BADARPUR THERMAL POWER STATION

(3 X 95 MW + 2X210 MW)
COOLING TOWER PACKAGE
BIDDING DOCUMENT NO.: CS-1508-135B(R&M)-2
TECHNICAL SPECIFICATION
SECTION - VI
PART-B
SUB-SECTI ON I I I B-08
TRANSFORMER
CLAUSE NO.
TECHNICAL REOUIREMENTS
BADARPUR THERMAL
POWER STATlON COOLlNG
TOWER PACKAGE
Bid Doc. No.:
CS-1508-135B
(R&M)-2
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1.00.00 TECHNICAL PARAMETERS
1.01.00 Outdoor Trans|ormers
(a)
Rated output As per details o| Trans|ormers under
Cl. 1.02.00 below
(b)
Cooling ONAN
(c)
Type Two winding
(d)
Voltage Ratio As per details o| Trans|ormers under
Cl. 1.02.00 below
(e)
Frequency 50 Hz
(|)
Phase Three (3)
(g)
Service Outdoor
(h)
Duty Continuous
(i)
Overload capacity As per lS: 6600 and speci|ied
elsewhere in the speci|ication.
(j)
Permissible Temperature rise over
an ambient temp. o| 50 deg. C
i)
Winding (by resistance method) 55 deg. C
ii)
Top oil (by thermometer) 50 deg. C
(k)
lmpedance at 75 deg.C As per details o| Outdoor
Trans|ormers under Cl.1.02.00
below.
(l)
Noise Level As per NEMA TR- 1
(m)
System |ault level
i)
12 kV or Trans. |ed |rom 11 KV
side
40 kA
ii)
6.9 kV or Trans. |ed |rom 6.6 KV
side
40 kA
iii)
0.433 kV 45 kA
(n) Winding
Sr. No.
Highest System Voltage(kV) 12 7.2 0.433
i)
Lightning impulse withstand voltage, kVp 75 60 -
ii)
One min power |requency withstand voltage,
kVrms
28 20 3
iii)
lnsulation uni|orm uni|orm uni|orm
iv) Method o| neutral earthing and Vector group:
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KVA RATING
HV
RATING
{kV)
LV
RATING
{kV)
Vector
Group
Method of Neutral Earthing
5,000
{Located at
CT area)
11.5 6.6 YNd11
5,000
{Located at
STP area)
11 6.9 Dyn1
1,600 6.6 0.433 Dyn11
630 6.6 0.433 Dyn11
(o) Tap changer details:
i) Tap range +/- 5% in steps o| 2.5% on HV winding
ii) Tap Control O|| circuit tap change switch (OCTC)

(p) Bushing Parameters
Sr. No. Parameters 12kV 7.2kV 433 V
i)
Rated Voltage(kV) 12 7.2 1.1
ii)
Lightning impulse withstand
voltage, kVp
75 60 -
iii)
One min power |requency
withstand voltage , kV (rms)
28 20 3.0
iv)
Minimum total creepage
distances (mm)
25mm/kV x Rated Voltage o| Bushing.
v)
Mounting Tank / Trans|ormer body
vi)
Rated Current See Table below (q).

(q) Bushing Rated Current (in Amperes)
SR. No.
KVA
RATING
HV RATING
{kV)
LV
RATING
{kV)
HV-Line LV-Line Neutral
i)
5,000 11.5 6.6 1000 1250 1000
ii) 1,600 6.6 0.433 250 3150 3150
iii)
630 6.6 0.433 250 2000 2000




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(r) Termination Details
i)
HV Phase Terminal
11.5kV, 6.6kV
Cable box suitable |or XLPE insulated
cable.
ii)
LV Phase Terminal
6.9KV
Cable box suitable |or XLPE insulated
cable.
iii)
HV Neutral Terminal
11.5 kV
Solidily grounded through Copper |lat
connection.
iv)
LV Neutral Terminal
6.9 kV
Earthed with copper |lat through NGR ( in
the scope o| this contract)
v)
LV Phase Terminal
0.433KV
Busduct (Non-Segregated) Or Cable Box

vi)
LV Neutral Terminal
0.433kV
Solidily grounded through Copper |lat
connection.
(s) XLPE Cable size
SR. No.
KVA
RATING
HV RATING
{kV)
LV
RATING
{kV)
HV side LV side
i)
5,000 11.5 6.6 3-1CX300 6-1CX300
ii) 1,600 6.6 0.433 3 Cx150
Busduct/Ca
ble
iii)
630 6.6 0.433 3 Cx150 Cable
(t) Minimum Clearance in air (mm)

System voltage 11 kV 6.6 KV 433 V
i)
Phase to Phase 130 100 25
ii)
Phase to Earth 120 90 25
(u) Bushing CT Parameters


Sr No.
KVA RATlNG HV (kV) LV (kV)
R.E.F. CT
Class: PS

i) 5,000 11.5 6.6
630/1A, RCT 3 , VK 200V, lm
30mA at VK/2
ii)
1,600 6.6 0.433
2500/1A, RCT 12.5 , VK
450V, lm 30mA at VK/2
iii)
630 6.6 0.433
1000/1A, RCT 5 , VK 350V,
lm 30mA at VK/2
NOTE : THE PARTlCULARS OF CURRENT TRANSFORMER ARE TENTATlVE AND LlABLE TO CHANGE
WlTHlN REASONABLE LlMlTS. CONTRACTOR SHALL OBTAlN PRlOR APPROVAL OF THE
EMPLOYER BEFORE PROCEEDlNG WlTH THE DESlGN.
MANUFACTURER.
CLAUSE NO.
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BADARPUR THERMAL
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TOWER PACKAGE
Bid Doc. No.:
CS-1508-135B
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Neutral Grounding Resistors
6.9 kV NGR

i) Resistance Value at 50 deg. C. 13.28 ohm
ii) Rated current 300A |or 10 seconds
iii) Application Neutral Grounding o| Star connected
LV winding o| trans|ormers
iv) Service Outdoor
v) Resistor material & connection Punched stainless steel grid element
type
vi) Maximum allowable temperature
rise over ambient 50
o
C
350 deg. C
vii) Mounting 7.2 kV grade insulators.
viii) Power |requency test level 20 KV rms.

1.02.00 Details of Transformers

Sr. No.


TRANSFORMER NAME


OTY.


NGR


KVA
RATlNG

HV
RATlNG
(kV)

LV
RATlNG
(kV)
Z%
@
normal
tap with
(+/-) lS
Toleran
ce
1.
CT Trans|ormers
(6.6/11.5 kV)
2 X 5,000 11.5 6.6
As
per
reqt.
2.
CT Trans|ormers
(11/6.9 kV)
2 2 5,000 11 6.9
As
per
reqt.
3. CT Aux. Trans|ormer 2 X 1,600 6.6 0.433
As
per
reqt.
4.
MWPH Aux.
Trans|ormer
2 X 630 6.6 0.433
As
per
reqt.

2.00.00 GENERAL
2.01.00 STANDARDS
All equipment provided under the speci|ication shall in general, con|orm to the
latest issue o| the |ollowing standards:
Indian
Standards
No.
Title International &
internationally
recognized standards
lS: 2026 Power trans|ormers lEC: 60076
lS: 3639 Fittings & accessories |or power
trans|ormers

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Indian
Standards
No.
Title International &
internationally
recognized standards


lnsulating oils |or trans|ormer and
switchgear
lEC: 60296, BS:148
lS: 2099 Bushing |or alternating voltages
above 1000 V
lEC: 60137, BS: 223
lS: 2705 Current trans|ormers lEC: 60185
lS: 325 Three phase induction motors lEC: 60034
lS: 3637 Gas operated relays
lS: 10028 Code o| practice |or selection
installation & maintenance o|
trans|ormers

lS: 4691 Degree o| protection provided by
enclosure |or rotating electrical
machinery

lS: 13947 Speci|ication |or low voltage
switchgear & control gear Part - l
lEC: 144
lS : 5 Colours |or ready mix paints
lS: 1866 Code o| practice |or maintenance &
Supervision o| mineral insulating oil
in equipment

lS: 6272 lndustrial cooling |ans
lS: 6600 Guide |or Loading o| oil immersed
trans|ormers
lEC: 60076-7
lS: 3347
lS:8603
Speci|ication |or dimensions o|
porcelain bushing

lS: 8468 Tap changers lEC: 214
High voltage test technique lEC: 60
lnsulation co-ordination lEC: 71


NEMA standard publication |or
Power trans|ormers
NEMA-TR-1
lS: 10596 Code o| practice |or selection,
lnstallation operation &
maintenance o| pumps |or
lndustrial applications

lS: 9434 Guide |or sampling & analysis o|
|ree & dissolved gas & oil |rom oil
|illed electrical equipment
lEC: 567
lS: 2544 Porcelain post insulators |or
systems with nominal voltage
greater than 1000 V

lS: 5561 Speci|ication |or electric power
connectors

lS: 5621 Hollow insulators |or use in
electrical equipment

lS: 2633 Methods |or testing uni|ormity o|
coating o| Zinc coated articles

lS: 12676 Dimensions |or OlP insulated
condenser bushings

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2.02.00 The electrical installation shall meet the requirements o| lndian Electricity act 2003.

3.00.00 PERFORMANCE
(a) The maximum |lux density in any part o| the core & yoke at the rated MVA,
voltage & |requency shall be such that under 110% continuous voltage condition
it does not exceed 1.9 Tesla.
withstand without injury the thermal & mechanical e||ects o| any external short
circuit to earth & o| short circuits at the terminal o| any winding |or a period o| 2
sec.
(c) Trans|ormers shall withstand, without injurious heating, combined voltage &
|requency |luctuations, which produce the |ollowing over |luxing condition:
110 %- continuous
125%- |or one minute
1)
140%- |or |ive seconds
2) Bidder shall indicate 150% & 170% over voltage withstand time.
3) Over |luxing characteristics up to 170 % shall be submitted.
(d) The trans|ormers shall be capable o| being operated continuously without danger
on any tapping at the rated MVA with voltage variation o| 10% corresponding to
the voltage o| tapping.
(e) The trans|ormers shall be capable o| being loaded in accordance with lS: 6600 /
lEC: 60076-7 up to load o| 150 %. There shall be no limitation imposed by
bushings, tap changers etc. or any other associated equipment.


4.00.00 CONSTRUCTION
The |eatures & construction details o| each trans|ormer shall be in accordance with
the requirement stated hereunder.


4.01.00 TANK AND TANK ACCESSORlES
(a) Tank shall be o| welded construction & |abricated |rom tested quality low carbon
steel o| adequate thickness. The welding procedure speci|ication (WPS),
all joints shall be subjected to visual examination. ln case o| doubt particular weld
shall be checked by D.P.Test. However weld joints o| load bearing member shall
be le|t unpainted till carrying out o| jacking test |ollowed by DP Test during |inal
inspection o| trans|ormer. Details o| acceptance norms o| welding shall be
ich shall include permissible undercut,
overlap, sur|ace crack, porosity, out o| alignment o| plate sur|ace in butt joints,
maximum gap due to incorrect |it up o| |illet joint etc.

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(b) Each tank shall be provided with :
(i.) Li|ting lug suitable |or li|ting the equipment complete with oil.
(ii.) A minimum o| |our jacking pads in accessible position to enable
the trans|ormer complete with oil to be raised or lowered using
hydraulic or mechanical screw jacks.
(iii.) Suitable haulage holes shall be provided |or trans|ormer wheeling
in all |our directions.
(c) For all trans|ormers, suitable bi-directional skids with pre-drilled holes shall be
provided integral with the tank body |or |ixing the trans|ormer tank on |oundation.
These skids shall be such that the bottom o| the tank body is at a su||icient height
above |oundation |or cleaning purposes.

The trans|ormers (except trans|ormers upto and including 2 MVA) are to be
provided with |our no. o| bi - directional |lat rollers o| detachable type & shall be
mounted on wheels on |oundation. Suitable locking arrangement shall be provided
|or the wheels to prevent accidental movement o| trans|ormer.
(d) At least two adequately sized inspection openings one at each end o| the tank
shall be provided |or easy access to bushing & earth connections. The inspection
covers shall not weight more than 25 Kg. Handles shall be provided on the
inspection cover to |acilitate li|ting.

(e) All bolted connections shall be |itted with weather proo|, hot oil resistant,
rubberized cork gasket in between |or complete oil tightness. l| gasket is
compressible, metallic stops shall be provided to prevent over compression.
(|) The tank shall be designed in such a way that it can be mounted on the plinth
directly.
(g) Wherever possible the trans|ormer tank & its accessories shall be designed
without pockets wherein gas may collect. Where pockets can not be avoided,
pipes shall be provided to vent the gas into the main expansion pipe.
(h) The main tank body shall be capable o| withstanding |ull vacuum.
4.02.00 Core
(a) The core shall be constructed |rom cold rolled, super grain oriented (CRGO),
silicon steel laminations.
(b) The core isolation level shall be 2 kV (rms.) |or 1 minute in air.
(c) Adequate li|ting lugs will be provided to enable the core & windings to be li|ted.
4.03.00 Windings
(a) The contractor shall ensure that windings o| all trans|ormers are made in dust
proo| & conditioned atmosphere. The bidder shall |urnish details o| the |acilities
available at his works along with the bid.
(b) The conductors shall be o| electrolytic grade copper |ree |rom scales & burrs.
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(c) All windings o| the trans|ormers having voltage less than 66 kV shall be |ully
insulated.
(d) Tapping shall be so arranged as to preserve the magnetic balance o| the
trans|ormer at all voltage ratio.
4.04.00 Insulating Oil
No inhibitors shall be used in the trans|ormer oil. The oil supplied with trans|ormers
shall be new and previously unused and must con|orm to lS 335 while tested at
Subsequently oil samples shall be drawn at:
(a) Prior to |illing in main tank at site & tested |or
Sr.
No.
Parameters Before filling in main
tank at site & tested for
i) BDV 60 kV (min)
ii) Moisture content 10 ppm (max.)

(b) Prior to energization at site for following properties & acceptance norms:

Sr.
No.
Parameters Prior to energization at site
for following properties &
acceptance norms:
i) BDV 60 kV (min)
ii) Moisture content 10 ppm (max.)

4.04.02 Oil Preservations System
(a) The trans|ormers shall have the |ollowing types o| oil preservation systems:
(i.) Conventional Conservator
The trans|ormer shall be provided with conventional single
compartment conservator with dry air |illing the space above the oil.
The top o| the conservator shall be connected to the atmosphere
through a silicagel breather. The Buchholz relay shall also be
provided.
The conservator shall be |itted with a silicagel |ilter breather, which
shall be so designed that:
Passage o| air is through a dust |ilter and silicagel.
Silicagel is isolated |rom atmosphere by an oil seal.
Moisture absorption indicated by a change in colour o| the
tinted crystal can be easily observed |rom a distance.
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Breather is mounted not more than 1400 mm above rail top
level.
4.05.00 Terminal Arrangements
4.05.01 Bushings
(a) The electrical & mechanical characteristics o| bushings shall be in accordance
with lS: 2099, lS: 3347 & lS: 12676.
(b) Bushings |or 52 kV & above shall be o| the oil |illed condenser type & shall be o|
draw lead/ rod type to |acilitate removal. Bushings o| rating below 52 kV shall be
solid porcelain or oil communicating type.
(c) Condenser type bushings shall be provided with :
(i.) Oil level gauge,
(ii.) Oil |illing plug & drain valve ( i| not hermetically sealed)
(iii.) Tap |or capacitance & tan delta test.
(d) Clamps & |ittings shall be o| hot dip galvanized steel.
(e) Bushing & |ittings shall be provided with vent pipes that shall be connected to
route any gas collection through the Buchholz relay.
(|) No arcing horns shall be provided on the bushings.
(g) Wherever cable termination is speci|ied, bushing terminals shall be
provided with suitable terminal connectors o| approved type and size |or cable
termination.
(h) Where current trans|ormers are speci|ied, the bushings shall be removable
without disturbing the current trans|ormer.
4.05.02 Neutral Terminal Arrangement
4.05.03 Neutral Termination (0.433kV)
(a) The neutral terminal o| 433 V winding shall be brought out on a bushing
alongwith the 433 V phase terminal to |rom a 4 wire system |or the 433 V. Neutral
(b) The neutral terminal o| 433 V winding shall also be brought out through an
outdoor bushing. Further this neutral terminal shall be connected by a copper |lat
o| size 50 mm x 8 mm, which shall be brought down upto 100 mm above ground.
The copper |lat shall be insulated and supported |rom the tank body. The
connection shall be made by using two (2) bolted neutral grounding terminals
with necessary accessories.
4.05.04 Bus Duct Terminations
(a) A |langed throat or equivalent connection shall be provided |or termination o|
busduct enclosure. The winding termination shall be on outdoor type o| bushings.
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The Employer would provide necessary |lexible connection between the bushing
terminal & the bus duct conductor. The material o| the busduct termination shall
be non-magnetic.
(b) The shape o| the bus duct conductor shall be in|ormed during detailed
engineering. The bushing pads shall be silver plated. A drain with stopcock
arrangement shall be provided at |lange to drain leakage o| oil/water at
termination. As bus duct will be pressurized stopcocks shall be airtight.
(c) Tolerance permissible |or the height o| the terminal connected to busduct over
rail top level is 10 mm. Contractor has to ensure that radiator & conservator
does not obstruct the path o| the bus ducts in position & during movement o|
trans|ormer. The contractor shall co-ordinate |inal design o| terminal arrangement
to suit bus duct arrangement during detailed engineering.
(d) The trans|ormer bushing enclosed in bus duct enclosure shall be designed |or
satis|actory operation in the high ambient temperature existing inside the bus
duct enclosure. The temperature inside the bus duct enclosure may be o| the
105 deg. C & temperature in the bus duct enclosure will be o| the order o| 80 deg.
C.
4.05.05 Cable boxes & disconnecting chamber
(a) HV Cable boxes shall be o| phase segregated air insulated type & shall be o|
su||icient size to accommodate Employ
segregation shall be achieved by insulating barriers.
(b) Cable boxes shall have bus bars / terminal connectors o| adequate size & bolt
holes to receive cable lugs.
(c) A suitable removable gland plate o| non-magnetic material drilled as per the
(d) The support |rom base |or the cable box shall be o| galvanized iron.
(e) The contractor shall provide earthing terminals on the cable box, to suit
(|) The minimum length provided |or terminating 11KV & 6.6KV XLPE cable shall be
650 mm (|rom cable gland plate to the cable lug) |or the cable boxes, |or 433V
side suitable length shall be provided (shall be discussed during detail
engineering)The |inal cable size, number & length o| terminating XLPE cable
shall be |urnished during detailed engg.
(g) All necessary cable terminating accessories such as supporting clamps &
cable shall be provided by the contractor to suit the |inal cable sizes.
(h) Cable boxes shall be designed such that it shall be possible to move away the
trans|ormer without disturbing the cable terminations, leaving the cable box on
external supports.
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(i) Cable boxes shall have removable top cover & ample clearance shall be provided
to enable either trans|ormer or each cable to be subjected separately to high
voltage test.
4.05.06 TERMINAL CONNECTOR (l| applicable)
(a) Bushing terminal shall be provided with terminal connectors o| approved type &
size |or connection to external part. Terminal connectors must have been
success|ully type tested as per lS: 5561.
(b) Aluminium alloy i| used shall con|orm to designation 4600 M o| lS: 617 or o|
better quality.
(c) No current carrying part o| a clamp shall be less than 10 mm thick.
(d) All |errous parts shall be hot dip galvanized con|orming to lS: 2633.
(e) For bi-metallic clamp, copper alloy liner o| minimum 2-mm thickness shall be cast
integral with aluminum body. Alternatively Bidder may o||er bimetallic connector
with loose bimetallic sleeve.
(|) Flexible connectors shall be made |rom tinned copper sheets.
(g) Size o| terminal/conductor |or which the clamp is suitable & rated current under
the conditions shall be embossed / punched on each component o| the clamp,
except hardware.
(h) Rated current o| the terminal connectors shall be same as that o| corresponding
bushing.
4.06.00 Bushing Current Transformer
(a) Current trans|ormer shall comply with lS: 2705.
(b) lt shall be possible to remove turret mounted current trans|ormers |rom the
trans|ormer tank without removing the tank cover. Necessary precautions shall
be taken to minimize eddy currents & local heat generated in the turret.
(c) All secondary leads shall be brought to a weatherproo| terminal box near each
bushing. These terminals shall be wired out to trans|ormer marshalling box using
separate cables |or each core.
4.07.00 Terminal Marking
The terminal marking & their physical position shall be as per lS: 2026 unless
speci|ied otherwise.
4.08.00 Marshalling Box{M. BOX) Unit
(a) Each trans|ormer shall be provided with one Marshalling Box housing all the
cooler control, OTl & WTl etc.
(b) The sheet steel used |or all the cabinet boxes shall be at least 2.5 mm thick. The
gasket used shall be o| neoprene rubber. A space heater & cubicle lighting with
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thermal overload device |or controlling the AC auxiliary supply shall be provided.
(c) Terminal Blocks
(1.) The terminal blocks to be provided shall be |ully enclosed with
removable covers & made o| molded, non-in|lammable plastic
material with blocks & barriers molded integrally. The terminal
blocks shall be o| 650V grade & have 10 A continuous rating.
Terminal blocks |or current trans|ormer secondary leads shall be
provided with test links & isolating |acilities. Also current trans|ormer
secondary leads shall be provided with short circuiting & earthing
|acilities. At least 20% spare terminals shall be provided on each
panel & these spare terminals shall be uni|ormly distributed on all
terminal blocks.
(2.) Terminal blocks shall be suitable |or connecting the |ollowing
conductors on each side :
copper wires each side
each side
(3.) Terminal blocks numbering shall be made inline with the tender
drawing no. 0000-203-PVE-B-001
E, sub-section-l o| Technical Speci|ication.

(d) The temperature indicators shall be so mounted that the dials are not more than
1500 mm |rom ground level. Glazed door o| suitable size shall be provided |or
convenience o| reading.
(e) All incoming cables shall enter the marshalling box |rom the bottom. A removable
undrilled gland plate shall be provided at the bottom o| the box |or
not be less than 450 mm |rom |inished |loor level.
(|) All devices and terminal blocks inside the marshalling box shall be clearly
identi|ied by symbols corresponding to those used on applicable schematic or
wiring diagram.
(g) lt shall be located in such a way that, the same shall not |ace towards the
trans|ormer.
(h) The gland plate shall be made into two detachable halves, |or |acilitating the
plate and the associated compartment shall be sealed in a suitable manner to
prevent the ingress to moisture, rodents, insects etc.
(i) One dummy terminal block in between each trip wire terminal shall be provided.
(j) Wiring Scheme shall be engraved in a plate and the same shall be |ixed inside
the Marshalling Box door.
CLAUSE NO.
TECHNICAL REOUIREMENTS


BADARPUR THERMAL
POWER STATlON COOLlNG
TOWER PACKAGE
Bid Doc. No.:CS-
1508-135B(R&M)-2
TECHNlCAL
SPEClFlCATlONS
SECTlON Vl
SUB SECTlON lllB-08
AUXlLlARY TRANSFORMER
Page
13 o| 23


4.09.00 Control Wiring & Cabling
Supply, laying & termination o| all cables & accessories required o| proper
termination |rom the M. Box except |or those stated under next clause below so as
to make equipment complete & |unctional shall be in scope o| supplier. The cable
between the M. Box & trans|ormer shall be laid by the supplier through Gl conduits/
pipes. Cable box / sealing end shall be suitable |or |ollowing types o| cables:

1) 415 V power

1100 V grade PVC insulated aluminum conductor cable with
armour.
2) Control

1100 V grade PVC insulated 2.5 sq. mm stranded copper
conductor with armour.
4.10.00 Following cabling are speci|ically excluded |rom the scope o| the Bidder, however
interconnection drawings |or the same are to be submitted by the contractor:
(a) Cabling between unit control panel to M. Box.
contractor up to M. Box.
4.11.00 PAINTING
Painting o| trans|ormer and its accessories shall be in accordance with the
|ollowing chart.
S.No. PARTS NAME TYPE OF PAlNT NO.OF
COATS
TOTAL
DFT
i)
lnside o| tank and
accessories (except M
Box)
Oil & heat resistant
|ully glossy white
One coat atleast
30
micron
ii)
External sur|ace o|
trans|ormer and
accessories including
M Box (except radiator)
Chemical resistant
epoxy zinc
phosphate primer,
MlO (Micaceious
iron oxide) as
intermediate paint
|ollowed by
polyurethane |inish
paint o| blue colour
corresponding to
RAL 5012.
One coat
each
Atleast
100
micron
iii)
External radiator
sur|ace
Anticorrosive
primary paint
|ollowed by high
quality |ull glossy
outer |inish paint
(blue colour
corresponding to
RAL 5012.)
Two coats
each
Atleast
100
micron
iv)
lnternal radiator sur|ace Hot oil proo|, low
viscosity varnish and
subsequent |lushing
with trans|ormer oil
--- ---
CLAUSE NO.
TECHNICAL REOUIREMENTS


BADARPUR THERMAL
POWER STATlON COOLlNG
TOWER PACKAGE
Bid Doc. No.:CS-
1508-135B(R&M)-2
TECHNlCAL
SPEClFlCATlONS
SECTlON Vl
SUB SECTlON lllB-08
AUXlLlARY TRANSFORMER
Page
14 o| 23

S.No. PARTS NAME TYPE OF PAlNT NO.OF
COATS
TOTAL
DFT
v)
lnternal sur|ace o| M
Box
Chemical resistant
epoxy zinc
phosphate primer
|ollowed by chemical
and heat resistant
epoxy enamel white
paint
Two coats
each
Not less
than 100
micron

4.12.00 Cooling Equipment
The radiators shall be detachable type, mounted on the tank. Each radiator shall
be provided with the |ollowing:
(a) A drain plug at the bottom.
(b) An air release plug at the top.
(c) Shut o|| valve at each point o| connection to the tank. The location and
4.13.00 TAP CHANGER DEVICE
4.13.01 O|| Circuit Tap change Switch
(a) The tap change switch shall be three phase, hand operated |or simultaneous
switching o| similar taps on the three phases by operating on external hand
wheel.
(b) The tap changing shall be possible without disturbing the trans|ormer in any way
except de-energising.
(c) Arrangement shall be made |or securing and pad-locking the tap changer in any
o| the working positions, and it shall not be possible |or setting or padlocking it in
any intermediate position. An indicating device shall be provided to show the tap
in use.
(d) The Cranking device |or manual operation o| the o|| circuit tap changing gear
shall be removable and suitable |or operation by a man standing on ground level.
The mechanism shall be complete with the |ollowing:-
(i.) Mechanical tap position indicator which shall be clearly visible |rom near the
trans|ormer.
(ii.) Mechanical stops to prevent over cranking o| the mechanism beyond the
extreme tap positions.
(iii.) The manual operating mechanism shall be labeled to show direction o|
operation |or raising the secondary voltage and vice versa.



CLAUSE NO.
TECHNICAL REOUIREMENTS


BADARPUR THERMAL
POWER STATlON COOLlNG
TOWER PACKAGE
Bid Doc. No.:CS-
1508-135B(R&M)-2
TECHNlCAL
SPEClFlCATlONS
SECTlON Vl
SUB SECTlON lllB-08
AUXlLlARY TRANSFORMER
Page
15 o| 23

4.14.00 VALVES
(a) All valves upto and including 50 mm shall be o| gun metal or o| cast steel. Larger
valves may be o| gun metal or may have cast iron bodies with gun metal |ittings.
They shall be o| |ull way type with internal screw and shall open when turned
counter clockwise when |acing the hand wheel.
(b) Suitable means shall be provided |or locking the valves in the open and close
positions. Provision is not required |or locking individual radiator valves.
(c) Each valve shall be provided with the indicator to show clearly the position o| the
valve.
(d) Gland packing/gasket material shall be o| te|lon rope/nitrile rubber. ln case o|
gate/globe valves, gland packing pre|erably o| te|lon rope shall be used to
prevent oil seepage through the gland.
(e) A|ter testing, inside sur|ace o| all cast iron valves coming in contact with oil shall
be applied with one coat o| oil resisting paint/varnish with two coats o| red oxide
zinc chromate primer |ollowed by two coats o| |ully glossy |inishing paint
con|orming to lS:2932 and o| a shade (Pre|erably red or yellow) distinct and
di||erent |rom that o| main tank sur|ace. Outside sur|ace except gasket setting
sur|ace o| butter|ly valves shall be painted with two coats o| red oxide zinc
chromate con|orming to lS:2074 |ollowed by two coats o| |ully glossy |inishing
paint.
(|) All hardware used shall be cadmium plated/electro galvanised.
(g) Sampling & drain valves should have zero leakage rate.

4.15.00 Bolts & Nuts
All bolts & nuts exposed to weather shall be hot dip galvanised steel /cadmium
plated steel.

4.16.00 Gasket
The gaskets shall not deteriorate during the li|e o| trans|ormer i| not opened |or
maintenance at site. Supplier shall also recommend quality & make o| gaskets to
be used |or replacement during maintenance i| required. All joints |langed or
welded associated with oil shall be such that no oil leakage or sweating occurs
during the li|e o| trans|ormer. The quality o| these joints is considered established,
only i| the joints do not exhibit any oil leakage or sweating |or a continuous period
o| at least 3 months during the guarantee period. ln case any sweating / leakage is
observed, contractor shall recti|y the same & establish |or a |urther period o| 3
months o| the same. l| it is not established during the guaranteed period, the
guaranteed period shall be extended until the per|ormance is established.
5.00.00 FITTINGS
5.01.00 The |ollowing |ittings shall be provided with each trans|ormer covered in this
speci|ication:
CLAUSE NO.
TECHNICAL REOUIREMENTS


BADARPUR THERMAL
POWER STATlON COOLlNG
TOWER PACKAGE
Bid Doc. No.:CS-
1508-135B(R&M)-2
TECHNlCAL
SPEClFlCATlONS
SECTlON Vl
SUB SECTlON lllB-08
AUXlLlARY TRANSFORMER
Page
16 o| 23

1) Conservator |or main tank with oil |illing hole and cap, isolating valves,
drain valve, magnetic oil level gauge with low level alarm contacts and
dehydrating silicagel breather. Breather |or conservators shall be
mounted not more than 1400 mm above rail top.
2) Oil preservation system: - as speci|ied elsewhere.
3) Minimum two Nos. o| spring operated pressure relie| devices with
alarm/trip contacts |or trans|ormer o| 2 MVA & above rating. Discharge o|
PRD shall be properly taken through pipes & directed away |rom the
trans|ormer /other equipment.
4) Buchholz relay double |loat type with isolating valves on both sides,
bleeding pipe with Gas collecting device at the end to collect gases and
alarm and trip contacts. Control cable termination at Buchhloz relay shall
be properly sealed to prevent water entry.

5) Air release plug.

6) lnspection openings and covers.

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

8) Cover li|ting eyes, trans|ormer li|ting lugs, jacking pads, towing holes and
core and winding li|ting lugs.

9) Protected type Mercury or alcohol in glass thermometer.

10) Bottom and top |ilter valves with threaded male adapters, bottom
Sampling valve & drain valve.

11) Rating and diagram plates on trans|ormers (English & Hindi) and auxiliary
apparatus.

12) Radiator as speci|ied.

13) Prismatic/toughened glass oil gauge |or trans|ormers.

14)
150 mm dial type oil temp indicator with alarm and trip contacts,
maximum reading pointer & resetting device. Accuracy class shall be
1.5 % or better.


15) 150-mm dial type Winding temp indicator with alarm and trip contacts,
maximum reading pointer & resetting device. Accuracy class shall be
1.5 % or better.

16) Flanged bi-directional wheels.

17) Marshalling Box.

CLAUSE NO.
TECHNICAL REOUIREMENTS


BADARPUR THERMAL
POWER STATlON COOLlNG
TOWER PACKAGE
Bid Doc. No.:CS-
1508-135B(R&M)-2
TECHNlCAL
SPEClFlCATlONS
SECTlON Vl
SUB SECTlON lllB-08
AUXlLlARY TRANSFORMER
Page
17 o| 23

18) O|| load tap changing gear

19) Cooling equipment.

20) Bushing current trans|ormers.

21) lnsulating oil.

22)
Drain valves/plugs shall be provided in order that each section o| pipe
work can be drained independently. Sludge valve at bottom most point o|
tank to be provided |or easy |lush out/removal o| sludge during
maintenance.

23) Terminal marking plates.

24) Valves schedule plates.

25) Two (2) earthing terminals on all the equipment mounted separately
suitable |or connection to suitable Gl |lat along with 2 Nos. tapped holes.
M10 bolts etc.

26) Rain hoods to be provided on Buchholz, MOG & PRD. Entry points o|
wires shall be suitably sealed.
5.02.00 The |ittings listed above are only indicative and other |ittings, which generally are
required |or satis|actory operation o| the trans|ormer, are deemed to be included.

6.00.00 INSPECTION AND TESTING

(a) The Contractor shall carry out a comprehensive inspection and testing program
during manu|acture o| the trans|ormer. An indication o| inspection envisaged by
the Employer is given elsewhere in the speci|ication. This is however not
intended to |orm a comprehensive program, as
draw up and carry out such a program in the |orm o| detailed quality plan duly
approved by Employer |or necessary implementation.
(b) The Contractor shall carry out all type tests and routine tests on the trans|ormers.
The tests are listed elsewhere in the speci|ication.
(c) The charges |or conducting each type test to be carried out by the Contractor
shall be indicated separately in the bid.
(d) The equipment checks to be carried out by the Contractor are given elsewhere in
the speci|ication.
(e) The requirements o| site tests are given elsewhere in the speci|ication.
CLAUSE NO.
TECHNICAL REOUIREMENTS


BADARPUR THERMAL
POWER STATlON COOLlNG
TOWER PACKAGE
Bid Doc. No.:CS-
1508-135B(R&M)-2
TECHNlCAL
SPEClFlCATlONS
SECTlON Vl
SUB SECTlON lllB-08
AUXlLlARY TRANSFORMER
Page
18 o| 23

approval. The contractor shall also prepare a comprehensive inspection and
testing program |or all bought out/sub-contracted items and shall submit the
same to Employer.
(g) Each trans|ormer shall be completely assembled with all |ittings and accessories
meant |or the particular trans|ormer be|ore o||ering |or inspection and testing by
Employer.
CLAUSE NO.
TECHNICAL REOUIREMENTS


BADARPUR THERMAL
POWER STATlON COOLlNG
TOWER PACKAGE
Bid Doc. No.:CS-
1508-135B(R&M)-2
TECHNlCAL
SPEClFlCATlONS
SECTlON Vl
SUB SECTlON lllB-08
AUXlLlARY TRANSFORMER
Page
19 o| 23


6.01.00 Type and Routine tests
6.01.01 Routine Tests
KVA Rating
5000 5000 1600 630
Sr.No. Voltage Ratio {kV)
6.6/
11.5
11 /
6.9
6.6/
0.433
6.6/
0.43
3
1
All routine test in accordance with lEC 60076 shall be
carried out in all the trans|ormers.

2 Measurement o| Voltage Ratio


3
Measurement o| winding resistance on HV & LV on all
the taps (as per cl. No. 10.2 o| lEC 60076-1)

4 Vector group and Polarity Check (Cl.no.10.3 o| lEC
76-1)

5 Magnetic Balance Test


6 Measurement o| no load current with 415 V, 50 Hz AC
supply

7 Measurement o| no load losses and current at 90%,
100% & 110% o| rated voltage (as per cl.10.5 o| lEC
60076-1)


8 lmpedance & Load Loss Measurement on principal,
Max & Min. Taps


9 lR measurement (As per cl. no:- 10.1.3 o| lEC 60076-
1)


10 Dielectric tests shall be carried out as per lEC 60076-
3.


11 Separate Source Voltage Withstand Test (Table-2, 4 &
cl. 11 o| lEC 60076-3)

12 lnduced Over Voltage Withstand test as per lEC
60076-3


13
Repeat no load current/loss measurement & lR
measurement a|ter completion o| all dielectric test

14 Measurement o| capacitance & tan delta to determine
capacitance between winding & earth. (As per cl. no:-
i, 10.1.3 o| lEC 60076-1)


15 Oil leakage test: (as per cl 6.02.00 (a) (1) o| this
sub section)


16 Jacking test |ollowed by D.P. test


17 Marshalling Box/Cable box: lt shall not be possible to
insert a thin sheet o| paper under gaskets and through
enclosure joints.


18 lR measurement on wiring o| Marshalling Box.




CLAUSE NO.
TECHNICAL REOUIREMENTS


BADARPUR THERMAL
POWER STATlON COOLlNG
TOWER PACKAGE
Bid Doc. No.:CS-
1508-135B(R&M)-2
TECHNlCAL
SPEClFlCATlONS
SECTlON Vl
SUB SECTlON lllB-08
AUXlLlARY TRANSFORMER
Page
20 o| 23

6.01.02 Type Test

KVA
5000 5000 1600 630
S.
No.
Voltage Ratio {kV)
6.6/
11.5
11 /
6.9
6.6/
0.433
6.6/
0.43
3
19 Short circuit test (special test) as per lEC 60076-5.

20 Temp. rise test at a tap corresponding to maximum
losses. DGA shall be conducted on oil sample
taken be|ore & immediately a|ter temp. rise test.
Gas analysis shall be as per lS: 9434 (based on
lEC: 60567), results will be interpreted as per lS:
10593 (based on lEC: 60599).

21 Lightning impulse (Full & Chopped Wave) test on
windings (as per cl 14 o| lEC 60076-3)

22 Zero sequence impedance measurement test
(Special test)
X X
23 Measurement o| acoustic noise level as per
NEMA TR-1 (special test)


Note:
i) ( ) mark indicates that the test to be carried out.
(x) Mark indicates that the test need not be carried out.
ii) All the type tests shall be conducted a|ter short circuit test. l| Tank Vacuum &
Pressure Test is to be carried out then it shall be conducted be|ore SC test.

6.01.03 Type tests on Components
Type test reports shall be submitted |or |ollowing:
(a) Tank Vacuum & Pressure Test
6.02.00 TANK TEST
(a) Routine test
{1.) Oil leakage test on assembled transformer
All tank & oil |illed compartment shall be tested |or oil tightness by being
completely |illed with oil o| viscosity not greater than that o| speci|ied oil at the
ambient temperature & applying pressure equal to the normal pressure plus 35
KN/sq. m measured at the base o| the tank. The pressure shall be maintained
|or a period o| not less than 6 hours during which time no sweating shall occur.
This test shall be done on completely assembled trans|ormer.


(b) Type Tests
i) Vacuum Test
Each type o| trans|ormer tank shall be subjected to the vacuum test as per
CBlP norms.

CLAUSE NO.
TECHNICAL REOUIREMENTS


BADARPUR THERMAL
POWER STATlON COOLlNG
TOWER PACKAGE
Bid Doc. No.:CS-
1508-135B(R&M)-2
TECHNlCAL
SPEClFlCATlONS
SECTlON Vl
SUB SECTlON lllB-08
AUXlLlARY TRANSFORMER
Page
21 o| 23

ii) Pressure Test
Trans|ormer tank o| each type shall be subjected to a pressure test as per
CBlP norms.
6.03.00
(a) Check |or interchangeability o| similar trans|ormers |or mounting dimensions.
(b) Check |or proper packing and reservation o| accessories like radiators, bushings,
dehydrating breather, rollers, Buchhloz relay, |ans, control cubicle, connecting
pipes, conservator etc.
(c) Check |or proper provision |or bracing to arrest the movement o| core and
winding assembly inside the tank.
6.04.00 Inspection and Testing at Site
The Contractor shall carry out a detailed inspection and testing program |or |ield
activities covering areas right |rom the receipt o| material stage up to
commissioning stage. An indicative program o| inspection as envisaged by the
Employer is given below. This is however not intended to |orm comprehensive
ility to draw up and carry out such a
program duly approved by the Employer. Testing o| oil sample at site shall be
carried out as speci|ied elsewhere in this speci|ication.
6.04.01 Receipt and Storage Checks
Following checks as detailed out in |inalized/agreed FOP shall be |ollowed.
(a) Check and record condition o| each package, visible parts o| the trans|ormer etc.
|or any damage.
(b) Visual check |or wedging o| core and coils be|ore |illing up with oil and also check
conditions o| core and winding in general.
6.04.02 Installation Checks
(a) lnspection and per|ormance testing o| accessories like tap changers etc.
(b) Check whole assembly |or tightness, general appearance etc.
(c) Check oil sample prior to |illing.
(d) Leakage test on bushing be|ore erection.
(e) Capacitance & tan delta measurement o| condenser bushing be|ore |ixing /
connecting to the winding, contractor shall |urnish these values |or site re|erence.
6.04.03 Commissioning Checks
(a) Check the colour o| silica gel in silicagel breather.
CLAUSE NO.
TECHNICAL REOUIREMENTS


BADARPUR THERMAL
POWER STATlON COOLlNG
TOWER PACKAGE
Bid Doc. No.:CS-
1508-135B(R&M)-2
TECHNlCAL
SPEClFlCATlONS
SECTlON Vl
SUB SECTlON lllB-08
AUXlLlARY TRANSFORMER
Page
22 o| 23

(b) Check the oil level in the breather housing, conservator tanks, cooling system,
condenser-bushing etc.
(c) Check the bushing |or con|ormity o| connection to the lines etc. and tan delta test
|or bushing.
(d) Check |or correct operation o| protection devices and alarms:
(i.) Buchhloz relay.

(ii.) Excessive winding temperature

(iii.) Excessive oil temperature

(iv.) Low oil level indication

(v.) Pressure relie| valve

(e) Check |or the adequate protection on the electric circuit supplying the
accessories.
(|) Check resistance o| all windings on all steps o| the tap changer.
(g) lnsulation resistance measurement |or the |ollowing:
(i.) Control wiring.

(ii.) Main windings

(h) Check |or cleanliness o| the trans|ormer and the surroundings.
(i) Check the |ollowing
(i.) Buchholz, oil level indicator, pressure gauges, temp indicators etc.
|or |itting & operation.

(ii.) Earthing o| main tank, marshaling Box, tap changer driving gear,
cable box, |an motor etc.

(iii.) Neutral earthing

(iv.) Calibration o| WTl and OTl

(v.) Earthing o| bushing test tap

(vi.) Connection o| WTl CT with its heater

(vii.) Tightness o| CT secondary connection and shorting o| unused
CTs

(viii.) All valves |or their correct opening and close sequence


CLAUSE NO.
TECHNICAL REOUIREMENTS


BADARPUR THERMAL
POWER STATlON COOLlNG
TOWER PACKAGE
Bid Doc. No.:CS-
1508-135B(R&M)-2
TECHNlCAL
SPEClFlCATlONS
SECTlON Vl
SUB SECTlON lllB-08
AUXlLlARY TRANSFORMER
Page
23 o| 23

(j) Phase out and vector group test.
(k) Ratio test on all taps.
(l) Magnetizing current test (HV winding & LV winding).
(m) Capacitance and Tan delta measurement o| winding
(n) Oil Dielectric strength test-the various test on oil shall be conducted prior to |illing
in main tank at site & prior to energization at site as speci|ied elsewhere in this
speci|ication. Oil samples are to be drawn |rom top & bottom o| main tank &
cooling system.
(o) DGA o| oil be|ore commissioning
(p) Magnetic balance test
(q) Short circuit impedance measurement
(i.) lR value between secondary winding & earth and between
windings
(ii.) Secondary resistance
(iii.) Polarity
(iv.) Ratio test
(v.) Magnetization current
(s) WTl and OTl setting |or alarm/trip, |an start/stop (i| applicable) and pump
start/stop (i| applicable).

(t) Final lR Value
(i.) HV/E+LV
(ii.) LV/E+HV
(iii.) HV/LV
(u) Continuously observe the trans|ormer operation at no load |or 24 hrs. w.r.t.
Voltage, no load current, temperature rise and noise.
(v) Gradually put the trans|ormer on load, check and measure increase in
temperature in relation to the load and check the operation with respect to
temperature rise and noise level etc.