Type
ratings & quoted max. losses.

11 Type -------Repeat tests at sr. nos. 8, 9 ------

Oil leakage test at 35 KN/m2 (0.357kg/sq.cm) over

12 Type
max. static head of oil measured at the base for 12hrs.

13 Type Jacking test

Bushing current transformer ratio & polarity
14 Type
tests.

15 Routine Magnetic balance test at nay one tap.

IR value t 10/60/600sec (before & after HV & TR

16 Routine
tests)
17 Routine Winding resistance at all taps.
18 Routine Oil BDV test (before & after HV & TR tests)

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 TECHNICAL SPECIFICATIONS FOR 66/11 kV POWER TRANSFORMER

Voltage ratio at all taps and polarity/phase

19 Routine
displacement at normal tap.

20 Routine Separate source voltage withstand test.

21 Routine Induced over voltage withstand test.

Load loss at extreme taps and normal tap &

22 Routine impedance at all taps by 3W, 3A, 3V meter
method.

23 Routine Tests on OLTC:

1). Circuit insulation test 2kV – 1Min.

2). Operations tests: 8Cy, 1Cy at 85%V, 1Cy at

no load and rated V, 10Cy +/-2 steps from
normal tap and rated current.

24 Routine Cooling Control test:

1). Circuit insulation test 2kV-1Min.
2). Operating test.
25 Routine SFRA

Capacitance and Tan Delta (before & after HV

& TR tests) at 5kV & 10kV: HV to LV + tank; HV
26 Special
+ LV to tank under grounded and guarded
specimen modes.

Harmonic analysis of no load current at 90%,

27 Special
110% of rated V

Zero sequence impedance test at 10% / 20% /

28 Special 60% / 80% / 100% of test current at extreme
taps and normal tap.

29 Special Acoustic noise level test.

Measurement of power consumption by fans &
30 Special
pumps
31 Special Dynamic short circuit test

NOTE: 1. CT, PT, Ammeter, Voltmeter, Wattmeter, frequency meter shall be of appropriate
class of accuracy and shall have valid calibration certificate.

2. T.R- Temperature rise test.

Temperature rise test shall be conducted on all units.

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12.4.1

The manufacturer shall carry out the Sweep Frequency Response Analysis SFRA)
Test at their works and also during pre-commissioning at site. The values / data shall be
furnished to KP TCL for future reference. The required instruments/equipments for
conducting the SFRA test at Site shall be arranged by transformer
manufacturer/Contractor.

13.0 NITROGEN REQUIREMENT

Power transformer 31.5MVA (66/11KV class) rating shall be provided with “Nitrogen”
Injection drain and stir method type fire prevention and extinguish system along with all
associated fittings and control equipment. The bidder shall furnish full details of the fire
extinguishing system offered. In case if the system is not being manufactured by the
bidder full details of the manufacture experience and performance of the system shall be
furnished with the offer.

14.0 MINIMUM EXPERIENCE FOR QUALIFYING AS A BIDDER

i. Bidders shall have a minimum experience of five years in the design,

manufacture, testing and commissioning of power transformer similar of the
type specified in the present enquiry. At least 50% of the quantity of similar type
of transformer called for in the present enquiry shall be successful operation for
a minimum period of two years. The Bidder shall furnish the performance
certificate for satisfactory operation of similar equipment for a minimum period
of two years. The Bidder shall furnish the type test certificate conducted on a
similar equipment not later than five years as on the last date of submission of
bidfrom the date of bid opening.

ii) The purchaser however reserves the right to waive the minimum experience
condition stipulated in clause 13.04.00 (i) in case of firm having collaboration
with well experience firms. The experience of the collaborating firms in the
manufacture of similar type power transformer shall be not less than ten years.
The waiving of minimum experience condition will be considered by the
purchaser only on furnishing the performance guarantee for the power
transformer manufactured by the collaborating firms.

15.0 PERFORMANCE GUARANTEE

The equipments offered shall be guaranteed for satisfactory performance for a period of
42 months from the date of satisfactory commissioning of equipment. The equipment found
defective/failed with in the above guarantee period shall be replaced or repaired by the
supplier free of cost with in one month from receipt of intimation.

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If the defective/failed equipments are not replaced/repaired as per the above guarantee
clause, the KPTCL shall recover an equivalent amount plus 15% supervision charges from
any of the supplier’s bills.

16.0 REJECTION

Apart from rejection due to failure of the transformer to meet the specified test
requirements or in service during the guaranteed period, the transformer shall be liable
for rejection on any of the following reasons.

a) No load loss exceeds the guaranteed value by 10% or more.

b) Load loss exceeds the guaranteed value by 10% or more.

c) Impedance value exceed the guaranteed value by ± 10% or more.

d) Oil temperature exceeds the specified value by 5 ° C.

e) Transformer is proved to have been manufactured not in accordance with the

agreed specifications.

If the transformer is rejected after it is serviced for any of the above reasons the
transformer shall be retained till the same is replaced by the supplier and commissioned
successfully.

17.0 DOCUMENTATION

17.01.00

The following tender drawings shall be submitted in triplicate for each type of transformer.

a) A general outline and shipping dimension, net and shipping weights, height of
crane hooks for lifting core and busing etc.

b) Sectional views of bushings, heat exchangers, etc.

c) Schematic electric control circuit diagram for OLTC control, cooler control etc.

17.02.00

The supplier shall within four weeks of placement of order submit four sets of drawings,
which will describe the equipment in detail for purchaser’s approval. The purchaser shall
communicate his comments/approval on the drawings within reasonable period.

The following drawings for each item are to be supplied as part of the contract.

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a) Outline dimensional drawings of transformers and accessories.

b) Assembly drawings and weight of main component parts.

c) Shipping drawings showing dimensions and weights of each package.

d) Foundation: The weight of the individual parts which require separate

foundations and the position of separate bolts and nuts required shall be
advised by the supplier. Foundation design and drawings giving full particulars
shall be supplied to the purchaser in time to enable the foundation to the erected
by the time the transformers arrive at site. The position of ducts, trenches, oil
piping etc., shall clearly be indicated on the same. The safe bearing pressure of
the soil may be assumed as 0.5 tonne per sq.ft.

e) Tap changing and name plate diagrams.

f) Schematic control and wiring diagram for all auxiliary equipments.

g) Schematic diagram showing the flow of oil in the cooling system as well as each
limb and winding. Longitudinal and cross sectional views showing the ducts
sizes, cooling pipes, etc., for the transformer heat exchanger drawing to scale
shall be furnished.

h) Bushing drawing with sectional views and specification.

i) Test reports.

j) Diagram and rating plates.

k) Electrical connections of windings, number of taps, tapping switchgear terminal

vector group polarity etc.

l) Control circuits and wiring diagrams, schematic circuit diagrams for cooler
control, paralleling interlock, wiring diagrams of control cabinets, signalling and
indicating devices, block diagram showing interconnecting control cable
schedule to enable the purchaser to prepare the schedule of control cables etc.

m) Assembly of core and coils: Details of winding connection, insulation spacers,

barriers clearances, core bolt insulation, etc., which will help the purchaser to
replace a set of winding in any future eventuality. The component parts shall be
suitably numbered, and parts shipped shall have similarly numbered tags.

n) Drilling details and internal wiring of devices supplied lose for mounting on the
purchaser’s control board.

o) Assembly of OLTC gear mechanism: Full details of the mechanism parts, limits
and fits contours wearing parts, timing gear adjustments.

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p) Detailed assembly drawing to enable the purchaser to do the core and coil
assembly. Parts shall be identified by separate numbers.

q) Dimensional drawings showing cooling passage on transformers and windings.

r) The supplier shall, if necessary, modify the drawings and resubmit four copies
of the modified drawings for purchaser’s approval within two weeks from the
date of comments.

17.03.00

After the approval of drawings, the Bidder should supply the drawings and manuals as
detailed below:

i. 12 sets of blueprint copies and one set of reproducible originals of all the
approved drawings and 12 sets instructions, erection, commissioning and
maintenance manuals to the officer designated in purchase order.

ii. Three sets blueprint copies of all approved drawings and three sets instruction,
erection, commissioning and maintenance manual to the consignee in respect
of each transformer.

iii. Marked erection drawings shall identify the component parts of the equipment
as shipped to enable purchaser to carryout erection with his own personnel.
Each manual shall also contain one set of all the approved drawings, type test
reports as well as acceptance reports of the corresponding consignment
dispatched.

17.04.00

The manufacturing of the equipment shall be strictly in accordance with approved

drawings and no deviation shall be permitted without the written approval of the
purchaser. All manufacturing and fabrication work in connection with equipment prior to
the approval of the drawing shall be at the supplier’s risk.

17.05.00

The firm should supply the contract drawings and manuals detailed in clause 14.02.00
well before the supply of transformer. Further the firm should give a specific confirmation
to this effect.

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 TECHNICAL SPECIFICATIONS FOR 66/11 kV POWER TRANSFORMER

17.06.00

TEST REPORTS

i. Four copies of type test reports shall be furnished to purchaser within three
weeks of conducting the tests. One copy will be returned duly certified by
purchaser to the supplier within two weeks thereafter and on receipt of the same
Bidder shall commence with the commercial production of the concerned
material.

ii. Four copies of acceptance test reports shall be furnished to the purchaser. One
copy will be returned duly certified by the purchaser and only there after shall
the materials be dispatched.

iii All records of routine test reports shall be maintained by the supplier at his
works for periodic inspection by the purchaser.

iv All test reports for tests conducted during manufacturer shall be maintained by
the supplier. These shall be produced for verification as and when requested for
by the purchaser

18.0 PACKING AND TRANSPORTATION

18.01.00

The equipment shall be packed in crates suitable for vertical/horizontal transport as the
case may be and suitable to withstand handling during transport and outdoor storage
during transit. The supplier shall be responsible for any damage to the equipment during
transit, due to improper and inadequate packing. The easily damageable material shall be
carefully packed and marked with the appropriate caution symbol. Wherever necessary,
proper arrangement for lifting, such as lifting hook etc. shall be provided . Any material
found short inside the packing cases shall be supplied by supplier without any extra cost.

18.02.00

The transformer shall be transported, thoroughly dried under vacuum and sealed under
positive pressure with inert gas (Nitrogen). Nitrogen gas pressure gauge shall be
provided.

18.03.00

All brass fitting should be dismantled after test at the factory and should be transported
separately to avoid loss during transit. The opening should be suitably plugged except
inert gas inlet and outlet which should be fitted with iron fittings.

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18.04.00

All parts shall be adequately marked to facilitate field erection. Boxes and crates shall be
marked with the contract number and shall have detailed packing list containing the
following information.

a) Name of the consignee.

b) Details of consignment

c) Destination
d) Total weight of consignment.

e) Sign showing upper/Lower side of the crate.

f) Handling and unpacking instructions.

g) Bill of material indicating contents of each packing.

18.05.00

The supplier shall ensure that the packing and bill of materials are approved by the
purchaser before dispatch.

18.06.00

The Bidder shall supply the factory assembled transformer and the accessories will be
assembled at site. However, if the Bidder choose to supply the transformer in knocked
down condition, Bidder should make his own arrangement for assembly and delivery of
transformer at site.

18.07.00

LIMITING DIMENSION

The manufacturer has to note the limitations of transporting, package dimensions and
weights for transportation over the railways/public transport as notified in the tender and
should take the responsibility of transporting the units to site.

19.0 TRAINING

19.01.00

The successful Bidder shall be required to provide facilities for in plant training, at no
extra cost to the purchaser, to at least 4 engineers to be nominated by the purchaser for
a period of three weeks (i.e., 12 man weeks) at his works, where the equipments offered
shall be manufactured. The scope of the training shall cover assembly, factory testing,
site testing, periodical maintenance operation and possible trouble shooting of the
transformers & Nitrogen Fire Prevention / Extinguishing System.

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19.02.00 TESTS

Type test certificates not later than 5 5 years as per relevant standards for Nitrogen
injection fire protection system as a whole unit shall be furnished.

19.03.00

PERFORMANCE GUARANTEE

The equipments offered shall be guaranteed for satisfactory performance for a period of
42 months from the date of satisfactory commissioning of equipment. The equipment
found defective/failed with in the above guarantee period shall be replaced or repaired by
the supplier free of cost with in one month from receipt of intimation. If the defective/failed
equipments are not replaced/repaired as per the above guarantee clause, the KPTCL shall
recover an equivalent amount plus 15% supervision charges from any of the suppliers bills.

19.04.00

MINIMUM EXPERIENCE FOR QUALIFYING AS BIDDER

The Bidder shall have a minimum experience of five years in the design, manufacture,
testing and commissioning of Nitrogen injection fire protections system in the present
enquiry. At least 50% of the quantity called for in the present enquiry shall be in successful
operation for a minimum period of two years. The Bidder shall also furnish the details of
similar Nitrogen injection Fire protection system supplied by them so far, giving order
reference name and address of the customer etc., also indicating the period of
commissioning. The Bidder shall also furnish performance certificates for a period of
minimum two years of similar Nitrogen injection fire protection system in proof of the
satisfactory operation of the equipment.

The purchaser however reserves the right to waive the minimum experience condition
stipulated.

i. In case of firms having collaboration with well experienced firms the experience
of the collaborating firm in the manufacture of similar equipment shall be not
less than ten years. The waiving of minimum experience condition will be
considered by the purchaser only for furnishing the performance guarantee for
the nitrogen injection fire protection system by the collaborating firm.

ii. In case of new entrant who had supplied to KPTCL one system free of cost for
watching performance for a period of one year and for having worked
satisfactorily.

iii. Furnish type test certificates for the operation of the entire system as a whole
instead of individual components.

iv. Furnish Guarantee for performance for a period of 5 years.

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20.0 TESTING AND COMMISSIONING

The Bidder shall note that their commissioning Engineers have to be deputed at no extra
cost for testing and commissioning of transformer, in case orders are finalized on them.

21.0 GENERAL

21.01.00

INFORMATION TO BE FILLED INVARIABLE BY THE BIDDER For ready reference of the

tenderer, the information required to be invariably furnished by the tenderer in his offer,
are listed below:

Following information is to be submitted physically along with offer (Techno

commercial bid).

i) GTP

ii) List of type test conducted

iii) Certificate of accreditation of the testing laboratory where the type test are
conducted.

iv) Drawings, test certificate & documents as per Qualifying requirement clause of
this specification.

v) Performance certificates

vi) Type Test reports

vii) Undertaking in the form of affidavit regarding CRGO as per clause nos: 9.01.01
and 12.01.00 (iii)

Offers without the above information or with incomplete information may be rejected.

The scope of supply shall include supply of 2.5% extra quantity of bolts, nuts, washers,
split pins, cotter pins and such other small loose items free of cost.

21.02.00

The chargers, if any, for delivery at site inclusive of transit risk insurance, loading and
unloading charges, etc., are to be clearly indicated. Please note that there should be
definite commitment by you for delivery of the transformer at site. Any statement like the
probable estimated transportation charges etc., will be considered as non-responsive and
such offers will be overlooked without any further correspondence.

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22.0 NITROGEN INJECTION FIRE PROTECTION

22.03.01

The transformers shall be supplied along with the Nitrogen injection fire protection
system. However, the price towards the same shall be quoted separately.

22.03.02

Nitrogen injection fire prevention and extinguishing system should be provided for
transformers (using Drain and stir method). This system should prevent tank explosion
and fire in case of internal failure and also protect the transformers from external fire.
Dedicated system shall be provided for individual transformer. It should be fully automatic
and shall require minimum maintenance and practically no running cost.

23.0 DEVIATION FROM TECHNICAL SPECIFICATION

The Bidder shall furnish the details of deviation modification proposed by him to improve
overall performance of the system. The deviation if any shall be brought in the tender
clause by clause.

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