TECHNICAL SPECIFICATION OF 25 MVAR 220 KV SHUNT REACTOR AND OTHER

ASSOCIATED ITEMS

1.0 Scope

1.1 This specification covers design, engineering, manufacture, testing at manufacturer's works,
delivery of 3 phase 25 MVAR Shunt Reactors(Bus Type) 220 kV Shunt Reactor and other items
including all material, accessories, spares at site including proper transportation, handling, proper
storage at site of the equipment specified.

1.2 The scope also covers the supervision services (for erection, testing and commissioning) of the
above mentioned item. The bidder shall also freely exchange any information required (such as
foundation arrangements / designs, layout requirements, erection, testing and commissioning
procedures for supplied equipments, field quality plans etc.) for integration of these equipments in
new / existing sub-station with the successful contractor (s) of other 220 kV bay package (s) to
ensure efficient and trouble free satisfactory operation.

1.3 Type of Reactor

1.3.1 The shunt reactor shall be of either gapped core type or magnetically shielded air core type
construction.
1.3.2 The impedance ratio (X0/X1) specified shall be achieved by any one of the following methods:
1.3.2.1 Adopting 5 limb core construction.
1.3.3 In case of coreless construction following requirements are stipulated.
1.3.3.1 A magnetic shield shall be provided around the coreless coils.
1.3.2.2 Non-magnetic material sheet shall form the central core to minimize the vibrations.

1.4 Reference Drawing

i. Arrangement of CTs on Shunt Reactor : RVPN/EHV/DESIGN/ Drawing no-1 (Annexure-5)

1.5 Transportation

1.5.1 The Contractor shall despatch the reactor filled with oil or in an atmosphere of nitrogen or dry air
at positive pressure. In the former case, the contractor shall take care of the weight limitation on
transport and handling facility at site. In the latter case, necessary arrangement shall be ensured
by the contractor to take care of pressure drop of nitrogen or dry air during transit and storage till
completion of oil filling during erection. The nitrogen or dry air cylinder provided to maintain
positive pressure can be taken back by the contractor after oil filling. A gas pressure testing valve
with necessary pressure gauge and adaptor valve shall be provided. Reactor shall also be fitted
with sufficient number of Electronic impact recorders (on returnable basis) during transportation
to measure the movement due to impact in all three directions. The acceptance criteria and limits
of impact in all three directions which can be withstood by the equipment during transportation
and handling shall be submitted by the contractor during detailed engineering. The recording shall
commence in the factory before despatch and must continue till the unit is installed on its
foundation. The data of electronic impact recorder(s) shall be down loaded at site and a soft copy
of it shall be handed over to Engineer-in-charge. Further, within three weeks the contractor shall
communicate the interpretation of the data.

1.5.2 In case reactor is transported, nitrogen or dry air filled, the insulating oil for reactors shall be
delivered at site not before 90 days from the date of commissioning, which will be informed by
the Employer.

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2.0 Performance

2.1 Shunt Reactors will be connected to the 220 kV transmission systems for reactive load
compensation and shall be capable of controlling the dynamic over voltage occurring in the
system due to load rejection. Typical line parameters of 220 kV Transmission Lines are given
below:

S. Line Positive sequence Zero sequence Susceptance Susceptance

No. impedance impedance mhos/km mhos / km
ohms/km ohms/ km positive Zero
1 220 kV D/C 0.0265 + j0.309 0.263 + j1.1326 3.69 x 10-6 2.17x10-6
Line
2 220 kV S/C 0.0264 + j0.3294 0.2015 + j1.095 3.356 x 10-6 2.646x10-6
Line

2.2 Shunt Reactors shall be capable of operating continuously at a voltage 5% higher than their rated
voltage without exceeding hot spot temperature of 150 deg C at any part of the reactor.

2.3 Temperature rise shall be guaranteed when shunt reactor is operating at 245 kV.

2.4 The reactors shall be subjected to switching surge overvoltage of 2.5 p.u. and temporary
overvoltage of the order of 2.3 p.u. for few cycles followed by power frequency overvoltage upto
1.5 p.u. The reactor must withstand the stress due to above transient dynamic conditions which
may cause additional current flow as a result of changed saturation characteristics/slope beyond
1.5 p.u. voltage.

2.5 DGA of oil shall be periodically monitored by the Employer and the interpretation of DGA
results will be as per IEC-60599.

2.6 Design review

The Reactors 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 reactor(s) provide long life with least maintenance.

Design reviews shall be conducted by Employer or an appointed Consultant at different stages of

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

Employer 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 reactor(s) under scope of this
specification.

The design review shall be conducted generally following the “Guidelines for conducting design
reviews for transformers 100 MVA and 132 kV and above” prepared by Cigre SC 12 Working
Group 12.22.

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 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 and lead design
3. Thermal design including review of localised potentially hot area.
4. Cooling design
5. Overload capability
6. Eddy current losses
7. Seismic design, as applicable
8. Insulation co-ordination
9. Tank and accessories
9.1 Bushings and barrier design
9.2 Radiators
9.3 Sensors and protective devices – its location, fitment, securing and level of redundancy
9.4 Oil and oil preservation system
10. Corrosion protection of metallic surface and aesthetics
11. Electrical and physical Interfaces with substation
12. Earthing
13. Processing and assembly
14. Testing capabilities
15. Inspection and test plan
16. Transport and storage
17. Sensitivity of design to specified parameters
18. Acoustic Noise
19 Vibration and Tank stress
20 Spares, inter-changeability and standardization
21. Maintainability

2.7 LOSSES

As the reactor shall be in constant operation, the maximum permissible losses of shunt reactor
shall be as under:
i. Maximum load loss at rated current & at 75 degree centigrade (In KW): 50 kW without
any positive tolerance.
ii. Maximum I2R loss at rated current & at 75 degree centigrade (In KW): 28 kW without
any positive tolerance.
iii. (Core+Stray+Eddy) current losses : 22 kW
iv. Percentage Impedance : 44%

2.7.1 The bidder shall indicate values of losses in KW at the rated MVAR, voltage & normal
frequency.
2.7.2 The 25 MVAR, 220 kV Bus reactor under no circumstances shall be accepted, if the measured
losses are more than the Maximum guaranteed losses at rated voltage.

2.7.3 DELETED

2.7.4 Purchaser reserves the rights to reject the shunt reactor, if the losses exceed beyond Maximum
guaranteed losses at rated voltage.
2.7.5 The supplier shall provide along with the bid the design details of core assembly showing the
construction details, core diameter, net/gross sectional area of the core assembly, gross and net

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 weight of CRGO used in the core assembly and stacking factor etc. The information must also be
given in respect of volts per turn at principle tap for normal voltage. The loss curves for
type/grade of steel laminations being used for the core shall also be provided along with the
tender.

3.0 Construction Details

The feature and construction of the reactors shall be in accordance with the requirements stated
hereunder.

3.1 Tank and Tank Accessories

3.1.1 Tank

3.1.1.1 Tank shall preferably be of welded construction and fabricated from tested quality low carbon
steel of adequate thickness. Unless otherwise approved, metal plate, bar and sections for
fabrication shall comply with BS-4360 / IS 2062). The components and fitting associated with
reactor are subject to Employer’s approval and design review.

3.1.1.2 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 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 shall be
based on recommendation of BS-5500 table 4.4.3.1.

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

3.1.1.4 The shunt reactor tank shall have either bolted/welded joint. In case the joint is welded it shall be
provided with flange suitable for repeated welding. The joint shall be provided with a suitable
gasket to prevent weld splatter inside the tank. Proper tank shielding shall be done to prevent
excessive temperature rise of the joint.

3.1.1.5 Each tank shall be provided with

(a) Four symmetrically placed lifting lugs so that it will be possible to lift the complete
reactor when filled with oil without structural damage to any part of the reactor. The
factor of safety at any one point shall not be less than 2. The lifting lugs shall be so
arranged and located as to be accessible for use when the reactor is loaded on the
transport vehicle.
(b) A minimum of four jacking pads in accessible position to enable the reactor complete
with oil, to be raised or lowered using mechanical/hydraulic screw jacks. Each jacking
pad shall be designed to support with an adequate factor of safety for at least half of the
total mass of the reactor filled with oil allowing in addition for maximum possible
misalignment of the jacking force to the centre of the working surface.
(c) Suitable haulage holes.

3.1.1.6 The tank shall be designed in such a way that it can be mounted on the plinth directly.

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

3.1.1.8 Paint system and procedures

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 The painting details for reactor main tank, pipes, conservator tank, radiator, control cabinet/
marshalling box / oil storage tank etc. shall be as given below. The detailed painting procedure
shall also be submitted along with the bid which shall be finalized before award of the contract.
The quality of paint such that its colour should not fade during vapour phase drying process and
shall be able to withstand temperature up to 120 deg C.

Surface Primer coat Intermediate Finish Total dry film Colour

preparation undercoat coat thickness (DFT) shade

Main tank, Blast Epoxy base Zinc Epoxy high Aliphatic Minimum Grey shade
pipes, cleaning Sa 2 primer (30- build polyureth ane 155µm
conservator ½* 40µm) Micaceous (PU)
tank etc. iron oxide (HB (Minimum
(external MIO) (75µm) 50µm)

Main tank, pipes Blast Hot oil -- -- Minimum Glossy white

surfaces)
(above 80 cleaning resistant, non- 30µm for paint
NB), Sa 2 ½* corrosive
conservator varnish or
tank etc. paint or
(Internal epoxy
surfaces)

Radiator Chemical / Epoxy base Zinc Epoxy base PU paint Minimum Matching shade of
(external Blast primer (30- Zinc primer (Minimum 100µm tank/ different
surfaces) cleaning 40µm) (30-40µm) 50µm) shade aesthetically
Sa 2 ½* matching to tank
Radiator and pipes Chemical Hot oil proof, -- -- -- --
upto 80 NB cleaning, if low viscosity
(Internal surfaces) required varnish and
flushing with
transformer oil

Control cabinet / Seven tank Zinc chromate -- EPOXY Minimum RAL 7035 shade
marshalling box process as per primer (two paint with 80µm for exterior and
IS:3618 & coats) PU top coat interior
IS:6005

Note: * indicates Sa 2 ½ as per Swedish Standard SIS 055900 of ISO 8501 Part-1.

3.1.2 Tank Cover

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

3.1.2.2 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 25kg. Handles shall be provided on the inspection cover to facilitate lifting.

3.1.2.3 The tank cover shall be fitted with pockets at the position of maximum oil temperature at
maximum continuous rating for bulbs of oil and winding temperature indicators. It shall be
possible to remove these bulbs without lowering the oil in the tank. The thermometer shall be
fitted with a captive screw to prevent the ingress of water.

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

3.1.2.5 All bolted connections shall be fitted with weather proof, hot oil resistant, resilient gasket in
between for complete oil tightness. If gasket is compressible, metallic stops/other suitable
means shall be provided to prevent over compression. Groove provided to accommodate round

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 nitrile rubber cord for rectangular openings shall be milled. Details of all gasket joints shall be
submitted for approval.

3.1.2.6 Current flowing in tank cover and bushing turrets.

To allow for the effect of possible induced and capacitive surge current, good electrical
connection is maintained between the tank and turrets.

3.1.2.7 The reactor shall be provided with a 100 mm nominal diameter pipe flange with bolted blanking
plate, gasket and shall be fitted at the highest point of the reactor for maintaining vacuum in the
tank.

3.1.3 Axles and Wheels

3.1.3.1 The shunt reactor shall be mounted on concrete plinth foundation directly.

3.1.3.2 One complete set of flanged bi-directional wheels and axles shall be provided for each sub-
station. This set of wheels and axles shall be suitable for fixing to the under carriage of shunt
reactor to facilitate its movement on rail track.

3.1.3.3 The rail track gauge shall be 1676 mm. (2 Nos across the length & 2 Nos. along the length of
the Shunt Reactor tank )

3.1.3.4 Bidder shall supply one set of trolley in place of rollers for movement of shunt reactor per sub-
station.

3.1.4 Foundation and Anti Earthquake clamping Device

3.1.4.1 To prevent reactor movement during earthquake, suitable a clamping device shall be provided
for fixing the reactor to the foundation.

3.1.5 Conservator & Oil Preservation System

3.1.5.1 Main conservator shall have air cell type constant oil pressure system to prevent oxidation and
contamination of oil due to contact with moisture, and shall be fitted with magnetic oil level
gauge with low oil level electrically insulated alarm contacts. Magnetic oil level gauge shall be
type tested. Magnetic oil level gauge and its terminal box shall conform to IP 55 degree of
protection.

3.1.6 Conservator tank and pipe work

3.1.6.1 Conservator tank shall have adequate capacity between highest and lowest visible-levels to meet
the requirements of expansion of total cold oil volume in the shunt reactor and cooling
equipment from minimum ambient temperature to 100°C.

3.1.6.2 The conservator shall be fitted with integral lifting lugs in such a position so that it can be
removed for cleaning purposes. Suitable provision shall be kept to replace air cell and cleaning
of the conservator, wherever applicable.

3.1.6.3 Conservator shall be positioned so as not to obstruct any electrical connection to reactor. Pipe
work shall not obstruct the opening of inspection or manhole covers.

3.1.6.4 Pipe work connections shall be of adequate size for their duty and as short and direct as possible.
Only radius elbows shall be used.

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3.1.6.5 The feed pipe to the reactor tank shall enter the reactor cover plate at its highest point and shall be
straight for a distance not less than five times its internal diameter on the reactor side of the
Buchholz relay, and straight for not less than three times that diameter on the conservator side of
the relay.

3.1.6.6 This pipe shall rise towards the oil conservator, through the Buchholz relay, at an angle of not less
than 5 degree.

3.1.7 Oil Preservation Equipment

The requirements of air cell type oil sealing system are given below.

3.1.7.1 Contact of the oil with atmosphere is prohibited by using a flexible air cell of nitrile rubber
reinforced with nylon cloth air cell.

3.1.7.2 The temperature of oil is likely to rise upto 100°C during operation. As such air cell used shall be
suitable for operating continuously at least at 100°C.

3.1.7.3 Air cell of conservator shall be able to withstand the vacuum during installation/ maintenance
periods. Otherwise provision shall be kept to isolate the conservator from the main tank when the
latter is under vacuum by providing a vacuum sealing valve or other suitable means in the pipe
connecting main tank with the conservator.

3.1.7.4 The connection of air cell to the top of the conservator is by air proof seal preventing entrance of
air into the conservator.

3.1.8 Self Dehydrating Filter Breather

Conservator shall be fitted with a self dehydrating maintenance free silica gel breather. It shall be
so designed that:
a) Passage of air is through a dust filter and silica gel.
b) Silica gel is isolated from atmosphere by an oil seal.
c) Moisture absorption indicated by a change in color of the tinted crystals can be easily observed
from a distance.
d) Breather is mounted not more than 1200 mm above rail top level.
e) To minimise the ingress of moisture following shall be provided.
i) Three breathers (of identical size) shall be connected in series for conservator of shunt reactor.

Specification for Self Dehydrating Maintenance free Silica Gel Breather are placed at Annexure-3.

3.1.9 Pressure Relief Device

Adequate number of pressure relief devices shall be provided at suitable locations. These 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 less than the
hydraulic test pressure of reactor tank. It shall be mounted directly on the tank. One set of
electrically insulated contacts shall be provided for alarm/tripping. Pressure relief device shall be
properly taken through pipe and directed away from reactor/other equipment and this shall be
prevented from spraying on the tank. The terminal box/boxes of PRD should conform to degree
of protection as per IP-55 of IEC- 60529. Following routine tests shall be conducted on PRD

a) Air pressure test

b) Liquid pressure test

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 c) Leakage test
d) Contact test
e) Dielectric test

3.1.10 Buchholz Relay

Two No. double float magnetic reed type Buchholz relay required. All gases evolved in the
reactor shall collect in these relays. 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/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 reactor in service. The device shall be provided with two
electrically independent contacts, one for alarm on gas accumulation and the other for tripping on
sudden rise of pressure.

3.1.11 Temperature Indicators

3.1.11.1 Oil Temperature Indicator (OTI)

Shunt reactor shall be provided with a 150 mm dial type thermometer for top oil temperature
indication. The thermometer shall have adjustable, electrically independent ungrounded alarm
and trip contacts.

The maximum reading pointer and resetting device for the thermometer shall be mounted in the
marshalling box. A temperature sensing element suitably located in a pocket on top oil shall be
furnished. This shall be connected to OTI by means of capillary tubing. Temperature indicator
dials shall have linear gradations to clearly read at least every 2 deg C. Accuracy of OTI shall be
+/-1.5% or better.

The setting of alarm and tripping contacts shall be adjustable at site and typical values are as
given below which will be reviewed during detailed engineering based on manufacturer’s
recommendation.

Alarm – 95°C ; Trip – 105°C

In addition to the above, the following equipment shall be provided for remote indication of oil
temperature:

a) Signal transmitter

Signal transmitter shall have additional facility to transmit signal for recording oil temperature at
Purchaser’s data acquisition system, for which duplex platinum RTD with nominal resistance of
100 ohms at zero degree centigrade shall be supplied. The RTD shall be three wire ungrounded
system. The calibration shall be as per SAMA (USA) standard or equivalent. The RTD may be
placed in the pocket containing temperature sensing element and image coil for OTI system
which will be used for both remote OTI and DAS. Necessary equipment for sending the signal to
remote OTI and DAS shall be provided. In lieu, separate RTD for each of the functions shall be
provided.

b) Remote oil temperature indicator

It shall be suitable for flush mounting on Purchaser’s panel. This shall not be repeater dial of local
OTI and will operate by signal transmitter. Any special cable required for shielding purpose, for
connection between cooler control cabinet and remote OTI control circuit, shall be in the scope of
Contractor. Only one ROTI with a four point selector switch shall be provided.

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3.1.11.2 Winding Temperature Indicator (WTI)

A device for measuring the hot spot temperature of winding shall be provided on shunt reactors
only. It shall comprise the following:

(i) Temperature sensing element

(ii) Image coil
(iii) Auxiliary current transformers if required to match the image coil shall be furnished and
mounted in the marshalling box.
(iv) 150 mm dia local indicating instrument with maximum reading pointer mounted in
marshalling box and with two adjustable, electrical independent, ungrounded contacts, one for
high winding temperature alarm and one for trip. Temperature indicator dial shall have linear
gradations to clearly read at least every 2 deg C.
(v) Calibration device.
(vi) Accuracy of WTI shall be +/-1.5% or better.

The setting of alarm and tripping contacts shall be adjustable at site and typical values are as
given below which will be reviewed during detailed engineering based on manufacturer’s
recommendation.

Alarm – 110°C; Trip – 120°C

(vii) In addition to the above, the following shall be provided for remote indication of winding
temperature for each reactor.

(a) Signal Transmitter

Signal Transmitter shall have additional facility to transmit signal for recording winding
temperature at Purchaser’s data acquisition system, for which duplex platinum RTD with nominal
resistance of 100 ohms at zero degree centigrade shall be supplied.

The RTD shall be three wire ungrounded system. The calibration shall be as per SAMA (USA) or
equivalent 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 these functions shall be provided.

b) Remote Winding temperature indicator

Remote winding temperature indicator shall be suitable for flush mounting on Purchaser’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 Marshalling box and remote WTI
control circuit, shall be in the scope of Contractor. Drawing showing the mounting details of
RWTI shall be submitted to the Purchaser.

3.1.12 Earthing Terminals

3.1.12.1 Two (2) earthing pads (each complete with two (2) nos. holes, M 10 bolts, plain and spring
washers) suitable for connection to 75 x 12 mm galvanised steel grounding flat shall be provided
each at position close to earth of the two (2) diagonally opposite bottom corners of the tank.

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3.1.12.2 Two earthing terminals suitable for connection to 75 x 12 mm galvanised steel flat shall also be
provided on cooler, marshalling box and any other equipment mounted separately.

3.2 Core

3.2.1 In case of gapped core construction the following requirements are stipulated.

3.2.1.1 The core shall be constructed from high grade, non-ageing, cold rolled, super grain oriented,
silicon steel laminations.

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

3.2.1.3 The insulation of core to bolts and core to clamp plates shall be able to withstand a voltage of 2
kV rms for 1 minute.

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

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

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

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

3.2.1.8 The supporting frame work of the 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.

3.2.1.9 Adequate lifting lugs as required shall be provided to enable lifting of the core and winding.

3.3 Windings

3.3.1 The Contractor shall ensure that windings of reactors are made in dust proof and conditioned
atmosphere.

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

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

3.3.4 Coil assembly and insulating spacer shall be so arranged as to ensure free circulation of oil and to
reduce the hot spots of the winding.

3.3.5 Coil shall be made up, shaped and braced to provide for expansion and contraction due to
temperature changes.

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3.3.6 The conductors shall be transposed at sufficient intervals in order to minimise eddy currents and to
equalise the distribution of currents and temperature along the winding.

3.3.7 Fiber optic sensors shall be embedded in each phase of the winding located at hottest spot. The
location and details shall be derived and indicated in the respective drawings along with
justification.

3.3.8 The insulation paper shall be of high quality and the value of degree of polymerization shall not be
less than 1200 Pv and the necessary test certificate shall be submitted along with the stage inspection
report. Provision shall be made for taking sample of paper for testing purpose and location shall be easily
accessible and indicated on the shunt reactor tank by affixing special caution plate.

3.3.9 The windings shall be done in dust free and conditioned atmosphere.

3.4 Unused uninhibited Insulating Oil

3.4.1 The insulating oil shall be virgin high grade uninhibited, conforming to IEC-60296 & all
parameters specified below, while tested at supplier's premises. The Supplier shall furnish test
certificates from the supplier against the acceptance norms as mentioned below, prior to despatch
of oil from refinery to site. Under no circumstances, poor quality oil shall be filled into the reactor
and only thereafter be brought up to the specified parameter by circulation within the reactor.

S.No. Property Test Method Limits

A. Function
1a. Viscosity at 100°C ISO 3104 or ASTM (Max.) 3 mm2/s
1b Viscosity at 40°C D445 or ASTM D 7042 (Max.)12 mm2/s
1c Viscosity at -30°C (Max.)1800 mm2/s
2 Appearance A representative The oil shall be clear and
sample of the oil shall bright, transparent and
be examined in a 100 free from suspended
mm thick layer, at matter or sediment
ambient temperature
3 Pour point ISO 3016 or ASTM (Max.)- 40°C
D97
4 Water content IEC 60814 or ASTM (Max.)
a) for bulk supply D1533 30 mg/kg
b) for delivery in drums 40 mg/kg
5 Electric strength IEC 60156 (Min.) 50 kV(new
(breakdown voltage) unfiltered oil) / 70 kV
(after treatment)
6 Density at 20°C ISO 3675 or ISO 12185 0.820 - 0.895 g/ml
or ASTM D 4052
7 Dielectric dissipation factor IEC 60247 or IEC (Max) 0.0025
(tan delta) at 90°C 61620 Or ASTM D924
8 Resistivity at 90°C IEC 60247 150 x 1012 Ohm–cm
(Min.)
9 Negative impulse Testing ASTM D-3300 145 (Min.)
KVp @ 25°C
10 Carbon type composition (% of IEC 60590 and IS Max. Aromatic : 4 to 12
Aromatic, Paraffins and 13155 or ASTM D 2140 %, Paraffins : <50%
Naphthenic compounds) & balance shall be
Naphthenic compounds.

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 B. Refining / Stability
1 Acidity IEC 62021-1 or ASTM (Max) 0.01 mg KOH/g
D974
2 Interfacial tension at 27°C ISO 6295 or ASTM (Min) 0.04 N/m
D971
3 Total sulfur content BS 2000 part 373 or 0.05% (Max)
ISO 14596 or ASTM D (before oxidation test)
2622 or ISO 20847
4 Corrosive sulphur IEC 62535 Non-Corrosive on copper
and paper
ASTM D1275B Non-Corrosive
5 Presence of oxidation inhibitor IEC 60666 or ASTM 0.08% (Min.) to 0.4%
D2668 or D4768 (Max.) Oil should contain
no other additives.
Supplier should declare
presence of additives, if
any.
6 2-Furfural content IEC 61198 or ASTM 25 Microgram/litre
D5837 (Max.)
C. Performance
1 Oxidation stability
-Total acidity IEC 61125 (method c) Max 0.3 mg KOH/g
-Sludge Test duration 500 hour Max 0.05 %
- Dielectric dissipation IEC 60247 Max 0.05
factor (tan delta) at 90°C
2 Gassing IEC 60628A or ASTM No general requirement
D2300
3 Oxidation stability ASTM D2112 (a) 220 Minutes (Min.)
(Rotating Bomb test)
D. Health, safety and environment (HSE)
1 Flash point ISO 2719 (Min.)135°C
2 PCA content BS 2000 Part 346 Max 3%
3 PCB content IEC 61619 or ASTM Not detectable (Less than
D4059 2 mg/kg)
E Oil used (inhibited) for first filling, testing & impregnation of active parts at
manufacturers works shall meet as mentioned at 3.4.2 below:

3.4.2 for first filling, testing & impregnation of active parts at manufacturers works shall meet and shall
be tested for

1. Break Down voltage (BDV) : 70kV (min.)

2. Moisture content : 5 ppm (max.)
3. Tan-delta at 90°C : 0.005 (Max.)
4. Interfacial tension : 0.04 N/m (Min.)

F. Each lot of the oil shall be tested prior to filling in the main tank at site for the following:

1. Break Down voltage (BDV) : 70kV (min.)

2. Moisture content : 5 ppm (max.)
3. Tan-delta at 90°C : 0.0025 (Max.)
4. Interfacial tension : More than 0.04 N/m

G. After filtration in settling and prior to energization at site oil shall be tested for following
properties & acceptance norms as per below generally in line with IS: 1866 / IEC 60422:

13
 1. Break Down voltage (BDV) : 70 kV (min.)
2. Moisture content : 5 ppm (max.)
3. Tan-delta at 90°C : 0.005 (max.)
4. Resistivity at 9 °C : 6 X 1012 ohm-cm (min.)
5. Interfacial tension : More than 0.04 N/m

6. *Oxidation Stability (Test method as per IEC 61125 method C, Test duration: 500 Hrs. for
inhibited oil)
a) Acidity : 0.3 (mg KOH /g) (max.)
b) Sludge : 0.05 % (max.)
c) Tan delta at 90 °C : 0.05 (max.)
7. * Total PCB content : Not detectable (<2 mg/kg total)

* For S. No. 6 & 7 separate oil sample shall be taken and test results shall be submitted within 45
days after commissioning for approval of Nigam.

3.4.3 At manufacturer's works the quality of oil used for first filling, testing and impregnation of active
parts shall meet at least parameter as mentioned in S.No. 1 to 5 of clause 3.4.2 ii) above. The oil
test results shall form part of equipment test report.

Oil sample shall be drawn before and after heat run test and shall be tested for dissolved gas
analysis. Oil sampling to be done 2 hours prior to commencement of temperature rise test. Keep
the pumps running for 2 hours before and after the heat run test. Take oil samples during this
period. For ONAN/ONAF cooled transformer, sample shall not be taken earlier than 2 hours after
shutdown.

The acceptance norms with reference to various gas generation rates shall be as per IEC 61181.

3.4.4 Oil for first filling together with 10% extra quantity to cover wastage, spillage etc. during
erection, shall be supplied with the shunt reactor in non-returnable steel drums. This 10% oil
quantity shall be determined by refilling the fully drained shunt reactor upto normal oil level in
the conservator after the completion of the test at manufacture’s work.

3.4.5 Sufficient quantity of oil necessary for maintaining required oil level in tank, radiator and
conservator etc. till completion of warranty period shall be supplied.

3.5 Terminal Arrangement

3.5.1 Bushings

3.5.1.1 The electrical and mechanical characteristics of bushings shall be in accordance with relevant
IEC. Bushing must have been type tested successfully as per IEC 60137.

3.5.1.2 Bushing for various voltage rating shall be as follows:

52 kV and Resin impregnated paper (RIP) bushing with porcelain or composite insulator.
above General Specification for RIP Bushing are placed at Annexure-4.
36 kV and Solid porcelain or oil communicating type. Dimensions of 36 kV bushing
below shall conform to IS: 3347 Part-V.

3.5.1.3 Oil filled condenser type bushings shall be provided with at least the following fittings:

(a) Oil level gauge

14
 (b) Tap for capacitance/tan delta test. Test taps relying on pressure contacts against the outer
earth layer of the bushing is not acceptable.

3.5.1.4 Where current transformers are specified, the bushings shall be removable without disturbing the
current transformers.

3.5.1.5 Bushings of identical rating shall be interchangeable.

3.5.1.6 Porcelain used in bushing manufacture shall be homogenous, free from laminations cavities and
other flaws or imperfection that might affect the mechanical or dielectric quality and shall be
thoroughly vitrified, tough and impervious to moisture.

3.5.1.7 Clamps and fittings shall be of hot dip galvanised steel.

3.5.1.8 Bushing turret shall be provided with vent pipe, to route any gas collection through the buchholz
relay.

3.5.1.9 No arcing horns shall be provided on bushings.

3.6 Terminal Marking

The terminal marking and their physical position shall be in accordance with IEC 60076.

3.7 Neutral Earthing Arrangement

3.7.1 Neutral of Reactors shall be grounded directly.

3.7.2 The neutral terminals of Reactors shall be brought to the ground level by a brass/tinned copper
grounding bar, supported from the tank by using porcelain insulators. The end of the brass/tinned
copper bar shall be brought to the bottom of the tank, at a convenient point, for making bolted
connection to two (2) 75 x 12 mm galvanised steel flats connected to Purchasr’s grounding mat.

3.8 Cooling Equipment

3.8.1 Oil immersed with natural cooling (ONAN)

3.8.1.1 The radiator bank of the shunt reactor shall be separately mounted.
3.8.1.2 Radiators shall be made from pressed steel.
3.8.1.3 Each radiator bank shall be provided with the following accessories:

(a) Top and bottom shut off valve

(b) Drain Valve and sampling valve
(c) Air release plug
(d) Two grounding terminals for termination of two (2) Nos. 75x12 mm galvanised steel flats.
(e) Thermometer pockets with captive screw caps at cooler inlet and outlet.
(f) Lifting lugs

3.8.1.4 Each radiator bank shall be detachable and shall be provided with flanged inlet and outlet
branches.

3.8.1.5 Expansion joint, if required, shall be provided on top and bottom cooler pipe connection.

15
3.8.2 Valves

3.8.2.1 All valves upto and including 100 mm shall be of gun metal or of cast steel/ cast iron. Larger
valves may be of gun metal or may have cast iron bodies. They shall be of full way type with
internal screw and shall open when turned counter clock wise when facing the hand wheel.

3.8.2.2 Suitable means shall be provided for locking the valves in the open and close positions. Provision
is not required for locking individual radiator valves.

3.8.2.3 Each valve shall be provided with the indicator to show clearly the position of the valve.

3.8.2.4 All valve flanges shall have machined faces.

3.8.2.5 All valves in oil line shall be suitable for continuous operation with shunt reactor oil at 115°C.

3.8.2.6 Gland packing/gasket material shall be of teflon rope/nitrile rubber. In case of gate/globe valves,
gland packing preferably of teflon rope shall be used to prevent oil seepage through the gland.

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

3.8.2.8 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 & size of the same shall be
finalised during detailed engineering stage.

3.8.2.9 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. Outside surface of the valves shall be painted with two
coats of red oxide zinc chromate primer followed by two coats of fully glossy finishing paint
conforming to IS:2932. Outside surface except gasket seating 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.

3.8.2.10 All hardware used shall be cadmium plated/electro-galvanised.

3.8.2.11 For estimation purpose of spares one set of valves mean one valve of each type used in Reactor

3.9 Marshalling Box

3.9.1 A sheet steel marshalling box of a suitable construction shall be provided for the reactor ancilliary
apparatus and this shall be vermin, dust & weather proof. All the terminals for remote indication
shall be wired upto the marshalling box from the reactor accessories. Necessary shorting of CT
secondary terminals shall be done at the marshalling box.

3.9.2 The marshalling box shall be tank mounted type. Suitable anti-vibration pads shall be provided so
that vibration from tank is not transferred to the marshalling box. The marshalling box shall have
sloping roof. It shall have double hinged doors and shall be provided with locking arrangement.
The exterior and interior painting shall be in accordance with painting clause no 3.1.1.8.

3.9.3 All doors, removable covers and plates shall be gasketed all round with neoprene gaskets.
Louvers shall have screens and filters. The screens shall be of fine wire mesh made of brass and
GI wire.

3.9.4 The marshalling box shall accommodate the following :

(a) Temperature indicator for winding and oil,

16
 (b) Terminal blocks and gland plates for incoming and outgoing cables.

3.9.5 The temperature indicator shall be so mounted that the dials are about 1200 mm above ground
level. Glass doors of suitable size shall be provided for convenience of reading. A space heater
and cubicle lighting with ON-OFF switch shall be provided. It shall be so designed that with the
space heater switched on continuously, the temperature inside the marshalling box does not
exceed the safe operating limits at the service conditions.

4.0 Fittings

4.1 The following fittings shall be provided with shunt reactor

4.1.1 Conservator for reactor main tank with filling hole and cap, drain valve, isolating valve, vent pipe
and magnetic oil level gauge with low level alarm contacts.

4.1.2 Air release devices.

4.1.3 Dehydrating breather complete with first fill of activated silicagel.

4.1.4 Inspection openings and covers.

4.1.5 Rating & diagram plate for reactors and current transformers. These plates shall be of material
capable of withstanding continuous outdoor service.

4.1.6 Terminal marking plate conforming to IEC-60076.

4.1.7 Two earthing terminals each on shunt reactor tank, radiators & marshalling box etc.

4.1.8 Ladder to climb up to the reactor tank cover with suitable locking arrangement to prevent climbing
during charged condition.

4.1.9 Double float/reed type Buchholz relay with alarm and trip contacts.

4.1.10 Bottom oil sampling valve and drain valves.

4.1.11 Filter valves at top and bottom.

4.1.12 Shut off valves on the pipe connection between radiator bank and reactor tank.

4.1.13 Shut off valves on both sides of Buchholz relay at accessible height.

4.1.14 Sampling gas collectors for Buchholz relay at accessible height.

4.1.15 Four jacking pads.

4.1.16 Lifting lugs or eyes for the cover.

4.1.17 Suitable terminal connectors on bushings

4.1.18 Under carriage with provision for flanged bidirectional wheels, set of flanged bidirectional wheels,
set of flanged bidirectional rollers/trolley for transportation.

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

17
4.1.20 Pressure relief devices with alarm/trip contacts.

4.1.21 Bushing with metal parts and gaskets to suit the termination arrangement.

4.1.22 Winding temperature indicators for local and remote mounting (only for shunt reactor).

4.1.23 Oil temperature indicator for local and remote mounting.

4.1.24 Protected type mercury or alcohol in glass thermometer.

4.1.25 Marshalling box.

4.1.26 Haulage lugs.

4.1.27 Bushing CT

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

4.1.29 One set of hand tools of reputed make packed in a carry bag/box broadly comprising of double
ended spanners (open jaws, cranked ring, tubular with Tommy bar each of sizes 9mm to 24mm,
one set each), adjustable wrenches (8 &12 inch one set), gasket punches (of different sizes as used
in the reactor one set ), pliers (flat nose, round nose & side cutting one of each type), hammer with
handle (one ), files with handle (two), knife with handle (one), adjustable hacksaw (one), and cold
chisel (one) shall be supplied per Substation.

4.1.30 Suitable galvanized iron tray for cabling on main tank for better aesthetics.

5.0 Inspection and Testing

The Contractor shall carry out a comprehensive inspection and testing programme during
manufacture of the equipment. An indication of inspection envisaged by the Purchaser is given
under Cl.5.1 below. This is however not intended to form a comprehensive programme as it is
Contractor's responsibility to draw up and carry out such a programme in the form of detailed
Quality Plan duly approved by Purchaser for necessary implementation.

5.1 Inspection

5.1.1 Tank and Conservator

5.1.1.1 Certification of chemical analysis and material tests of plates.

5.1.1.2 Checks for flatness
5.1.1.3 Electrical interconnection of top and bottom tank by braided tin flexible
5.1.1.4 Welder's qualification and weld procedure.
5.1.1.5 Testing of electrodes for quality of base materials.
5.1.1.6 Inspection of major weld preparation.
5.1.1.7 Crack detection of major strength weld seams by dye penetration test.
5.1.1.8 Measurement of film thickness of
(a) Oil insoluble varnish
(b) Zinc chromate paint
(c) Light grey paint
5.1.1.9 Check correct dimensions between wheels, demonstrate turning of wheels through 90°C and
further dimensional check.

18
5.1.1.10Check for physical properties of materials for lifting lugs, jacking pads, etc. All load bearing
welds including lifting lug welds shall be subjected to non destructive test (NDT).
5.1.1.11 Leakage test of conservator.
5.1.1.12 Certification of all test results.

5.1.2 Core

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

5.1.2.2 Check on the quality of varnish if used on the stampings.

(a) Measurement of thickness and hardness of varnish on stampings.

(b) Solvent resistance test to check that varnish does not react in hot oil.
(c) Check over-all quality of varnish on stamping, ensure uniform shining colour, no bare
spots, no over burnt varnish layer and no bubbles on varnished surface.

5.1.2.3 Check on the amount of burrs.

5.1.2.4 Bow check on stampings.
5.1.2.5 Check for the overlapping stampings. Corners of the sheets are to be apart.
5.1.2.6 Visual and dimensional check during assembly stage.
5.1.2.7 Check for inter-laminar insulation between core sections after pressing.
5.1.2.8 Visual and dimensional check for straightness and roundness of core.
5.1.2.9 High voltage test (2 kV for one minute) between core and clamps.
5.1.2.10 Check of pressure during dimensional stabilisation of winding/core assembly.
5.1.2.11 Certification of all test results.

5.1.3 Insulation Material

5.1.3.1 Sample check for physical properties of material.

5.1.3.2 Check for dielectric strength.
5.1.3.3 Visual and dimensional checks.
5.1.3.4 Check for the reaction of hot oil on insulating materials.
5.1.3.5 Dimensions stability test at high temperature for insulating material.
5.1.3.6 Tracking resistance test on insulating material.
5.1.3.7 Certification of all test results.

5.1.4 Winding

5.1.4.1 Sample check on winding conductor for mechanical properties and electrical conductivity.
5.1.4.2 Visual dimensional checks on conductor for scratches, dent marks etc.
5.1.4.3 Sample check on insulating paper for pH value, electric strength.
5.1.4.4 Check for the reaction of hot oil on insulating paper.
5.1.4.5 Check for the bonding of the insulating paper on conductor.
5.1.4.6 Check and ensure that physical condition of all materials taken for winding is satisfactory and
free of dust.
5.1.4.7 Check for absence of short circuit between parallel strands.
5.1.4.8 Check for brazed joints wherever applicable.
5.1.4.9 Measurement of impedance by low voltage to be carried out when core/yoke is completely
restacked and all connections are ready.
5.1.4.10 Conductor-enamel test for checking of cracks, leakage and pin holes.
5.1.4.11 Conductor flexibility test.
5.1.4.12 Heat shrink test for enamelled wire.
5.1.4.13 Certification of all test results.

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5.1.5 Checks before drying process

5.1.5.1 Check conditions of insulation on the conductor and between the windings.
5.1.5.2 Check insulation distance between high voltage connection cables and earth and other live parts.
5.1.5.3 Check insulation distance between low voltage connections and earth and other parts.
5.1.5.4 Insulation of core shall be tested at 2 kV/minute between core to bolts and core to clamp plates.
5.1.5.5 Check for proper cleanliness and absence of dust etc.
5.1.5.6 Certification of all test results.

5.1.6 Checks during drying process

5.1.6.1 Measurement and recording of temperature, vacuum and drying time during vacuum treatment.
5.1.6.2 Check for completeness of drying by measuring IR and tan delta.
5.1.6.3 Certification of all test results.

5.1.7 Assembled Reactor

5.1.7.1 Check completed reactor against approved out line drawing provision for all fittings, finish level
etc.
5.1.7.2 Jacking test on all the assembled reactors.
5.1.7.3 Dye penetration test shall be carried out after Jacking tests.

5.1.8 Bought Out Items

All major bought items, such as Bushing etc. shall have satisfactory performance for a
period of five (5) years. The make of all bought out items shall be subject to Purchaser’s
approval.

5.1.8.1 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.

(a) Buchholz relay

(b) Axles and wheels/Trolley for transportation.
(c) Winding temperature indicators for local and remote mounting
(d) Oil temperature indicators for local and remote mounting
(e) Bushings
(f) Bushing current transformer
(g) Marshalling box
(h) Radiators
(i) Pressure relief device
The above list is not exhaustive and the Contractor shall also include all other bought out items in
his programme.

5.2 Factory Tests

The manufacturer shall be fully equipped to perform all the required tests as specified. Bidder
shall confirm the capabilities of the proposed manufacturing plant in this regard when submitting
the bid. Any limitations shall be clearly stated.

The contractor shall bear all additional costs related to tests which are not possible to carry out at
his own works.
The contractor shall submit an Inspection and test plan (ITP) for approval. A typical test plan is
indicated below.

20
 No Item Test First Other
Category unit * units
1. Measurement of winding resistance Routine √ √
2. Reactance and loss measurement Routine √H/C √C
3. Measurement of harmonic content of current Type √C NA
4. Temperature rise test Type √ NA
5. Measurement of insulation resistance Routine √ √
6. Measurement of insulation power factor and Routine √ √
capacitance between winding and earth
7. Lightning impulse test with chopped on tail on Routine √ √
all 3 windings.
8. Switching impulse test Routine √ √
9. Separate source voltage withstand test Routine √ √
10. Induced overvoltage test with Partial Discharge Routine √ √
measurement
11. Measurement of Acoustic noise level Type √H/C NA
12. Vibration and stress measurement Routine √H/C √C
13. Gas in oil analysis Routine √ √
14 Appearance, construction and dimension check Routine √ √
15 Core assembly dielectric and earthing continuity Routine √ √
16 test
Tank Vacuum test Routine √ √
17 Tank Pressure test Routine √ √
18 Knee point voltage measurement of Reactor Type √C NA
19 Frequency Response analysis Routine √ √
20 High voltage withstand test on Auxiliary Routine √ √
equipment and wiring after assembly
21 Oil leakage on assembled Reactor Routine √ √

H/C Measured in cold and hot state of temperature rise test

C Measured in cold state
* Means the first unit manufactured against the LOA at each manufacturing plant

5.2.1 Routine tests on Shunt Reactor

All the routine tests listed in IEC-60289/IS-5553 (part-I) shall be carried out on each
reactor and complete test report shall be submitted to purchaser after proper scrutiny and
signing on each page by the test engineer of the contractor.

5.2.1.1 Switching impulse on line terminals.

5.2.1.2 Partial discharge measurement test (As per IS: 2026/IEC 60076).

Acceptance criteria

Partial discharge (PD) levels measured at the end of the 60 minute test period shall not
exceed 100pC or show any rising tendency in the last 15 minutes of more than 5%. Gas

21
 evolution of DGA before and after PD test shall be interpreted in line with IEC/Cigre
guidelines.

5.2.1.3 Oil leakage test on reactor tank

All tanks and oil filled compartments shall be completely filled with air or oil of a
viscosity not greater than that of insulating oil conforming to IS:335 at the ambient
temperature and subjected to a pressure equal to normal tank pressure plus 35 kN/sq.m (5
psi) measured at the base of the tank. This pressure shall be maintained for a period of not less
than 12 hours for oil and 1 hour for air during which no leakage shall occur.

5.2.1.4 Lightning impulse voltage withstand test as per relevant IEC (on all phases).

5.2.1.5 Vibration and stress measurement test.

5.2.1.6 Frequency Response Analysis (FRA).

5.2.1.7 Loss and current measurements

The load losses and load current of every reactor shall be measured as specified in
IEC60076/ IEC 60289. Measurements shall be also made with maximum flux conditions in
the magnetic circuit. In each case the measurement shall be made at 0.90pu, 1.00pu &
1.10pu.

The following details shall be recorded and submitted with the test certificates

• The voltage readings

• The mode of response and scaling of the voltmeters
• The current reading
• The power reading
• The frequency reading
• The instrument constants and corrections
• Correction made to power and current result, due to non sinusoidal wave form of voltage
and current
• The magnetisation curve of the reactor

5.2.1.8 Core assembly dielectric and earthing continuity tests

The insulation of the magnetic circuit, and between the magnetic circuit and the core
clamping structure, including core-bolts, bands and/or buckles shall withstand the
application of a test voltage of either 2kV AC or 3kV DC for 60 seconds.

5.2.1.9 Reactance and loss measurement

• The type tested unit shall be measured in cold and hot state.
• In other units, measurement shall be carried out in the cold sate and corrected as per
factors derived from type test.

5.2.1.10 Tank Tests

5.2.1.10.1 Vacuum Tests

22
 Shunt reactor tank 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 plates after the vacuum has been released shall not
exceed the values specified below:

Horizontal length of flat plate (in mm) Permanent deflection (in mm)
Upto and including 750 5.0
751 to 1250 6.5
1251 to 1750 8.0
1751 to 2000 9.5
2001 to 2250 11.0
2251 to 2500 12.5
2501 to 3000 16.0
above 3000 19.0

5.2.1.10.2 Pressure Test

Shunt reactor tank of each size, its radiator, conservator vessel and other fittings together or
separately shall be subjected to an air pressure corresponding to twice the normal head of
oil or normal pressure plus 35KN/sq.m whichever is lower, measured at the base of the
tank and maintained for one hour. The permanent deflection of the flat plate after the
excess pressure has been released shall not exceed the figures specified above for vacuum
test.

5.2.1.11 Measurement of capacitance and tan delta to determine capacitance between winding and
earth. Tan delta value shall not be more than 0.5% corrected at 20°C. Temperature
correction factor table shall be given by the Contractor and shall form the part of test results.

5.2.2 Routine tests on bushings as per IEC 60137.

5.2.3 Type tests on Shunt Reactor

Type test shall be carried out on first shunt reactor of each lot ordered on firm
manufactured at each manufacturing plant (if applicable) All type & routine tests shall be
carried out without any extra cost of purchase.

5.2.3.1 Temperature rise test (As per IEC-60289). Gas chromatographic analysis test on oil shall be
conducted before and after this test. The sampling shall be in accordance with IEC-60567.
For the evaluation of the gas analysis in temperature rise test, the procedure shall be as per IS:
9434 (based on IEC: 60567) and results interpreted as IS: 10593 (based on IEC-
60599)/CIGRE guidelines.

The test shall be done for a minimum of 24 hours with saturated temperature for at least 4
hours.

5.2.3.2 Measurement of zero-sequence reactance-As per IS: 2026 for 3-phase shunt reactor only.

5.2.3.3 Measurement of acoustic noise level-As per IS: 2026/ IEC 60076.

5.2.3.4 Lighting impulse test on neutral –As per IS: 2026/ IEC 60076.

5.2.3.5 Measurement of knee point voltage.

5.2.3.6 Degree of protection test on marshalling box as per IP-55 in accordance with IS: 13947.

23
 5.2.4 Type test 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. The list of fittings and
the type test requirement is:

1. Bushing (Type Test as per IS: 2099/ IEC: 60137, including snap ack test)
2. Buchholz relay (Type Test as per IS: 3637 and IP-55 Test on terminal box)
3. Control cabinet (IP-55 test)
4. 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 reactor tank pressure test at Cl.
No. 5.2.1.10 2. 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.
5. Magnetic Oil Level gauge & Terminal Box for IP-55 degree of protection.
6. 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.
7. OTI & WTI – Switch setting & operation, switch differential, switch rating.

5.2.5 Pre-Shipment Checks at Manufacturer's Works

5.2.5.1 Check for inter-changeability of components of similar reactors for mounting dimensions.
5.2.5.2 Check for proper packing and preservation of accessories like radiators, bushings,
dehydrating breather, rollers, buchholz relay, marshalling kiosk, connecting pipes,
conservator etc.
5.2.5.3 Check for proper provision for bracing to arrest the movement of core and winding
assembly inside the tank.
5.2.5.4 Gas tightness test to confirm tightness.
5.2.5.5 Derivation of leakage rate and ensure the adequate reserve gas capacity.
5.2.5.6 Measure and record the dew point of nitrogen in the main tank before despatch.

6.0 Supervision Services:

6.1 The bidder shall be responsible for the supervision of all the erection, testing and commissioning
of the supplied equipments at various sub-stations by the successful bidders under various 220 kV
sub-station / bay packages.

6.2 The bidder shall depute his expert engineer(s) alongwith technicians (if required) etc. for
supervision at each stage i.e. erection, pre-commissioning testing and commissioning of supplied
equipments. They shall bring any special testing equipment, tools & tackles (as required for these
ETC activities of supplied equipments / items.

6.3 The bidder shall submit the detailed stepwise / activity wise procedure for receipt & storage
inspections, erection, site testings and commissioning of supplied material / items for the approval
of the purchaser. The same shall be handed over to the successful bidders of 220 kV sub-station /
bay packages for reference and implementation.

6.4 The purchaser, in consultation with the other contractor, shall approve the detailed schedule /
program for various ETC activities at various sub-stations. The bidder shall be responsible for

24
 deputing his expert engineer (s) as per the approved schedule.

6.5 The bidder shall submit (well in advance to approved schedule) list of the various installation and
testing equipments, tools / tackles, consumables etc. which are to be arranged by the successful
bidder (s) of 220 kV Sub-station / bay packages and to be utilised during various activities / steps
of erection, testing and commissioning. The bidder shall also indicate any special testing
equipment (such as FRA etc.), tools / tackles, consumables etc. which shall be bought by him for
any specialized testing.

6.6 The bidder shall supervise each activity / step as per the approved procedure / schedule by the
purchaser and guide / suggest the other contractor’s engineer (s) for safe handling, correctness
and methods to be adopted as per standard manufacturer practices.

6.7 The joint report shall be prepared for the successful erection and pre-commissioning test by
bidder and the contractor of the other 220 kV Sub-station / bay package for submission to the
consignee (s) / In-charge (s) of these projects.

6.8 The sample inspection and site testing procedure / programme is given below which is only for
the reference and the successful bidder shall submit elaborated activity / step wise procedure /
program as mentioned above for the purchasers approval.

Sample Inspection and Site Testing Procedure / Program:

The Contractor shall carry out a detailed inspection and testing programme for field activities,
namely covering areas right from the receipt of material stage upto commissioning stage. A
detailed programme of inspection will be available by the contractor to the Employer a t the
respective sites. However, it is Contractor's responsibility to draw up and carry out such
a programme duly approved by the Purchaser. Testing of oil sample at site shall be carried
out as per Cl.3.4 above.

6.8.1 Receipt and Storage Checks

6.8.1.1 Check and record condition of each package, visible part of the reactors etc. for any
damage.
6.8.1.2 Check and record the gas pressure in the reactor tank as well as in the cylinder.
6.8.1.3 Visual check for wedging of core and coils before filling up with oil and also check for
condition of core and winding in general.
6.8.1.4 Check and record reading of impact recorders at receipt and verify the allowable limits as
per manufacturer's recommendation.

6.8.2 Installation Checks

6.8.2.1 Check the whole assembly for tightness, general appearance etc.
6.8.2.2 Oil leakage test
6.8.2.3.Visual check for Leakage on bushing before erection.
6.8.2.4 Measurement of capacitance and tan delta of the bushings before fixing/connecting to the
reactor. Contractor shall furnish these values for site reference.
6.8.2.5 Measure and record the dew point of nitrogen in the main tank before assembly.
manufacturer shall submit dew point acceptable limits along with temperature correction
factor and shall for part of instruction manual. In case dew point values are not within
permissible limit suitable drying out process shall be applied for dry out of active part in
consultation with the Manufacturer.

25
 6.8.3 Commissioning Checks
6.8.3.1 Check the colour of silicagel breather.
6.8.3.2 Check the oil level in the breather housing, conservator tank, cooling system, condenser
bushing etc.
6.8.3.3 Check the bushings for conformity of connection to the line etc.
6.8.3.4 Check for correct operation of all protection devices and alarms.

(a) Buchholz relay

(b) Excessive winding temperature
(c) Excessive oil temperature
(d) Low oil flow
(e) Low oil level indication

6.8.3.5 Check for adequate protection of electric circuit supplying the accessories.
6.8.3.6 Insulation resistance measurement for :

(a) Control wiring

(b) Main winding
(c) Bushing current transformer

6.8.3.7 2 kV/minute test between bushing CT terminal and earth.

6.8.3.8 Check for cleanliness of the reactor and the surrounding.
6.8.3.9 Measure vibration and noise level
6.8.3.10 DGA of oil sample just before commissioning and after 24 hours of commissioning.
6.8.3.11 Capacitance and tan delta measurement of winding & bushing.
6.8.3.12 Frequency Response Analysis (FRA).FRA equipments shall be arranged by the Purchaser.
6.8.3.13 Contractor shall prepare a comprehensive commissioning report including all commissioning
test results and forward to Purchaser for future record.

6.9 The bidders engineer (s) shall witness final commissioning of the supplied equipment / items and
prepare joint report of commissioning of these equipments / items to be signed by bidder’s
engineer, other 220 kV Sub-station / bay package contractor and consignee / in-charge of RVPN
for project for their successful ETC. This joint report shall be taking over certificate for these
equipments / items. The consignee shall report any recoveries/ deficiencies to be affected from
bidder under this contract before issue of this taking over certificate.

7.0 Technical Parameters

The parameters pertaining to the shunt reactor furnished under this specification are listed
below:
7.1 Shunt Reactor 25 MVAR

7.1.1 Rated Voltage 245 kV(1.0pu)

7.1.2 System Fault level 40 KA

7.1.3 Connection Star with neutral brought out

7.1.4 Insulation level (for winding)

(a) Lightning impulse 1.2/50 µ Sec withstand voltage 950 kVp

(b) Switching surge impulse20/200/500 µ Sec withstand voltage 750 kVp

26
7.1.5 Maximum temp rise over an ambient temp of 50°C and at 245 kV voltage class

a) of winding measured by resistance method 45°C

b) of top oil measured thermometer 40°C
c) The temperature of the hottest spot shall be as per relevant standards.

7.1.6 Cooling System Natural Oil circulation (ONAN)

7.1.7 Insulation level of neutral

(a) Impulse withstand voltage 170 kVp
(b) Power frequency voltage 70 kV rms
(c) Whether neutral is to be brought out Yes (through 36 kV class oil filled
condenser bushings)

7.1.8 Ratio of zero sequence reactance Between 0.9 & 1.0

to positive reactance (X0/X1)

7.1.9 Range of constant impedance Up to 1.4 p.u. voltage (the bidder shall
furnish complete saturation characteristics
of the Reactors upto 2.5 p.u. Voltage)

7.1.10 Tolerance on current 0 to +5% of rated current

7.1.11 Harmonic content in phase current The crest value of third harmonic
component in phase current not to exceed
3% of the crest value of fundamental when
reactor is energized at rated voltage with
sinusoidal wave form.
7.1.12 Permissible current unbalance among - ±2% of the average value
different phases.

7.1.13 Minimum clearance in air

Rated voltage Phase to phase Phase to ground

245 kV 2350 mm 2150 mm
36 kV 350 mm 320 mm

7.1.14 Noise level at rated voltage and frequency : 75 dB

7.1.15 Bushing (for 220 kV class Reactor)

S. No. Particulars Line side Neutral side

(a) Rated voltage 245 kV 36 kV
(b) Creepage distance (total) 25 mm/kV 25 mm/kV
(c) Mounting Tank cover Tank cover
(d) 1.2/50 µSec. Lightning impulse 1050 170
withstand voltage (kVp)
(e) Switching impulse (250/2500 750 -
µSec.) withstand voltage (kVp)
(f) One minute power frequency 505 kV rms 77 kV rms
with stand voltage (kV rms)
(g) Rated current (A) 800 800

27
 7.1.16 Vibration and stress level Not more than 200 microns peak to peak
at rated voltage and Average vibrations shall not exceed 60
frequency microns peak to peak. Tank stresses shall not exceed
2.0kg/sq.mm at any point on the tank.
Note: All the live part to ground clearance shall be as per CBIP manual/relevant IS/IEC.

8.0 Bushing Current Transformer

8.1 Current transformers shall comply with IS: 2705/IEC-60185.

8.2 It shall be possible to remove the turret mounted current transformers from the reactor tank
without removing the tank cover. Necessary precautions shall be taken to minimize eddy
currents and local heat generated in the turret.

8.3 Current transformer secondary leads shall be brought out to a weather proof terminal box near
each bushing. These terminals shall be wired out to cooler control cabinet/ marshalling box
using separate cables for each core.

8.4 Bushing Current transformer parameters indicated in this specification are tentative and
liable to change within reasonable limits. The Contractor shall obtain Purchaser's approval
before proceeding with the design of bushing current transformers.

8.5 Technical Parameters

8.5.1 Current Transformer Parameter for 220 kV Shunt Reactor (on each phase connection)

8.5.1.1 Ratio

Line Side Neutral side

Core 1 200/1A 200/1A

Core 2 200/1A 1500-1200-600/1A

Core 3 200/1A 1500-1200-600/1A

Core 4 200/1A Suitable for WTI

8.5.1.2 Minimum knee point voltage or burden and accuracy class : The accuracy class of WTI
CT shall be one or better.

Line Side Neutral side

Core 1 ≥200 V Class PS ≥200 V Class PS
Core 2 ≥200 V Class PS Suitable for WTI being supplied
Core 3 ≥200 V Class PS 1000-500 -250 V Class
Core 4 10 VA Class 1.0 1000-500 -250 V Class

8.5.1.3 Maximum CT Resistance

Line Side Neutral side

Core 1 1 ohm 1 ohm

28
 Core 2 1 ohm --
Core 3 1 ohm 10-5-2.5 ohm
Core 4 -- -do-

8.5.1.4 Application

Line Side Neutral side

Core 1 Reactor Differential Reactor Differential

Core 2 Restricted Earth fault (REF) Temp. indicator

(On one phase only)
Core 3 Reactor Backup Line Protection
(Main-I)/ Tzone
differential
Protn./spare
Line Protection
Core 4 Metering (Main-II)/ Tzone
differential
Protn./spare

8.6 Note :

8.6.1 The secondary excitation current of class PS shall not be more than 4% of rated
secondary current at 25% of knee point voltage.
8.6.2 Accuracy class PS as per IS: 2705.
8.6.3 Class (for the relevant protection and duties) as per IEC 60185.
8.6.4 CT characteristics shall be subject to the purchaser's approval.
8.6.5 Any change in the parameters of CT required at the time of detailed engineering will have to
be incorporated without any extra cost.

9.0 NITROGEN INJECTION FIRE PREVENTION & EXTINGUISHING SYSTEM:

9.1. INTENT OF SPECIFICATION:

i. It is not the intent to completely specify all details of design and construction.
Nevertheless, the system design and equipment shall conform in all respect to high
standard of engineering, design and workmanship and shall be capable of
performing in continuous commercial operation in a manner acceptable to the
owner. The system design shall also confirm to TAC/ NFPA norms.
ii. The scope of work includes complete supply, erection, testing & commissioning of
fire protection system wherever it is required.
iii. Bidders have to quote unit F.O.R. Destination prices for supply, erection, testing &
commissioning of Nitrogen Injection Fire Prevention & Extinguishing System. The
cost of this system shall be included while working out the comparative offer.

9.2. GENERAL:
Provision of inbuilt Complete Nitrogen Injection Fire Prevention cum Extinguishing
System.

29
 Nitrogen Injection System for the Protection of Bus Reactor against fire due to an
arc, during internal faults and external fires is required to be provided with the Bus
Reactor for preventing tank explosion.

9.3. The system should comprise the following:-

i. Fire Extinguishing Cubicle with base frame and containing oil drain assembly,
nitrogen cylinder, electric mechanical control unit for oil drain and nitrogen release
detections necessary for monitoring system, flanges on top panel for connecting pipe
connections from Bus Reactor, panel lighting etc.
ii. Control Box for monitoring system operation, automatic control and remote
operation with alarms, indication light switches, push buttons, audio signal, suitable
for tripping and signaling on 110/220V DC supply.
iii. Pre-stressed non-return valve (PNRV) working on transformer oil flow rate with
proximity switch for remote alarm indication and with visual position indicator.
iv. Required number of fire detectors rated for 141º C for heat sensing, each fitted with
two number cable glands.
v. Signal box for terminating cable connections from PNRV and fire detectors.
vi. Pressure relief valve with limit switch.

9.4. The following arrangements are required to be made on the Bus Reactor Tank at
the time of fabrication of the tank:

1. 2 Nos. Oil drain opening with pipe, flange and manual gate value at about
120mm below the top cover.
2. Nitrogen injection openings with suitable size of pipe with flange and manual
gate valve on tank sides at about 50-200 mm from the bottom plate.
3. Flanges on the conservator pipe between Buchholz relay and conservator tank
for fixing PNRV.
4. Supply and welding of the fire detector brackets on top cover.
5. Supply and welding of the brackets for fixing signal box at a suitable location on
top cover or tank side wall.

The supplier is required to make necessary arrangements during fabrication

of tank for incorporating provision of NIFPES.

All the civil works such as construction of plinth oil pit below the Bus Reactor
shall be in bidder’s scope. All the detailed drawing and design for the same shall
be furnished by the supplier.

9.5. ACTIVATION OF NIFPES.

(1) Mal-functioning of fire prevention/ extinguishing system is their major

shortcoming which leads to interruption in power supply. The bidders shall
ensure that the chances of malfunctioning of NIFPES are practically NIL. To
achieve this objective, the supplier shall work out his scheme of activating
signals which, while preventing mal-operation, should not be to rigorous to
make the operation of NIFPES impracticable in case of actual need. Bus
Reactor isolation shall be mandatory pre-requisite for activation of the system in
Automatic mode or Remote mode in the control room/SAS SCADA of
substation. In addition, at least following electrical– signals shall be provided in
series for activating NIFPES.

30
 (2) Auto Mode

a) For prevention of Fire :

i) Differential Relay operation.
ii) Buchholz Relay parallel with Pressure Relief Valve.
iii)Tripping of all concerned breakers is a pre-requisite for initiation of system
activation.
b) For Extinguishing Fire:
i) Fire Detector.
ii) Buchholz Relay paralleled with Pressure Relief Valve.
iii) Tripping of all connected breakers is a pre-requisite for initiation of system
activation.

(3) Manual Mode (Local/Remote)/SAS SCADA Mode:

Tripping of all connected breakers is a pre-requisite for initiation of system

activation.

(4) Manual Mode (Mechanical):

Tripping of all connected breakers is a pre-requisite for initiation of system
activation.

9.6. General Description of NIFPES.

(1) Schematic of the System.

NIFPES should be a standalone dedicated system for oil filled Bus Reactor. It
should have a Fire Extinguishing (FE) cubicle placed on a plinth at a distance of
6 to 10 meter from the Bus Reactor. The F.E. cubicle may be connected to the
Bus Reactor oil tank (near its top) and to the oil pit from its bottom through oil
pipes with gate valves. The F.E cubicle should house a pressurized nitrogen
cylinder connected to the Bus Reactor oil tank (near its bottom). Cable
connections are to be provided from signal box placed on the Bus Reactor to
the control box in the control room and from control box to F.E cubicle. Fire
detectors placed at the top of Bus Reactor are to be connected in parallel to the
signal box. The signal box may be connected to a pre-stressed non-return valve
fitted between the conservator tank and Buchholz relay. Control box is also be
connected to relay panel in control room/SAS SCADA of substation for system
activation signals.

(2) Operation.

On receipt of all activating signals, drain of pre-determined quantity of oil

commences thus removing high temp. top oil layer. Simultaneously nitrogen is
injected under high pressure at a pre-fixed rate, string the oil thus bringing the
temperature of top oil layer down. Nitrogen occupies the spaces created by oil
drained out and acts as an insulating layer between the tank oil & fire on top
cover. Pre-stressed non return valve blocks oil flow form conservator tank, thus
isolating it & preventing aggravation of fire.

(3) System Components.

31
 Broadly, NIFPES shall consist of the following components. It is emphasized
that all components irrespective of their exclusion in the details given below,
necessary for fast reliable & effective working of NIFPES shall be considered
with the scope of supply.

(4) Fire Extinguishing Cubicle.

It shall be made of 3mm thick steel sheet, painted dark red from inside &
outside with hinged split doors fitted with high quality tamper proof lock. It
shall be complete with the base frame and the following:

 Nitrogen gas cylinder with regulator and falling pressure electrical contact
manometer.
 Oil drain pipe with mechanical quick drain valve.
 Electro mechanical control equipment for oil drain and pre-determined regulated
nitrogen release.
 Pressure monitoring switch for back-up protection for nitrogen release.
 Limit switches for monitoring of the system.
 Flanges on top panel for connecting oil drain and nitrogen injection pipes for
Bus Reactor.
 Panel lighting (CFL/LED Type)
 Oil drain pipe extension of suitable sizes for connecting pipes to oil pit. The
pipe inside the FEC shall have oil leakage detection arrangement for
detecting oil leakage from drain valve.
 Provision for alarm should also be provided on detection of oil leakage from
oil drain valve, inside the oil collection compartment.

9.7. Control Box.

Control Box for monitoring system operation, automatic control and remote
operation alongwith SAS/SCADA (if required) with following alarms
indication, light switches, push buttons, audio signal, line fault detection
suitable for tripping and signaling on 110/220V DC supply.

 Lamp test.
 Visual / audio Alarm.
 System on *.
 PNRV open*.
 Oil drain valve closed*.
 Gas inlet valve closed*.
 PNRV closed^.
 Fire detector Trip^.
 Buchholz Relay Trip^.
 Oil drain valve open^.
 Extinction in pressure^.
 Cylinder pressure low^.
 Differential relay trip^.
 PRV trip^.
 Bus Reactor trip^.
 System out of service.
 Line fault free detector.
 Line fault differential relay.
 Line fault Buchholz relay.
 Line fault PRV.

32
  Line fault Bus Reactor trip.
 Line fault PNRV.
 Auto / Manual / Off.
 Extinction release on.
 Extinction release off.
 Visual /Audio alarm for DC supply fail.
 Alarm/facia for Leakage from oil drain valve.

The signals marked (*) shall be in the topmost row of control box panel. The
signals (^) shall follow next and thereon.

9.8. Pre-stressed Non Return Valve (PNRV).

PNRV is to be fitted in the conservator pipe line between conservator &

Buchholz relay. It shall have the proximity switch for remote alarm, indication
and with visual position indicator. The PNRV should be of the best quality
because malfunction of PNRV shall be of serious consequences as its closing
leads to stoppage of breathing of Bus Reactor.

9.9 Fire Detectors.

The system shall be complete with adequate number of fire detectors fitted on
the top of oil tank, OLTC /Off ckt. Tap changer rated for 141ºC for heat sensing
each fitted with two no. cable glands (water proof / weather proof).

9.10 Signal Box.

It shall be fitted on the Bus Reactor for terminating cable connections from
PNRV & fire detectors and for further connection to the control box.

9.11 Cables.
Fire survival multi strand cables, able to withstand 750ºC, 4 core x 1.5mm sq.
for connection of fire detectors in parallel shall be used. Fire retardant low
smoke (FRLS) cable 12 core x 1.5mm sq. for connection between Bus Reactor
signal box / marshaling box to control box and control box to fire extinguishing
cubicle shall be used.

Fire retardant low smoke (FRLS) cable 4 core x 1.5mm sq. for connection
between control box to DC supply source and fire extinguishing cubicle to AC
supply source, signal box marshaling box to pre-stressed non return valve
connection on Bus Reactor shall be used.
(All control cables shall be multi-strand cable)

9.12 Pipes.
Pipes, complete with connections, flanges, bends and tees etc. shall be supplied
along with the system.

9.13 Other Items

a) Oil drain and nitrogen injection openings with gate valves on Bus Reactor tank
at suitable locations.
b) Flanges with dummy piece in conservator pipe between Buchholz relay and
conservator tank for fixing PNRV.
c) Fire detector brackets on Bus Reactor top cover.
d) Spare potential free contacts for system activating signals i.e. differential relay,
Buchholz relay, pressure relief valve, Bus Reactor isolation (master trip relay).

33
 e) Pipe connection between Bus Reactor to fire extinguishing cubicle and fire
extinguishing cubicle to oil pit.
f) Cabling on Bus Reactor top cover for fire detectors to be connected in parallel
and inter cabling between signal box to control box and control box to fire
extinguishing cubicle.
g) Gate valves on oil drain pipe & nitrogen injection pipe should be able to
withstand full vacuum. A non-return valve shall also be fitted on nitrogen
injection pipe between Bus Reactor & gate valve.
h) The F.E cubicle shall be painted with post office red colour (Shade 538 of IS-5).
All the exposed parts i.e. pipes, supports, signal box etc. shall also be painted
with enameled paint as above.

9.14. Mandatory spares.

For each NIFPE System.

1 No. filled nitrogen cylinder (68 liter water capacity).
3 no. fire detectors.

9.15. Interlocks.

It shall be ensured that once the NIFPES gets activated manually or in auto mode,
all the connected breakers shall not close until the system is actually put in OFF
mode. Also PNRV shall get closed only if all the connected breakers are open.

9.16. Scope of work.

a) The scope includes supply, erection & commissioning of suitable capacity

NIFPES for protection of Bus Reactor as specified.
b) Required lengths of various pipes & cables including civil works.
c) The design of NIFPES to ensure that it does not interfere with general
maintenance / other activities carried on the Bus Reactor & in the substation and
provision of NIFPES on remaining Bus Reactor at the substation.

9.17. Technical Particulars.

Fire Extinction period.

On commencement of Nitrogen : Maximum 30 seconds.

Injection

From the moment of system : Maximum 3 minutes

activation to Complete cooling.
Fire detectors heat sensing : 141ºC
temperature

Heating sensing area : 800 mm radius.

Pre-stressed on return valve for Minimum 60 ltr. Per Minute (as per
setting requirement of Bus Reactor).

Capacity of Nitrogen cylinder : Minimum 68 liter water capacity and shall hold
minimum 10 cubic Meter gas at 150 bar pressure (as
per requirement of Bus Reactor).

34
 Power source. : 110/220 Volt DC

Control Box Fire Extinguishing : 230 Volt AC

cubical for lighting

The supplier shall furnish three copies of erection, operation & maintenance
manual clearly incorporating the following, in addition to others as required:-

a) The maintenance and testing schedule of NIFPES.

b) All the steps required to be undertaken for restarting the Bus Reactor and
connected equipment after operation and mal-operation (if any) of the NIFPES.
c) The process of venting nitrogen in case nitrogen pressure in the cylinder exceeds
the stipulated maximum value.

9.18. Codes and Standards:

The design and installation of complete fire protection system shall comply with
the latest applicable Indian standards / codes.

9.19. Tests.

Type Tests

The test reports including that for detectors along with declared response time as
per TAC’s letter shall be submitted along with the drawings for approval.

Certificates of the test on the system carried out by national / international

testing bodies and TAC’s approval, if any, shall also be submitted with the
drawings for approval.

Factory Test

Tests will be carried out on individual equipment of the system, as applicable

and the total system in the supplier’s workshop in presence of purchaser’s
representative.

Performance Test:
Performance test of the complete system shall be carried out after complete
erection at site by the supplier representative. These tests shall include
simulation and verification of the response of the complete system without
injection of the Nitrogen gas.

Drawing and Manuals:

Detailed layout drawings along with the equipment drawing & control circuit
drawing shall be given by the supplier along with complete bill of material.
After awarding of contract detailed dimensional drawing of the system
complete bill of material shall be submitted for approval.

35
 DOCUMENTATION:

All drawings shall conform to International standards Organization (ISO). All

dimension and data shall be in system International units. Supplier shall submit
four sets of following drawings:
a. A detailed write up on operation of the offered protection system also describing
it’s effectiveness for quenching fire in an oil filled power Bus Reactor.
b. General outline drawing of the complete system with technical parameters.
c. Drawing showing clearances from ground and other live points of Bus Reactor
and system.
d. The drawing showing the details of detectors to be provided on Bus Reactor.
e. Drawing indicating the details of fire alarm control panel.
f. Mounting details/Installation and commissioning instruction of system
equipment.
g. The manufacturing of the equipment shall be strictly in accordance with the
approved drawings and no deviation shall be permitted without the written
approval of the purchaser. All manufacturing and fabrication work in connection
with the equipment prior to the approval of drawing shall be at the supplier’s
risk.

h. Approval of drawings by the purchaser shall not relieve the supplier from
responsibility and liability for ensuring correctness and correct interpretation of
the drawings for meeting the requirement of the latest revision of applicable
standards, rule and codes of practices and effective performance of the system.
The purchaser shall have the power to reject any work or material which in his
judgment is not in accordance therewith.

NOTE:-

1. Bidders have to quote unit prices separately for supply, erection, testing and
commissioning of nitrogen injection fire prevention and extinguishing system in
the financial bid (Cover-III). The cost of this system shall be included while
working out the comparative offer. The Nitrogen Injection Fire Prevention and
Extinguishing System should have the following:

2. The Nitrogen Injection Fire Prevention and Extinguishing system shall be

suitable to operate on 220V/110VDC which is normally available at GSS in our
system.

3. One additional oil drain valve shall be provided on opposite side of oil drain
valve on Bus Reactor tank for NIFPE System.

4. All the Civil works such as construction of plinth oil pit below the Bus Reactor
shall be in contractor’s scope. Detailed drawing & design of same shall be
furnished by the supplier.

9.20. Mild steel oil tank (5mm thick sheet) of suitable capacity (atleast 10% of total oil
quantity) with moisture/corrosion/rust proof coating (5mm thick sheet) on external
and internal surface with internal paint which is corrosion / rust/ chemical resistive
preferably in white colour or in lighter shades of yellow and grey, with water tight
cover, to be placed in the oil pit. The inner side of tank shall be painted with
chemical resistive paint preferably in white colour or in lighter shades of yellow and
grey. This tank shall be provided with the manhole, air vent pipe through silica gel
breather, drain valve and a spare gate valve at the top.

36
 In case of ETC/ Turnkey projects, Civil works is to be Carried out by contractor for
MS Tank including Excavation, Laying of 75 mm PCC, Constructing brick wall
jacket around the tank, laying of 200 mm RCC raft, leveling and alignment of MS
Tank, backfilling with excavated sand, Top leveling by laying of PCC, as per site
requirement and Technical specifications (complete job).

9.21 PASSIVE FIRE PROTECTION FOR REACTOR:

The passive fire protection system, to prevent spreading and for containment of fire,
must consist of Fire Retardant Bandage and Fire stop Barrier (MORTAR FIRE
BARRIER) for cable entry in transformer and accessories to avoid damages of
equipment in case cable catches fire. This passive fire Protection system for reactor
shall be applicable for cables / Cables sets from reactor and at entry point of cable from
reactor Marshalling Box main cable trench.
A. FIRE RETARDANT CABLE BANDAGE:
The fire retardant cable bandage must be flexible composite fiber glass fabric with
external fabric and internal anthracite, thermoplastic in tumescent coating, when
exposed to fire or extensive heat it should form a thermally insulating layer of foam.
Thickness of the cable bandage must be less than 0.9 mm +/-0.3 for 2 hour fire rating.
The weight of bandage shall be 1000 grams +/- 150 grams per Sq Mtr. Test Certificate
for bandage from any National/ International laboratory as per IEC 60332-3-22, Cat A:
2000 for 120 minutes fire rating shall be submitted. Any CRACKING of cable bandage
shall not be accepted.
The fire retardant cable bandage shall be used at following position:

a. Reactor M.K. box to first Mortar barrier

completely i.e. up to entry point of main cable
trench.
b. 1.5 Mtr on both side of Mortar barrier which is
installed in main cable trench.
The cable bandages shall be tied up with CRCA
clamps
B. MORTAR FIRE BARRIER :

The Mortar Fire Barrier must in powder form and add sufficient water during
installation at site. After installation of fire barrier, the cables on the both sides must be
fixed with Fire Retardant Bandages at least 1.5 meters on the both sides. The test
certificate from National or International laboratory as per BS 476 for two hours fire
rating must be submitted. The Fire barrier must be UL1479 approved.

Mortar Barrier up to depth & width of trench and 0.5 meter in thickness shall be fixed
at the location as under:
a. Two Nos. barriers in reactor cable trench at the
position parallel to firewall (i.e. at the
distance of soak pit +1.5 Meters from the
reactor) at both side of reactor.
b. One No. barrier at entry point of cable from
reactor Marshalling Box main cable trench.
The gross density of dry mortar shall be greater
than 900 Kg /M3 with pressure resistance of 2.5

37
 N/mm2. The mortar barrier shall be implemented
when temperature is above 50 C.
c. From the bottom of trench, a provision of
semicircular/ rectangular hole for drainage of
water/ rain water at least 20 cm in diameter/
wide and 10 cm in height shall be made with each
barrier.

9.22 Test on Nitrogen Injection Fire Prevention & Extinguishing System.

The Nitrogen Injection Fire Prevention & Extinguishing System shall be subjected to
the operational test at manufacturer’s works of Nitrogen Injection Fire Prevention &
Extinguishing System in presence of purchaser's representative. The manufacturer's
test certificate of various accessories of Nitrogen Injection Fire Prevention &
Extinguishing System shall be furnished at the time of inspection to inspecting officer.
9.23 The dispatch clearance/ instructions of satisfactorily inspected reactor can be issued
subject to withholding 15% cost of reactor, if compliance of any one of or all of the
following is not received from supplier.
a) Test report from CPRI/ ERDA for the composite oil sample drawn
from the oil drums for testing as per IEC:60296 and specification.
b) Test report from CPRI /ERDA for oil sample drawn from reactor tank
for Dissolved Gas Analysis before and after temp. rise test.
c) Test report from Govt./Govt. approved/ Govt. recognized lab. for
the core material sample drawn during stage inspection of core
building for measurement of specific losses at 1.6 tesla,
magnetization characteristics and thickness.
d) The above 15% withheld payment shall be made after receipt of
satisfactory test reports as above.

9.24 The supplier shall provide the manufacturers routine test certificate for bought out items
to the Inspecting Officer during inspection.

38
 Annexure-I

REQUIREMENT OF MANDATORY SPARE PARTS

Total quantity to be supplied with each 25

S.No Particulars
MVAR Shunt Reactor
Local and remote WTI complete with
1. 1 SET
sensing device and contacts
Local and remote OTI complete with
2. 1 SET
sensing device and contacts
3. Pressure release device 1 Nos.
4. Buchholz relay complete with assembly 2 Nos.
5. Magnetic oil level gauge 1 Nos.
Set of Valves (Complete set for one
6. 1 SET
reactor)
7. Breather assembly 1 SET

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 ANNEXURE-2

GUARANTEED AND OTHER TECHNICAL PARTICULARS OF 25 MVAR, 220 kV class

SHUNT REACTOR

Item No. Description Specification GTP

A SHUNT REACTOR
1. Manufacture name & country
2 Type of reactor Gapped / Air
Core
3 Standards applicable IEC:60076-6
4 Rated MVAR capacity at rated 25 MVAR
voltage 245 kV
5 Rated voltage, Ur (1p.u) 245 kV
6 Connection (3 Phase) Star
7 Cooling System Natural air
circulation
(ONAN)
8 Thermal Data :
a) Temperature rise over 50°C
ambient temperature at rated
voltage
i. Top oil measured by thermometer 40°C
ii. Average winding measured by 45°C
resistance method
b) Maximum design ambient 50°C
temperature
c) Rated frequency (Hz) 50
9 Number of phases 3 (THREE)
10 Service Outdoor
11 System Fault Level 40 kA
12 Guaranteed max, losses at rated 50 KW
voltage and frequency at rated
output at 75 deg. C (KW)
13 Maximum I2R Losses at rated 28 kW
voltage and frequency at rated
output at 75 deg. C (KW)
14 Permissible current unbalance ± 2%
among different phases
15 Noise level at rated voltage and 75
frequency (dB)
16 Insulation level for Winding
a) Lightning impulse (1.2/50 HV : 950 kVp
microscopes) withstand voltage

40
Item No. Description Specification GTP
(kVp)
b) Switching Impulse withstand HV : 750 kVp
voltage (kVp)
c) One Minute power frequency HV : 245 kVrms
withstand voltage
17 Insulation level for Neutral
a) impulse withstand voltage (kVp) 170 kVp
b) Power frequency withstand voltage 70 kVrms
(kVrms)
18. Range of constant impedance Up to 1.4 p.u.
(However, complete saturation voltage
characteristic of the reactors up to
2.5 p.u. voltage shall be furnished)
19 Tolerance of current 0 to +5%
20 Ten Delta of winding < 0.005
21 Ratio of zero sequence reactance to 0.9 to 1.0
positive reactance (X0 / X1)
22. a) Vibration and Tank Not more than
200 µ Peak-
Stress level at rated voltage and
Peak.
frequency
Average
vibration shall
not exceed 60 µ
peak to peak.

Tank stresses ≤ 2
kg/sq.mm at any
point of tank
b) Vacuum withstand capacity of tank 25 TORR
23 Crest value of Third Harmonic Not to exceed
content in phase current at rated 3% of the crest
voltage with sinusoidal waveform value of
fundamental
24 Shipping weights and dimensions
a) Size of largest package (mm ) x
(mm) x (mm)
b) Weight of largest package (Kg.)
c) Gross weight to be handled (Kg.)
d) Gross volume to be handed (Kg.)
e) Approx. overall dimensions (l x b x
h) mm
f) Approx. quantity of oil required for
first filling (kL)

41
Item No. Description Specification GTP
g) Untanking height mm
25 Proposed method of transportation Oil/N2/Dry Air
filled
26 Compliance to technical
specification w.r.t. parameter
specified for
a) Oil
b) Bushing CT
c) Bushings As per
applicable
IS/IEC
d) Terminal connectors
27 Whether similar equipment are type
tested & are in successful operation
for at least two years. (If yes,
furnish type test reports)
28 Overall General Arrangement
Drawing of shunt reactor with all
accessories to be enclosed.
29 Bushing
a) Rated Voltage
HV 245 kV
Neutral 36 kV
b) Rated current (Minimum)
HV 800 A
Neutral 800 A
c) Lightning Impulse withstand
voltage
HV 1050 kVp
Neutral 170 kVp
d) Switching Impulse withstand
voltage
HV 750 kVp
e) Power Frequency withstand voltage
HV 505 kVp
Neutral 77 kVp
f) Minimum Total Creepage Distance
HV 6125mm
Neutral 900mm
g) Ten Delta Bushing

42
Item No. Description Specification GTP
HV < 0.004
h) Maximum Partial Discharge Level
at Ur
HV 10 pC
Maximum Partial Discharge Level 100 pC
at 1.58Ur/√3

43