Power Transformer Manual PDF

SECTION-3
CHAPTER-1
TECHNICAL SPECIFICATION FOR
100 MVA, 220/132 kV AUTO TRANSFORMER
1.00
2.00
SCOPE:
a)
This specification covers the design, manufacture, assembly testing at
manufacturers works before despatch, supply and delivery at site as per
schedule of Requirement of 100 MVA, 220/132 kV AUTO TRANSFORMER.
b)
All drawings, schedules and annexures appended to this specification
shall form part of the specification and supplement the requirements specified.
The equipment/materials offered by the Bidder shall be complete in all respects
and, whether called for specifically or not, all accessories, hardware and services
required for normal satisfactory operation of the system shall be deemed to be
included in unit rates quoted. Design and manufacture shall also be such that
equipment/ accessories of the same type and rating would be interchangeable.
Specific reference in this specification and documents to any material by trade
name, make or catalogue number shall be construed as establishing standard of
quality and performance and not as limiting competition. All equipment/
accessories offered shall also be of proven design and manufacture. The make
of all accessories and hardware shall be subject to employers approval.
CODES & STANDARDS:
All standards, specifications and codes of practice referred to herein shall be the latest
editions including all applicable official amendments and revisions as on date of opening
of bid.
IS:5
Colour for ready mix paints.
IS:325
Three phase induction motors.
IS:335
New insulating oils for transformer.
BS:148/IEC:296
IS:375
Marking & arrangement of Switch-gear Bus-bars main connections and
auxiliary wiring.
IS:1866
Code of practice for maintenance of insulation oil
IS:2026
Specification for Power Transformers.
&IEC:76
IS:2099
Bushing for alternating voltages above 1000 volts
& 3347
IS:2147
Degree of protection provided by enclosures for low voltage
switchgear & control gear.
IS:2705
Current transformer
IS:3637
Gas operated relay.
IS:3639
Fittings and accessories for Power Transformers.
IS:6600
Guide for loading of oil immersed transformers.
&IEC-354
IS:8468
&IEC:214
IS:5561
On load tap changer.

Electricity power connectors.
G:\REC-138 New\Technical specification 21.04.15.doc
CT-59
IS:617
IS:2629
IS:8478
IS:8603 :
3.00
4.00
Aluminium Alloy grade.

Recommended practice for hot-dip Galvanising.
On load tap changer application guide.
Dimensions for porcelain transformer bushings for use in heavily polluted
atmosphere (36 kV Class). Dimensions for oil filled porcelain transformer
bushings for use in medium polluted atmosphere.
IS:9434
Guide for sampling and analysis of free and dissolved gas in oil filled
equipment.
IS:10028
Code of practice for selection, installation and maintenance of
transformers.
IS:12676
Dimensions for OIP insulated condenser bushings.
CBIP Manual on transformer.
Equipment complying with other internationally accepted standards would also be
considered if these ensure performance and constructional features equivalent or
superior to standards listed above. In such a case the Bidder shall clearly indicate the
standards adopted, furnish a copy in English of the latest revision of standard alongwith
copies of all official amendments and revisions in force as on date of opening of bid and
clearly bring out the salient features for comparison.
CLIMATIC CONDITIONS:
The transformers are required to operate satisfactorily under the following site
conditions:
3.1
Max. temperature
50 C
3.2
Min. temperature
-2.5 C
3.3
Max. relative humidity
100%
3.4
Min. relative humidity
26 %
3.5
Average number of rainy days per annum
Nearly120 days
3.6
Average annual rain fall
900mm
3.7
Average number of dust storm days per annum.
35
3.8
Isoceraunic level
45
3.9
Max. Wind pressures
195 kg/sqmt.
3.10 Altitude above mean sea level
Less than 1000 mt.
TYPE AND RATING:
4.1
The transformer shall be of 3 phase oil immersed core type with
ONAN/ONAF/OFAF cooling suitable for outdoor service as step down
transformer. The transformer shall not be provided with the tertiary delta winding.
4.2
The ratings and other characteristics which are not covered elsewhere
shall be, as detailed in following clauses:
4.2.1 Max. Continuous capacity:
a)
ONAN
50 MVA
b)
ONAF
75 MVA
c)
OFAF
100 MVA
4.2.2 Number of phases
3
4.2.3 Frequency
50 Hz (5%)
4.2.4 Rated Voltage:
a)
HV side
220 kV
b)
LV side
132 kV
CT-60
4.2.5
Connections:
a)
HV side
b)
LV side
4.2.6 Vector group
4.2.7 %age Impedance
4.2.8 Tapping
Star auto with neutral solidly earthed

YaO
12.5% at 100MVA base
On load tappings for variation 5% to +15% in steps of 1.25%
each on 132 kV side
4.2.9
a)
i)
Insulation level
Lightning impulse voltage
ii)
Power frequency withstand voltage
b)
i)
ii)
Insulation level of Bushings

Lightning impulse voltage
Power frequency voltage
4.2.10 Creepage:
a) Total
LV
132 kV
550 kV
Neutral
33 kV
170 kV
395 kV
(rms)
230 kV
(rms)
70 kV
(rms)
1050
460
(rms)
650 kV
275 kV
(rms)
170 kV
70 kV
(rms)
25mm per kV corresponding to

highest system voltage i.e. 245
kV, 145 kV and 36 kV.
50% of the total creepage
distance
b) Protected
5.00
HV
220 kV
950 kV
GENERAL DESIGN OF TRANSFORMER:

5.1
The transformer and accessories shall be so designed as to facilitate
inspection, cleaning and repairs. The requirement of Indian Electricity Rules
shall be kept in view.
5.2
The design shall ensure satisfactory operation under severe working
conditions due to fluctuating load of steel furnaces and voltage variations in the
system including those, due to short circuits. The transformer shall be designed
as to minimize the risk of accidental short circuits caused by animals, birds or
vermins.
The design shall incorporate every reasonable precaution and provision for the
safety of all those concerned in the operation and maintenance of the equipment
keeping in view the requirements of Indian Electricity Rules.
5.3
All material used shall be of the best quality and of class most suitable for
working under specified conditions and shall withstand the atmospheric
conditions and temperature variations without undue deterioration or distortion or
setting up of undue stress in any part thereof.
5.4
Cast iron shall not be used for any parts other than the radiator valve bodies.
CT-61
5.5
5.6
5.7
5.8
5.9
5.10
5.11
5.12
5.13
5.14
5.15
5.16
5.17
Corresponding parts liable to replace shall be interchangeable.

All taper pins to be used in the mechanism shall be split types as per latest
edition of IS: 2393.
All mechanism should be rust and corrosion proof. Means shall be provided for
lubrication of moving parts not immersed in oil.
The construction shall be such as to avoid air or water pockets. Special care
shall be exercised to reduce noise and vibration to the minimum level.
Steel bolts of suitable finish will be used for diameters above 6mm. Brass bolts
or studs used for electrical connections shall not be of less than 6mm diameter.
On outdoor equipment, all bolts, nuts & washers in contact with current carrying
non-ferrous parts shall be phosphor bronze.
All nuts, bolts and pins shall be locked except those, which are external to the
transformer. If bolts and nuts are so placed as to be inaccessible by means of
ordinary spanners, the contractor shall provide suitable special spanners.
Labels shall be provided for all apparatus like relays, switches, fuses, etc.
housed in any cubicle or marshalling kiosks. These shall be of incredible material
with matt/satin finish and permanent lettering. Labels mounted on black surface
shall have white letters and danger notices shall have red lettering on a white
background. The labels shall be secured by means of brass screws or rust
protected steel screws.
Surface in contact with oil shall not be galvanized or cadmium plated.
Before painting, all un-galvanised parts shall be cleaned, made free from rust,
scale and grease and external rough surfaces smoothened (filled with metal
deposition). The interior of the tank and other oil filled chambers shall be cleaned
by shot blasting or any other suitable method.
All external surfaces shall be given three coats of paints except for nuts, bolts
and washers which may be given one coat after assembling of transformer at
works. The final coat shall be a glossy oil and weather proof, non-fading paint of
shade 631 of IS: 5
The interior of mechanism chambers and kiosks shall be given 3 coats of paint,
the final coat being of a light coloured anti-condensation mixture.
The outer most radial spacers of the winding shall be locked in position by means
of vertical strips so that the same cannot fall off/get displaced.
The manufacturers must ensure proper & complete tightening of the nuts of the
coil clamping bolts. The nuts of all the coil clamping bolts will be tightened to
designed value & the job be carried out with torque spanners.
The devices used for locking the nuts of coil clamping bolts must be of such a
quality and such care should be taken first in tightening. The nuts and next in
locking them in position that the arrangement does not become loose due to
stresses caused by short circuits and fluctuating loads etc.
5.18 The noise level shall not be more than 80 db.
5.19 The transformers shall be designed to have short circuit rating of five
seconds as per IS: 2026. The thermal ability to withstand short circuit shall be
judged by calculation to be supplied above in the tender. The dynamic ability to
with stand short circuit shall be demonstrated by test and their calculation will
also be supplied with drawings.
CT-62
6.00
7.00
8.00
9.00
10.0
5.20 Foundation bolts and nuts shall be supplied alongwith the transformer (Preferably
at the time of call for inspection) so that transformer plinth is ready by the time
transformer is received by the consignee.
INSULATING OIL:
Sufficient insulating oil of Napthenic type (made from Napthenic crude) in which
paraffinic content should be less than 50% and aromatic content 4 to 12%
conforming to BS: 148/IEC: 296 class-1 shall be supplied for first filling of
eachtransformer. Particular attention shall be paid to deliver the oil at site free
from moisture and of uniform quality through out in non-returnable steels drums.
The quantity of oil for first filling of each transformer shall be stated in tender
along-with trade mark of the oil to be supplied. Use of inhibitors in oil shall not be
resorted to. 10% extra oil of the total quantity of oil shall be supplied along with
the transformer.
LIMIT OF TEMPERATURE RISE
7.1
With the above climatic conditions, given in clause-3 each transformer
shall be capable of operating continuously on any tap at their normal rating
without exceeding following temperature rises:
i)
50o C in oil by thermometer.
ii)
55o C in winding by resistance.
iii)
Temperature of hot spot in winding not to exceed 98oC when calculated
over max. annual weighted average temperature of 32o C.
7.2
The limits of temperature rise mentioned above will have to be satisfied by the
manufacturer by carrying out the heat run test at the lowest negative tap. This
test shall be carried out by feeding 1.1 times the total losses at 75o C at highest
current tap.
7.3
OVERLOAD CAPACITY & CONTINUOUS RATING.
The safe over load capacity of the transformer and the duration of overload under
maximum temperature conditions without any damage to the winding or harmful
effects on the insulation shall be clearly stated in the tender which must be as per
IEC-354/IS: 6600, guide for loading of oil immersed transformer.
IMPEDANCE:
The transformer shall have 12.5% impedance on 100 MVA base with tolerance as per
IS: 2026/Part-1 (1983). Impedance shall include positive and zero sequence and shall
be expressed in terms of the branches of the star connected equivalent diagram, all on
the same KVA base and range shall be given for each branch of the equivalent circuit in
turn. Percentage tolerance allowed at extreme tap should be as applicable to normal tap.
FREQUENCY:
The transformer shall be suitable for continuous operation with a +/- 5% frequency
variation from a normal of 50 Hz without exceeding the temperature rise as specified in
Clause 7.1 above.
FLUX DENSITY, CORE CONSTRUCTION AND INSPECTION
10.1
The transformer should be so designed that the working flux density should
not exceed1.60 Tesla at normal voltage, frequency.
10.2
Tenders with higher flux density than specified limit shall not be considered.
CT-63
10.3
The core shall be built up with thin laminations of high grade. non-ageing, low
loss, high permeability cold rolled super grain oriented silicon steel. Known as
MOH High B Grade or superior grade CRGO steels of maximum 0.27 mm or
low lamination thickness especially suitable for transformer core.
10.4(a) (i)Bidder should have in house core cutting facility for proper monitoring & control
on quality and also to avoid any possibility of mixing of prime material with
defective/second grade material. The purchaser may witness the core-cutting
operation. In case the in house core cutting facility for core cutting is not
available then the same shall be carried out in the presence of the representative
of HVPN.
a)
b)
c)
d)
e)
(ii)Inspection call notice for the purpose should be accompanied with the
following documents as applicable as a proof toward use of Prime core
materials:Invoice of supplier.
Mills test certificates.
Packing list.
Bill of loading.
Bill of entry certificates by customs.
Core material shall be directly procured either from the manufacturer or
through their accredited marketing organisation of repute and not through any
agent.
10.4(b) After being sheared, the laminations shall be treated to remove all burrs. They
shall be coated with a baked enamel insulation coating. The insulation shall be
inert to the action of hot transformer oil and shall be perfectly adhesive. Paper
and varnish insulation shall not be accepted. Particulars of proposed
insulation shall be stated in the tender. Laminations shall be checked for burrs
during stage inspection.
10.5
The core shall be rigidly clamped and/or bolted to ensure adequate mechanical
strength and to prevent vibrations during operation. The bolts used in the
assembly of the core shall be suitably insulated and the clamping structure shall
be constructed that the eddy currents will be minimum.
10.6
Construction of the core shall be such that number of steps in the limb and
yoke shall be matching and dimensionally identical to minimize the effect of
cross fluxing and better mechanical strength.
10.7
The core shall be provided with Lugs suitable for lifting the complete core and
coil assembly of transformer. The Core & coil shall be fixed in the tank such
that its shifting will not occur when the transformer is moved or when a short
circuit occurs.
10.8
The design of magnetic circuit shall be such as to avoid static discharge

development of short circuit paths within itself or to the earthing clamping
CT-64
structure and the production of flux components at right angles to the

plane of the lamination which may cause local heating.
10.9
Every care shall be exercised in the selection treatment and handling of core
steel to ensure that the laminations are flat and that finally assembled core is
free from distortions.
10.10
The supporting frame work of the core shall be so designed as to avoid the
presence of pockets which would prevent complete emptying of the tank
through the drain valve or cause trapping of air during filling.
10.11
Oil ducts where necessary should be formed across the plane of the
lamination and be given a suitable slope to assist oil circulation. The overall
design of core and winding should be such that free flow of oil is not
obstructed.
10.12
The frame work and clamping arrangement shall be earthed by connecting to the
tank body through a copper strip. Yoke bolt area should be compensated if bolts
are used for fastening of the core.
10.13
The insulation of core to bolts and core to clamp plates shall be able to
withstand a voltage of 2 KV RMS for one minute.
10.14
Core and windings shall be capable of withstanding shocks during transport,

installation, service and adequate provision shall be made to prevent
movement of core and winding relative to tank during these conditions.
10.15
All steel sections used for supporting the core shall be thoroughly sand blasted
after cutting drilling and welding.
10.16
All the CRGO vendors having BIS certification and approval from PGCIL shall be
considered.
10.17
The tenderers should indicate the maximum flux density allowable continuously
as well as for time intervals of 1 minute and 5 seconds and the limit of flux density
at which core material used by them saturates.
10.18 The name of the core material must be mentioned in the tender. The
successful tenderer shall be required to furnish magnetization curves of the
core material/design calculations and such other data/documents deemed fit
by the Purchaser for being satisfied that flux density is as desired.
10.19
Purchaser shall inspect the built-up core for verification of flux density for which
all facilities shall be provided. The purchaser shall inspect/test the core material
for various tests as per relevant IEC/IS to ensure quality. Core may also be
inspected during horizontal assembly, built-up assembly.
NOTES :
i) The above flux density has been specified to meet with the over fluxing of the
core due to temporary over voltage of the order of 31% for l min, 44% for 5
CT-65
seconds that may appear abnormal conditions such as those following sudden
loss of large loads.
ii)
Yoke bolt area and flitch plate areas shall not be counted in the net core area
if these are provided for fastening core.
iii)
The design of limb and yoke shall be so co-ordinate that there is no cross fluxing
at the joints.
iv)
The tenderer shall ensure that the CRGO supplier should have BIS certification.
11.00 SUPPRESSION OF HARMONICS:

The transformer shall be so designed as to suppress the harmonics voltage specially the
3rd & 5th, to eliminate wave form distortion and interference with communication circuits
due to high frequency disturbances. Limiting percentage of harmonics at normal voltage
and at maximum system voltage shall be stated in the tender.
The transformer shall be so designed as to withstand thermal and electro-magnetic
stress under severe short-circuits where the fault level on 220 kV and 132 KV bus are of
the order of 20,000 and 10,000 MVA respectively.
12.00 WINDING:
12.1 The 220/132 kV windings shall have graded insulation whereas the
neutral points shall be insulated as amended in IS: 2026.
12.2 The transformers shall be capable of operation without danger on any particular
tapping at the rated KVA when the voltage may vary by 10% of the voltage
corresponding to the tapping.
12.3 The windings and connections as well as the insulating material shall not soften
ooz, shrink or collapse during service.
12.4 No strip conductor wound on edge shall have a width exceeding six times its
thickness. The conductors shall be transposed at sufficient intervals to minimize
eddy currents and equalize the current and temperature distribution along the
windings.
12.5 The windings and connections shall be properly brazed to withstand shocks
during transportation or transient conditions during service.
12.6 Adequate pre-shrinkage of the coil assembly using pre-compressed press board
material having low moisture content for the radial spacer blocks shall be
ensured by the manufacturers so that there is no displacement of the radial
spacer blocks due to frequent short circuits on the transformers.
12.7 All windings after being wound and all fibrous hygroscopic materials used in the
construction of the transformer shall be dried under vacuum and impregnated
with hot oil.
In addition to this the drying process be sufficiently extended for proper
stabilization of the coil assembly. More than one cycle of soaking in oil followed
by retightening of the coil assembly should be adopted.
12.8 The coil clamping rings wherever used shall preferably be of flat insulated steel
laminations. Axial laminated material except bakelised paper shall not be used.
CT-66
12.9
The clamping arrangement shall exert equal pressure on all columns of spacers
of the transformer windings built of sections or disc-coils separated by spacers.
In no case, spiral winding will be used either for HV or LV windings.
12.10 The radial spacer blocks must be made of pre-compressed pressboard
material, which will not soften while in contact with oil or fray out into fibers or
edges. The slots should be so dimensioned that the blocks will not come out of
the slots.
Uniform distribution of coil clamping force shall be designed by using an
adequately large number of coil clamping bolts and by transferring the clamping
force from clamping bolts to the clamping plates through intermediate members
which can spread the clamping force over a large area.
12.11 All joints shall be brazed/crimped considering the vibrations due to short circuits
and load fluctuations.
13.00 CURRENT DENSITY:
The employer shall be at liberty to inspect built-up winding for its quality, weight
of copper, insulation and overall weight of coil assembly. The size of conductor
used for different windings shall also be checked during stage inspection to
check the current density. The transformer shall be so designed that the current
density of all the windings and the regulating winding at the lowest tap should not
exceed 250 A/cm.Sq.
14.1
TANK CONSTRUCTION
14.1.1 The tank shall be fabricated of a suitable grade steel and strong enough to allow
the lifting of complete transformer with oil by means of a crane or jacks and
transported to site without over-straining the joints etc.
14.1.2 The main tank body shall be capable of withstanding a vacuum of 100.64 kN/m2
(760mm of Hg.)
14.1.3 The base shall be so designed as to allow the transformer to be moved by
skidding without any injury.
14.1.4 All channeled constructions and stiffeners shall be designed to avoid retention of
water.
14.1.5 The transformer shall preferably be of bell type tank with the joint 500 mm above
the bottom of tank.
14.1.6 The tank construction shall be free of air pockets. Where such pockets cannot be
avoided, vent pipes of 15 mm internal diameter shall be provided to vent gases
into the main expansion pipes. In case of short branch pipes, however, minimum
diameter may be taken as 6mm.
14.1.7 All joints other than those, which may have to be broken, shall be welded. When
required they shall be double welded. All bolted joints to the tank shall be fitted
with suitable oil tight gaskets, which shall give satisfactory service under the
operating conditions and guaranteed temperature rise conditions. Special
attention shall be given to the methods of making hot oil tight joints between the
tank and the cover and also, between the cover and the bushings and all other
out-lets to ensure that the joints can be remade satisfactorily at site and with
ease by semi-skilled labour.
14.1.8 Suitable lifting lugs for lifting the transformer filled with oil shall be provided on
the tank.
CT-67
14.1.9
Four jacking lugs shall be provided to enable the transformer complete with oil to
be lifted or lowered by means of jacks. The lugs shall be fitted at a minimum
height (excluding under base if detachable) of 300mm for transformer upto 10
tons weight and of 500mm for transformer above 10 tons weights.
14.1.10 The transformer shall be provided with detachable steel flanged wheels of
380mm diameter and suitable for moving transformer complete with oil. These
shall be suitable for 2 rails of 1676 mm gauge alongwith longer axis and 2 rails of
3353 mm alongwith shorter axis.
14.2
TANK COVER
142.1
The tank cover shall be of bolted type and of adequate strength so as not to
distort, when lifted. Suitable inspection cover shall be provided with lifting
arrangements to give access to bushings, winding connections or testing the
earth connections. The weight of each inspection cover shall not exceed 25 Kg.
14.2.2 Pockets shall be provided in the position of Max. oil temperature at CMR for
fitting a thermometer and for bolts of oil and winding temperature indicators. The
thermometer pockets shall be fitted with a captive screwed cap to prevent
ingress of water.
14.2.3 Suitable No. of jacking bolts shall be provided on tank cover, inspection
covers/windows including OLTC.
14.3
CONSERVATOR TANK, OIL GAUGE AND BREATHER
14.3.1 An adequate conservator tank of air cell type complete with sump and drain
valves shall be provided in such a position as not to obstruct the electrical
connections to the transformer.
14.3.2 If the sump is formed by extending the feed pipe inside the conservator, this
extension shall be atleast 25mm.
14.3.3 One end of the conservator shall be bolted type to facilitate cleaning.
14.3.4 The conservator shall be provided with a magnetic oil level gauge.
14.3.5 The oil connections from the transformer tank to the conservator shall be at rising
angle of 3 to 9 degrees to the horizontal upto Buchholz relay. The inside
diameter of the pipe shall be 80mm. The Buchholz relay will have suitable valves
on its both side so as to facilitate its testing at site as well as cut off oil supply to
the transformer.
14.3.6 The conservator shall be provided with oil preservation system, which may not
allow direct contact of atmospheric air with oil during operation, in addition to
silicagel-breather.
14.4
VALVES:
14.4.1 The transformers shall be provided with 2 No. filter valve each of 50 mm size one
mounted close to the top of the main tank & the other close to bottom of the tank
oil circulation and one drain valve of 80mm size with plug. The conservator shall
have drain plug of 25mm size.
14.4.2 Two robust sampling valves with spouts suitable for taking samples of top, and
bottom oil. The top sampling valves shall be brought down by internal pipe
connections. Suitable name plates shall be affixed to the sampling valves. The
sampling device shall not be fitted on the filter valve.
14.4.3 Two air release plug of 15mm shall be provided.
14.4.4 Plugs shall be supplied for all valves opening to atmosphere.
CT-68
14.4.5 All valves shall be of gun metal and comply with the latest edition of IS:3639.
14.5 PRESSURE RELIEF DEVICES:
A suitable pressure relief device shall be provided for rapid release of any pressure in
transformer which may endanger the equipment. The device (s) shall operate at static
pressure less than hydraulic test pressure for transformer tank of OLTC chamber. If
the device is mounted on tank cover, it shall be fitted with a skirt projecting 25mm
inside the tank and of such construction as to avoid gas accumulation.
In addition to pressure relief device(s) the provision of explosion vent should also be
made and the diaphragm shall be situated above max. oil level or second PRD on the
opposite side of first PRD be provided.
14.6 EARTHING TERMINALS:
Two earthing pads suitable for connecting 50x8mm mild steel flat shall be provided at
positions close to the two diagonally opposite bottom corners of tank. These grounding
terminals shall be suitable for bolted connection. Two earthing terminals shall also be
provided each on marshalling box and any other equipment mounted separately. The
earthing terminal should be suitable of carrying full low voltage short circuit current of
transformer for 4 seconds.
14.7 JOINTS AND GASKETS: All gaskets used for making oil tight joints shall be of granulated cork bonded with
synthetic rubber. Metal tops shall be provided for preventing over compression
wherever compressible gaskets are provided.
14.8
RATING AND DIAGRAM PLATES:
14.8.1 Each transformer shall carry a diagram plate showing internal connections, voltage
vector relationship of different windings, plan view of the transformer showing
physical relationship of the terminals and no load voltage and corresponding
current for each tap.
14.8.2.1 Each transformer shall be provided with a rating plate data as specified in IS: 2026
or equivalent international standard.
14.8.3 The transformer shall carry a valve schedule plate shorting the location and
function of all values and air release cock on plugs. This plate shall warn
operators to refer to the maintenance instructions before applying the vacuum
treatment for drying.
14.8.4 I.R. values along-with oil temperature at the time of testing at manufacturer's
works shall be indicated on rating plate or separate plate, to be provided on
transformer.
14.9
THERMOSYPHON FILTER ARRANGEMENT

Thermosyphon filter arrangement shall be provided on the transformer for
preserving the quality of Transformer Oil. The filter assembly shall be mounted
on the Transformer as well as ground supported and connected with pipes and
shut off valves. Suitable instructions required to be followed for commissioning,
dismantlement & maintenance of the filter arrangement, re-generation and
storage of the adsorbent etc. must be included in the instruction manual. A
detailed drawing showing internal arrangement shall also be required to be
submitted. Suitable capacity pump (alongwith motor) shall also be provided to
CT-69
boost circulation of oil. The pump and motor should not be in main pipe line. It
should be in bypass pipe line having suitable valve to isolate from main pipe line.
The main pipe line should have two shut off valves at the bottom.
NOTE: -
The pump and motor should be weather proof (Flow well Type).
The oil & absorbent capacity required in the Thermosyphon Filter is as under: (i)
(ii)
15.0
Quantity of oil
Quantity of absorbent
2.0% of total oil by weight.

NITROGEN INJECTION FIRE PROTECTION CUM EXTINGUISHING SYSTEM

FOR 100 MVA TRANSFORMER
The contractor shall provide the nitrogen injection fire protection cum
extinguishing system. The fire protection system using nitrogen as fire quenching
medium is required for the 100 MVA 220/132 kV T/F NIFPES shall act as fire
preventer by preventing transformer oil tank explosion and possible fire in case of
internal faults. In the event of fire by external causes such as bushing fire, OLTC
fires, fire from surrounding equipment etc, it shall act as a fast and effective fire
fighter. NIFPES shall accomplish its role as fire preventer and extinguisher
without employing water and/or carbon dioxide. Fire shall be put out within max.
3 minutes of system activation and within max. 30 seconds of commencement of
nitrogen injection.
15.1
Activation of NIFPES
Mal-functioning of fire prevention/extinguishing systems is their major shortcoming
which leads to interruption in power supply. The contractor shall ensure that the chances
of malfunctioning of NIFPES are practically nil. To achieve this objective, the contractor
shall work out his scheme of activating signals which, while preventing mal-operation,
should not be too rigorous to make the operation of NIFPES impracticable in case of
actual need. Transformer isolation shall be the mandatory pre-requisite for activation of
the system in automatic mode or remote mode in the control room. In addition, at least
following electrical-signals shall be provided in series for activating NIFPES.
15.1.1 Auto Mode

a)
For prevention of fire:
i) Differential relay operation
ii) Buchholz relay paralleled with pressure relief valve
CT-70
iii) Tripping of all connected 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.
15.1.2 Manual Mode (Local/Remote):
Tripping of all connected breakers is

pre- requisite for initiation of system
activation.
15.1.3 Manual Mode (Mechanical)

a

activation.
15.2
General description of NIFPES
15.2.1 Schematic of the system

NIFPES should be a stand alone dedicated system for oil filled transformer. It should have a fire
extinguishing (F.E.) cubicle placed on a plinth at a distance of 6-10 mtrs. from the transformer.
The F.E. cubicle may be connected to the transformer oil tank (near its top) and to the oil pit (of
capacity approx. equal to 10% of transformer oil tank) from its bottom through oil pipes with gate
valves. The F.E. cubicle should house a pressurised nitrogen cylinder connected to the
transformer oil tank (near its bottom). Cable connections are to be provided from signal box
placed on the transformer to the control box in the control room and from control box to F.E.
cubicle. Fire detectors placed at the top of transformer 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 to be connected to relay panel in control
room for system activation signals.
15.2.2 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, stirring the oil thus bringing the temperature of top oil layer
CT-71
down. Nitrogen occupies the space created by oil drained out and acts as an insulating
layer between the tank oil and fire on top cover. Pre-stressed non-return valve blocks oil
flow from conservator tank, thus isolating it & preventing aggravation of fire.
15.2.3 System components
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 and effective working of NIFPES shall be considered within the scope of
supply.
15.2.4 Fire Extinguishing cubicle
it shall be made of 3 mm thick steel sheet, painted dark red from inside and 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
transformer.
Panel lighting (CFL type)
Oil drain pipe extension of suitable sizes for connecting pipes to oil pit.
15.2.5 Control box

Control box for monitoring system operation, automatic control and remote operation,
with following alarms indication, light switches, push buttons, audio signal, line fault
detection suitable for tripping and signaling on 110V DC/220V DC supply.
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 progress^
Cylinder pressure low^
Differential relay trip^
PRV operated^
Transformer trip^
CT-72
System out of service

Line fault fire detector
Line fault differential relay
Line fault buchholz relay
Line fault PRV
Line fault transformer trip
Line fault PNRV
Auto / Manual/Off
Extinction release on
Extinction release off
Lamp test
Visual/Audio alarm
Visual/Audio alarm
Visual/audio alarm for DC supply fail
The signals marked (*) shall be in the top most row of control box panel. The
signals marked (^) shall follow next.
15.2.6 Pre-stressed non return valve (PNRV)

PNRV is to be fitted in the conservator pipe line between conservator and 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 consequence as its closing leads to stoppage of breathing of
transformer.
15.2.7 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 141 degree C for heat sensing each fitted
with two no. cable glands (water proof/weather proof).
15.2.8 Signal box
It shall be fitted on the transformer for terminating cable connections form PNRV and fire
detectors and for further connection to the control box.
15.2.9 Cables
Fire survival cables, able to withstand 750 degree C , 4 core x 1.5 mm sq. for connection
of fire detectors in parallel shall be used.
Fire retardant low smoke (FRLS) cable 12 core x 1.5 mm sq. for connection between
transformer signal box/marshalling box to control box and control box to fire
extinguishing cubicle shall be used.
CT-73
Fire retardant low smoke 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/marshalling box to
pre-stressed non return valve connection on transformer shall be used.
15.2.10 Pipes
Pipes, complete with connections, flanges, bends tees etc. shall be supplied alongwith
the system.
15.3 Other items
a. oil drain and nitrogen injection openings with gate valves on transformer 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 transformer top cover.
d. Spare potential free contacts for system activating signals i.e. differential relay buchholz
relay, pressure relief valve, transformer isolation (master trip relay).
e. Pipe connections between transformer to fire extinguishing cubicle and fire extinguishing
cubicle to oil pit.
f. Cabling on transformer 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. Mild steel oil tank with moisture proof coating and sheet thickness of minimum 5 mm,
with watertight cover, to be placed in the oil pit. 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.
The capacity of tank shall be 10,000 ltrs. and shall be provided as each S/Stn. The
location of the tank shall be approved by the employer. All the Transformers to be fitted
with NISPEF at that S/Stn. shall be connected through suitable piping arrangement to
this common tank.
h. DC-DC converter 220-110V DC (optional, incase 110V, supply is not available.)
i. Gate valves on oil drain pipe and nitrogen injection pipe should be able to withstand full
vacuum. A non-return valve shall also be fitted on nitrogen injection pipe between
transformer and gate valve.
j. 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 be painted with enameled paint.
k. Civil works of F.E.Cubicle and oil pit are not in the scope of bidder.
15.4
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.
CT-74
15.5
Technical particulars
15.5.1 Fire extinction period

On commencement of nitrogen injection : Max. 30 secs.
From the moment of system activation to : Max. 3 mins.
Complete cooling.
Fire detectors heat sensing temperature
:1410C
Heat sensing area
:800mm radius
Pre-stressed non return valve setting for
:minimum 60 ltr. Per operation.min.
Capacity of nitrogen cylinder
:minimum 68 ltr. water cap.
and shall hold minimum 10 cubic mete gas
to 150 bar pressure.
Power Source
:
Control Box
:110V DC/220V DC
Fire extinguishing cubicle for lighting
: 230V AC
16.00
COOLING PLANT:
16.1 The cooling equipment shall consist of the following:
a. 2-50 percent tank
b. 2-100% pumps one of these being stand by
c. 2-stand by fans one in each 50% Bank
16.2
In case separate cooler banks are used, they shall be suitable for mounting on a flat
concrete base. These shall be provided with a valve (25 mm) at each point of
connection to the transformer tank, removable blanking plates to blank off main oil
connections to each cooler. Thermometer pockets with captive screwed cap at inlet
and outlet of each separate cooler, filter valve at top and bottom and air release plug of
15mm.
16.3
The motor blowers shall be direct driven suitable for continuous out door operation and
complete with necessary air dusting. These shall be mounted independently from the
radiator and in the case, these are radiator mounting type, use shall be made of some
anti-vibration means. Care shall be taken that the blower unit is capable of being
removed without disturbing the radiator structure. The blades shall be suitably painted
and shall not be of hollow sections. Suitably painted wire mesh guards with mesh not
greater than 25mm shall be provided to prevent accidental contact with the blades.
16.4
MOTORS:
16.4.1 The motor shall be squirrel cage totally enclosed weatherproof type suitable for direct
starting and for continuous running from 415/240 volts, three-phase/single phase 50
HZ supply. The motors shall comply with IS as applicable for continuous rated
machine.
16.4.2 All motors shall be capable of continuous operation at frequency 50Hz with variation of
5% and 415/240 V AC 10% variation of the normal voltage without injurious over
heating.
16.4.3 All motors shall have ball or roller bearing with hexagonal nipples for greasing. In case
of vertical spindle, motor shall have bearing capable of withstanding thrust, due to
weight of the moving parts.
CT-75
16.4.4
16.5
16.5.1
16.5.2
16.5.3
16.5.4
17.00
17.1
17.2
17.2.1
17.2.2
Varnished cambric or glass insulator shall be used for connections from stator winding
to the terminal suitable for external wiring. The motor terminals shall be of stud type
and totally enclosed.
COOLER CONTROL:
Each motor or group of motors shall be provided with a 3 pole electrically operated
connector with control gear for motor operation by hand and automatically through
winding temperature indicator. Provision shall be made for over load protection but no
volt release shall not be provided.
All connection shall be so arranged as to allow either individual or collective operation
of the motors. Alarm indication (audio and visual) for failure of fans and to indicate
failure of power supply shall be provided.
The control equipment shall be installed in the marshaling box as specified in Cl.22 in
a readily accessible position.
The alarm indication for failure of power supply and failure of individual fans be
provided through independent non trip alarm scheme to be wired on the remote tap
charger control cubicle conforming to the following. : i)
The closing of an initiating contact shall actuate a buzzer and will be
accompanied by a flag indication on the concerned auxiliary relay.
ii)
The closing of an initiating contact shall glow a lamp, which will not reset until
the fault has been cleared.
iii)
It shall be possible to silence the buzzer by pressing 'Accept' push button. If,
after canceling the alarm but before resetting the visual signal, the same fault
persists the buzzer shall be suppressed.
iv)
If after canceling the alarm but before resetting the visual signal, some other
fault takes place, the alarm accompanied by flag indication on appropriate
auxiliary relay shall take place.
v)
If after canceling the alarm and after resetting the visual signal, the same
fault appears or some other fault takes place, the alarm, flag indication and
non-trip lamp indication shall reappear as usual.
vi)
The non-trip alarm acceptance shall be by means of push button and resetting
of visual signal may also preferably be done through a push button.
vii)
Means shall be provided for test checking the lamp and alarm circuit at
frequent intervals.
viii)
The equipment shall be suitable for 220 Volts DC operation.
Static facia aunnuciator conforming to the foregoing requirements of non-trip
alarm scheme too would be acceptable.
VOLTAGE CONTROL (ON LOAD TYPE):
The transformer shall by provided with OLTC which apart from being suitable for local
manual/electrical operation & remote electrical operation.
Equipment for 'local' and 'remote' electrical and 'local' manual operation shall be
provided and shall comply with the following conditions. Local/ remote switch may be
housed in remote control panel or in tap changer drive mechanism.
It shall not be possible to operate the electric drive when the manual operating gear is
in use.
It shall not be possible for any two electric controls to be in operation at the same time.
CT-76
17.2.3
17.2.4
17.2.5
17.2.6
17.3
17.4
17.4.1
17.4.2
17.5
17.6
17.7
17.8
17.9
17.10
The equipment suitable for supervisory control and indication on a multi way switch,
make-before break, having one fixed contact for each tap position, shall be provided
and wired to the tap changer drive gear. This switch shall be provided in addition to
any, which may be required for remote tap change position indication purpose.
Supervisory indication shall also be provided in the form of contacts to close on. "Tap
change incomplete" condition. All other components of the supervisory gear if required
be specified separately.
Operation from the local or remote control switch shall cause one tap movement only.
The control switch shall be returned to the 'neutral' position between successive
operations.
All Electrical control switch on the local operation gear shall be clearly labeled in a
suitable manner to indicate the direction of tap changing.
The local control switches shall be mounted, in the drive gear housing.
The equipment shall be so arranged as to ensure that when a tap change has
commenced, it shall be completed independent of the operation of the control relays or
switches. In case of failure of the auxiliary supply while tap change is in progress or
any other contingency such as stuck tap changer, adequate means shall be provided
to safe guard the transformers and its auxiliary equipment.
Suitable apparatus shall be provided for each transformer to give indications as
follows: To give indication, mechanically at the transformer and electrically at the remote
control cubicle of the position of tap in use.
To give an indication at the remote control cubicle that a tap change is in-progress, by
means of an illuminated lamp.
For remote control, the switches, tap position indicator, etc. shall be supplied duly
mounted on remote control cubicle.
All relays and operating devices shall be operated correctly at any voltage between the
limits specified in the relevant ISS.
The tap changing mechanism and mechanism shall be mounted in the oil tank or
compartment mounted in an accessible position on the transformer.
Any non oil filled enclosed compartment shall be adequately ventilated,
thermostatically controlled heaters shall be provided in the driving mechanism
chamber and in the marshaling box. All contactor & auxiliary relay coils or other parts
shall be suitably protected against corrosion or deterioration due to condensation,
fungi etc.
The tap changer contacts which are not used for making or breaking current like
separate selector switch contacts can be located inside main transformer tank where
tap changer construction permits such an arrangement. The oil in case of on load tap
changer having separate compartment for selector contacts shall be maintained under
conservator head by means of pipe connection from the highest point of the chamber
to the conservator. Such connection shall be controlled by suitable valve and shall be
arranged so that any gas leaving the chamber will pass into the gas and oil actuated
relay. A separate Bucholz relay may be provided for this compartment.
It shall not be possible for the oil in these compartments of the tap change equipment
which contain contacts used for making or breaking current, to mix with the oil in the
compartments containing contacts and not used for making or breaking current.
CT-77
17.11
17.12
17.13
17.14
17.15
17.16
17.17
17.18
17.19
17.20
17.21
18.00
18.1
18.2
18.3
Any 'DROP DOWN' tanks associated with the tap changing apparatus shall be fitted
with guide rods to control the movement during lifting or lowering operations. The
guide rods shall be so designed as to take support of the associated tank when in the
fully lowered position with oil. Lifting gear fitted to 'Drop Down' tanks shall include
suitable device to prevent run-away during lifting and lowering operations. They shall
be provided with adequate breathing arrangement.
Each compartment in which the oil is not maintained under conservator head shall be
provided with a suitable direct reading oil gauge.
The alternating supply for electrical operation of the control and indicating gear shall
be standard 415 Volts, three-phase, 3 wire, 50 Hz. alongwith 240 Volts single phase, 2
wire 50 Hz, subject to a variation of 5 percent so that the equipment offered can
withstand variation in AC
Limit switches shall be provided to prevent over-running of the mechanism and except
where modified in clause 17.15 shall be directly connected in the circuit of the
operating motor. In addition a mechanical stopper or other approved device shall be
provided to prevent over-running of the mechanism under any condition.
Limit switches may be connected in the control circuit of the operating motor provided
that a mechanical declutching mechanism is incorporated.
Thermal devices or other means like motor circuit breakers with shunt trip coil shall be
provided to protect the motor and control circuits. All relays, switches fuses, etc. shall
be mounted in the marshaling box or driving gear housing. These shall be clearly
marked for purpose of identification. They shall withstand the vibration associated with
tap changer gear operation.
The control circuits shall operate at 110V single phase to be supplied from a
transformer having a ratio of 415 or 240/55-0-55 V with the center point earthed
through a removable link mounted in tap changer drive.
The whole of the apparatus shall be of robust design and capable of giving satisfactory
service under conditions to be met in service including frequent operation.
A five-digit counter shall be fitted to the tap changing mechanism to indicate the
number of operations completed by the equipment.
A permanently legible lubrication chart shall be fitted within the driving mechanism
chamber, where applicable.
The indigenous make OLTC having voltage rating as 132 kV & current rating 500 Amp.
should be duly type tested from CPRI or other Govt. test house or from reputed lab
abroad to the extent the facilities of type test are available with CPRI.
PARALLEL OPERATION:
In addition to individual control of tap changer, provision shall be made to enable
parallel operation of the tap changer when one unit is running in parallel with another
transformer.
Suitable selector switch and controls shall be provided so that any transformer of the
group can at a time be selected as master, follower or independent. Arrangement shall
be made that only one of the transformers can be selected as master at a time.
An out of step device shall be provided for each transformer indicating out of step
condition by an indicating lamp and buzzer. It shall be arranged to prevent further tap
changing when transformers in a group operating in parallel control are one tap out of
step.
CT-78
19.0.
19.1
20.00
20.1
20.2
BUSHING INSULATORS AND TERMINALS:

Transformer shall be fitted with bushing insulators as follows: HV bushing: 245 kV class, condenser bushing of 800 Amp. rating without arcing
horns.
L.V. Bushing: 145 kV class condenser bushing of 800 Amp. rating without arcing
horns.
Neutral Bushing: 36 kV class, oil communicating type porcelain bushing of 1000
Amp. rating but without arcing horns.
The characteristics of the bushings shall be in accordance with IS: 2099 and IS:
3347.
The bushing insulators except for neutral bushing shall be provided with adjustable
arcing horns and the bidder shall furnish calibration gap to decide actual gap
setting.
A continuous flexible pull through lead suitably sweated to the end of winding
copper shall be connected to the connector in the helmet of the 220/132 kV
Bushing. The bushings may be filled with oil, which may not be in communication
with the oil in transformer.
All porcelain shall be free from defects and thoroughly vitrified with a smooth, hard
and uniform brown glaze. It should be capable of satisfactory use under the
climatic conditions as specified in clause-3.0.
In case of paper insulation care shall be taken to prevent ingress of moisture and a
final coat of non-hygroscopic varnish shall be given to them.
All clamps and fittings made of malleable iron or steel shall be galvanized as per
IS: 2629. The bushings flanges shall not be of re-entrant shape which may trap
air.
Bi-metallic terminal connectors shall be supplied suitable for single tarantula
conductor for HV LV side and neutral side. The take off for H.V. & L.V. connectors
will be Vertical and for Neutral it should be suitable for horizontal take off.
The connectors shall have six number bolts provided with check nuts & washers.
The connectors shall have rating corresponding to those of equipment or higher
and shall be designed most liberally with a higher factor of safety to comply in all
respects with temperatures rise, resistance, tensile strength short-circuit withstand
capability tests as specified in IS: 5561-1970 or amendment thereof (Latest
edition). Aluminum alloy used in the manufacture of Bi-metallic connectors shall
conform to designation Grade 4600 of IS:
617-1975. The steel bolts, nuts washers and check nuts shall be hot dip galvanized
marked with ISI certification mark or of GKW make.
TEMPERATURE INDICATING DEVICES:
All transformers shall be provided with a dial type thermometer for indicating oil
temperature. The indicator shall be fitted with a pointer to register maximum temp
recorded and adjustable set of mercury contact for alarm and trip.
In addition, all the transformers shall be provided with a dial type Hot Spot winding
temperature indicator in HV & LV winding. The indicator shall have a pointer to register
maximum temperature reached and four sets of adjustable mercury contacts for alarm,
trip, automatic control of fans & remote indication. The static remote repeater (for
winding temperature indicator) suitable for flush mounting shall be installed on remote
tap charge control cubicle.
CT-79
20.3
20.4
20.5
20.6
20.7
21.00
211
21.2
21.3
21.4
21.5
22.00
22.1
22.2
22.3
22.4
22.5
23.00
23.1
The temperature indicators shall be housed in marshaling box.

The alarm (mercury) contact of WTI & OTI shall be adjustable between 50oC to 100oC
where as their trip (mercury) contacts shall be adjustable between 60oC and 120oC.
The temperature difference between opening & closing of these mercury contacts shall
not be more than 10oC.
The mercury contacts used for controlling cooling plant motors shall be adjustable to
close between 50oC and 100oC. The temperature differential between opening &
closing of this mercury contract shall be between 10oC to 15oC.
All contacts should be accessible on removal of the cover adjustable to scale. It shall
also be possible to move the pointers by hand for checking the operation of contacts
and associated equipment.
In addition each transformer shall be provided with a dial type thermometer for
indicating the ambient temperature.
GAS AND OIL ACTUATED RELAYS: The transformer shall be provided with a gas and oil actuated relay fitted with alarm
and trip contacts for main tank & oil surge relay for its OLTC as per IS:3637.
Each such relay shall be provided with a test cock to take a flexible connection for
checking relay operation
A machined surface shall be provided on top of relay for checking mounting angles in
the pipe cross level of relay and its setting.
The pipe work shall be such as to allow any gas formed in the tank to pass through the
relay. The oil circuit through the relay shall not form a parallel delivery path with any
circulating oil pipe, nor shall it be tied into or connected through the pressure relief
vent.
Adequate clearance between oil pipe work and live metal parts shall be provided.
MARSHALING BOX: A sheet steel (of 10 SWG size) vermin proof well ventilated and weather proof
marshaling box of suitable construction shall be provided for the transformer auxiliary
apparatus. The box shall have domed or sloping roofs. Ventilation louvers, suitably
padded with felt, shall also be provided. It shall be painted as per Cl.5.14.
The marshaling box shall accommodate temperature indicators. Local electrical
control of tap changer (if same cannot be housed in motor drive housing.), Control &
protection equipment for cooling plant, terminal boards and gland plates for cable etc.
The equipment shall be mounted on panels and panels wiring shall be done at the
back for interconnections.
The temperature indicators shall be mounted at about 1600mm from ground level.
A metal clad heater with thermostat, controlled by a waterproof rotary switch on the
outside of the box, shall be provided.
The incoming cables shall enter from the bottom with gland plate not less than 450mm
from the base of the box. Care shall be taken to avoid ingress of water from the cable
trench.
CONTROL CONNECTIONS, INSTRUMENTS WIRING, TERMINAL BOARD AND
FUSES: All cables and wiring shall be suitable for use under the conditions as specified in
Section -I. Any wiring liable to come in contact with oil shall be of oil resisting
CT-80
23.2
23.3
23.4
23.5
23.6
23.7
24.0
insulation. The bare ends of stranded wire shall be sweated together to prevent oil
from creeping along the wire.
The instrument and panel wiring shall be run in PVC or non rusting metal cleats of
limited compression type.
The box wiring shall be as per relevant ISS. All wiring shall be of stranded copper of
660V grade and size not less than 4 Sq. mm. for CT leads and not less than 2.5 Sq.
mm for other connections. The panel wires and multi core cable shall bear ferrules of
white insulation material with indelible marking in black and as per relevant ISS. Same
ferrule number shall not be used on wires in different circuits. Double ferrule may be
provided where a change in number is required.
Stranded wires shall be terminated with tinned Ross Courtney terminals, washers or
crimped tubular lugs. Separate washers shall be used for each wire. Wire shall not be
jointed/tied between terminal points.
Where apparatus is mounted on panels all metal cases shall be separately earthed by
copper wire or strip not less than 2.5 sq. mm. The screens of screened pairs of multi
core cables shall be earthed at one end of the cable only.
All terminal boards shall be of stud-type & mounted obliquely towards the rear door
and these boards shall be spaced not less than 100mm apart. Suitable insulation
barriers shall be provided between adjacent connections. No live metal shall be
exposed at the back of terminal boards.
All fuses shall be of cartridge type and fuses and links shall be properly labeled.
EQUALIZATION FORMULA:
The losses at principal tap of each transformer shall be stated in the tender. The
manufacture shall state separately no load, load and Auxiliary losses at rated
frequency & voltage and load losses corresponding to OFAF rating (at full load at
750C) for fair comparison of difference of losses. It is essential that tenderers quote
firm losses.
For the purpose of arriving at comparable prices, the iron, copper and auxiliary losses
shall be capitalized as per formula given below:
=3,86,700 (Wi + 0.45 Wc + 0.45Wp)
Where
Wi
Wc
Wp
25.00
=
=
=
Iron (No. Load ) Losses

Copper (Load) Losses
Auxilary Losses
The maximum sealing of component and weightage average losses shall be as per clause
25.00 and no positive tolerance shall be allowed on these values.
In case losses of the T/F are found to be higher then the specified values at any stage
within three years from the date of commissioning the capitalized value of excess
losses, as compare to the specified value shall be recovered as per following
capitalization formula:Amount recoverable (Rs.)= 3,86,700(Wi + 0.45 Wc + 0.45Wp)
Losses:The losses of each transformer shall be stated in the tender for OFAF at principal tap
rating (at full load at 75 deg. C ) which shall be less than:-
CT-81
25.1
Sr. No.
Type of Losses
1
2
3
4
No Load Losses
Load Losses
Auxiliary Losses
overall average wt. losses (based on
capitalisation formula of W i+0.45 (W p+W c)
Noise level
100 MVA, 220/132

KV T/F
28 KW (Max)
233 KW(Max)
11 KW (Max)
124KW (Max.)
80 dB
Transformer offers shall be rejected if audible sound level is higher than max. 80 dB.
26.00
TESTS:
26.1
ROUTINE TESTS:
All routine test shall be carried out on each transformer as per IS-2026 in the presence
of employer's representative.
26.2
26.2.1
26.2.2
26.2.3
TYPE TESTS :
The following type tests shall be carried out on one transformer as per IS: 2026 in the
presence of employer's representative.
i)
Temperature rise test (alongwith DGA)
ii)
Impulse voltage withstand test as per ISS: 2026/Part-III/81 on one limb.
There will not be any separate schedule for type test charges. The charges if any may
be included in bid price.
In addition, the following tests shall be carried out on the Transformer Tank:
OIL LEAKAGE TEST:
All tanks and oil filled compartments shall be tested for oil tightness by being
completely filled with oil of viscosity not greater than that of insulating oil to IS: 335 at
ambient temperature and subjected to a pressure equal to normal pressure plus
35KN/M2 (5 lbs sq. inch) measured at the base of the tank. This pressure shall be
maintained for a period not less than 12 hours, during which period no leakage shall
occur.
Following tests shall be carried out on each transformer as reference test:
i)
Measurement of tan delta and capacitor of T/F Winding and bushings at 5 kV &
10 kV.
ii)
Partial discharge list.
iii)
Noise level test.
iv)
Magnetic balance test.
v)
Magnetising current at low voltage
vi)
Measurement of percentage impedance at all taps at low voltage.
TRANSFORMER OIL:
Sufficient quantity (along with 10% extra) of insulating oil of napthenic type (as per
Clause-6 of specification) conforming to BS:148/IEC-296 Class-1 shall be put up for
inspection, at least 3 weeks before putting up the transformer for testing/inspection, at
CT-82
26.2.4
26.3
26.4
sub-supplier works as per IS:335/BS/IEC. One sample of the oil shall also be got
tested from CPRI or any other Govt. approved testing house. The inspected oil shall
be dispatched to site as per dispatch instructions of purchaser.
SHORT CIRCUIT TEST
Short circuit test in accordance with latest IS-2026 Part (5) clause 4.2, IEC-60076-5
and CEA regulation-2010 shall be got conducted on one of the units of each voltage
and capacity at any test Agencies where facilities exist in the presence of Purchaser's
representative. However, in case of those manufacturers who have already got short
circuit test in accordance with Cl. 4.2 of IS-2026 Part(5) or latest edition conducted
during the last 7 years on same design and capacity of the Transformer, fresh short
circuit test is not required to be conducted. The bidder in such a case shall submit the
copy of type test report along with the bid. If this test is not conducted by the firm
earlier, then charges for this test shall be borne by the bidder.
The employer reserves the right to have any other, reasonable test carried out at his
expense either before shipment or at site to ensure that the transformer complies with
the requirement of this specification.
STAGE INSPECTION:
Stage inspection of built up core (in horizontal/vertical position), windings, tank and
radiators shall be carried-out as detailed below:a. CORE:i)
Measurement of flux Density.
ii)
No Load Loss Measurement by providing dummy oils.
iii) Tests of CRGO sample taken from the core shall be carried-out for Carlite test
(Resistance Measurement), Watt Loss Test, Lamination Thickness & Aging
Tests.
iv) Physical inspection for quality of workmanship.
v)
Slitting/Cutting of core.
b.
WINDINGS:
i.
Measurement of cross-sectional area for current density.
ii.
Measurement of weight of bare copper/ cover by resistance methods.
iii. The purity test of copper shall be got conducted on sample of copper for
assessing its quality, from two independent NABL accredited laboratories.
c. TANK:
i) Vacuum Test:
One transformer tank out of the lot shall be subjected to vacuum pressure of
100.64 kN (760 mm of hg). The tanks to be designed for full vacuum shall be tested
at an internal pressure of 3.33 KN/M2 (25mm of Hg.) for one hour.
The permanent deflection of flat plates after the vacuum has been released shall not
exceed the values given below without affecting the performance of the Transformer
-----------------------------------------------------------------------------------------------------------------Horizontal length of flat plate(mm).
Permanent deflection (mm).
-----------------------------------------------------------------------------------------------------------------Upto & including 750
5.0
751-1250
6.5
CT-83
1251-1750
8.0
1751-2000
9.5
2001-2250
11.0
2251-2500
12.5
2501-3000
16.0
above 3000
19.0
----------------------------------------------------------------------------------------------------------------ii) PRESSURE TEST:
One transformer tank out of the lot shall be subject to the pressure corresponding to
twice the normal head of oil or normal pressure plus 35KN/M2 (which ever is lower)
measured at the base of the tank and maintained for one hour. The permanent
deflection of flat plates after removal of excess pressure shall not exceed the figures
specified as above.
CT-84
d. RADIATORS:
Radiator shall be routine and type tested at sub contractors' work as per relevant
standard. Test reports are required to be supplied at the time of final inspection.
NOTE:
a.
27.00
27.1
27.1.1
27.1.2
27.2
The insulation resistance values of the transformer windings will be recorded at

the time of carrying out routine tests, for 20 seconds, one minute, two minutes
with the help of 5000V motorized meggar. (Preferably EVERSHED/ AVO &
VIGNOLE MAKE). The polarization index values (ratio of 120/20 sec. value)
will be accordingly calculated and recorded in the test certificates and it should
not be less than 1.5.
b.
Dissolved gas analysis test shall be got carried-out before and after heat run
test at CPRI.
c.
Capacitance and Tan Delta values for each transformer and condenser
bushings will be taken and recorded in the test certificates at 5 kV & 10 kV.
Insulation resistance value of condenser bushings shall also be recorded.
d.
Lightening impulse test with the chopped wave applications as per clause 13 of
IS: 2026/ 1981 (Part-III) amended upto date. This test will be carried out on one
of the limbs of HV and LV winding with positive polarity.
e.
The tender should clearly indicate the testing facilities available with them and
tests which are to be arranged outside.
Contractor shall submit in-house test certificate atleast 15 days in advance for final
testing of transformer.
For testing T/F, all measuring instruments shall be of highest efficiency and best
quality. These shall be got calibrated from NPL/ Govt. Agency and be got sealed by
calibrating agency. HVPN reserves the right to calibrate the instruments in the
manner it desires.
Losses shall be measured with 3-wattmeter method only. Resistance shall be taken
with Double-Kelvin Bridge. Losses can be measured directly from CTs and PTs and
not through the panel. Ratio of the measuring instrument shall be such that the
multiplying factor is the minimum.
All tests shall be carried out in the presence of the Employer before despatching the
material. Test certificates in quadruplicate will be submitted to the Employer for
approval. No material shall be despatched without prior inspection and approval of
test certificates unless otherwise agreed to. Type and routine test certificates of all
bought out items from recognised testing agency shall be submitted for approval
before commencing supplies. OLTC scheme including the master follower
functioning shall also be checked. Only fully assembled transformer including
mounting of radiators shall be put-up for inspection.
DRAWINGS:
The following drawings shall be supplied as part of the tender.
Outline dimensional drawing of transformer and accessories.
Bushing and terminal connectors drawing.
The successful bidder shall submit final version of drawings complete in all respects
as detailed in the following sub-clauses, in quadruplicate, within four weeks of
placement of order for employers approval. The employer shall communicate his
comments/approval on the drawings to the contractor within four weeks of their
CT-85
receipt. The manufacturer shall, if necessary, modify the drawings and resubmit the
same for employers approval within two weeks of receipt of comments. Such duly
revised drawings will be approved by the employer within two weeks of the receipt.
After receipt of employers approval to drawings, the manufacturer will submit a set
of re-producible of all the approved drawings and will also supply five sets of all
approved drawings and five sets of manual of instructions per transformer to substation Design Directorate, HVPNL, Panchkula.
ONE SET OF ALL THE APPROVED DRAWINGS AND MANUAL OF INSTUCTIONS
WILL BE SUPPLIED ALONGWITH EACH TRANSFRMER WITHOUT WHICH THE
SUPPLY WILL NOT BE CONSIDERED AS COMPLETE SUPPLY.
27.2.1
27.2.2
27.2.3
27.2.4
27.2.5
27.2.6
27.2.7
27.2.8
27.2.9
27.2.10
27.2.11
Outline general arrangement drawings showing plan, front elevation & side elevation
with all fittings and accessories etc. The following information must be specifically
included on the drawings.
a.
Make of transformer oil.
b.
Electrical clearances, minimum as well as actual.
c.
No. of radiator headers, number of radiator element in each header.
d.
Small sketch showing un-tanking details.
e.
Thickness of transformer tank bottom, side & top plates.
f.
Type, shade, shade No. and thickness of transformer paint.
g.
Roller, rail gauge sketch.
h.
Weight of oil, bare copper weight windings, core, un-tanking mass,
transportation mass and dimensions etc.
Detailed of bushings showing plan, elevation, terminal details, mounting details make
and type number incorporating electrical characteristics, description of various parts,
total creepage/ & protected creepage distance, weight of oil, total weight of bushing ,
dimensions, short time current rating etc.
Drawing showing HV & LV windings with arrangement of insulation and terminal
connections.
Schematic control and wiring diagram for auxiliary equipment like OLTC control gear,
cooler control gear, Marshaling Kiosk. Detailed write-up for schematic shall also be
supplied
Combined Rating & Diagram Plate.
Valve schedule plate.
Core assembly drawing with flux density calculations.
Interconnection diagram between OLTC panel, Drive mechanism and marshalling
kiosk.
Detailed calculations showing short circuit withstand capacity due to radial and axial
forces during short circuit and calculation for thermal withstand capability during
short circuit shall also be supplied.
Cable arrangement on the transformers.
Drawing showing connection of HV, LV lead with the respective bushing and their
place of storage during transportation.
CT-86
27.2.12
28.00
29.00
30.0
Detailed drawings of NIFPES System along with its detailed write up.
LIST OF SPARES
As per schedule of requirement.
SPARE WINDING
It will be obligatory on the part of the firm to supply spare winding, if needed, during
the normal life of the transformer.
ERECTION TESTING AND COMMISSIONING AT SITE:The employer intends to carry-out the erection, testing and commission of the
equipment, covered by this specification departmentally with or without the
supervisory services off the contractor. Accordingly the successful bidder shall
furnish sufficient copies of complete erection drawings and instruction manuals
containing all relevant date to enable the employer to arrange the requirement tools.
Plant and instruments and to successfully install test and commission the equipment.
Complete details for filling of insulating oil, hot oil circulation, vacuum treatment,
venting of air if trapped during oil filling etc. shall be specifically covered in the
manuals. Full details of commissioning tests shall also be furnished.
The employer may at his option avail the services of contractor engineer(s) for
supervision of erection, testing and commissioning of the equipment for which bidder
should indicate the charges separately.
These charges and other terms and conditions shall be valid for one and a half years
after the supply of the equipment. The contractor shall also furnish, if necessary,
special erection, tools and plant instruments on rental basis.
31.0
SCHEDULE OF GUARANTEED AND OTHER TECHNICAL PARTICULARS.

These particulars shall be furnished by the tenderers along with their tenders.
CT-87
SECTION-3
CHAPTER-2
TECHNICAL SPECIFICATION FOR
100 MVA, 220/33kV POWER TRANSFORMER
1.00 SCOPE:
a)
This specification covers the design, manufacture, assembly testing at
manufacturers works before despatch, supply and delivery at site as per
schedule of Requirement of 100 MVA, 220/33kV Power Transformer.
b)
of all accessories and hardware shall be subject to HVPNLs approval.
2.00 Codes & Standards:
of bid.
IS:5
IS:325
IS:335
BS:148/IEC:296
IS:375
Marking & arrangement of Switch-gear Bus-bars main connections and
auxiliary wiring.
IS:1866
IS:2026
&IEC:76
IS:2099
& 3347
IS:2147
Degree of protection provided by enclosures for low voltage
switchgear & control gear.
IS:2705
Current transformer
IS:3637
Gas operated relay.
IS:3639
IS:6600
&IEC-354
IS:8468
&IEC:214
CT-88
IS:5561
IS:617
IS:2629
IS:8478
IS:8603 :
Electricity power connectors.

Dimensions for porcelain transformer bushings for use in heavily
polluted atmosphere (36 kV Class). Dimensions for oil filled porcelain
transformer bushings for use in medium polluted atmosphere.
CT-89
IS:9434
3.00
4.00
equipment.
IS:10028
Code of practice for selection, installation and maintenance of
transformers.
IS:12676
CBIP
Manual on transformer.
Equipment complying with other internationally accepted standards would also be
CLIMATIC CONDITIONS :
3.1
Max. Temprature
50 C
3.2
Min. Temprature
-2.5 C
3.3
100%
3.4
26%
3.5
Nearly120 Days.
3.6
900mm
3.7
Average number of dust strom days per annum
35
3.8
Isoceraunic level
45
3.9
Max Wind pressures.
195kg/sqmt.
3.10 Altitude above mean sea level.
Less than 1000 mt.
TYPE AND RATING:
4.1
The transformer shall be of 3 phase oil immersed three legged core type
with ONAN/ONAF/OFAF cooling suitable for outdoor service as step down
transformer.
4.2
The ratings and other characteristics which are not covered elsewhere shall be,
as detailed in following clauses:
a)
ONAN
50 MVA
b)
ONAF
75 MVA
c)
OFAF
100 MVA
4.2.2 Number of phases
3
4.2.3
4.2.4
Frequency
Rated Voltage:
a)
HV side
b)
LV sid
4.2.5 Max. System Voltage

a)
HV Side
b)
LV Side
4.2.6 Connections:
CT-90
50 Hz(5%)
220 Kv
33 Kv
245 Kv
36 KV
4.2.7
a)
HV side
b)
LV side
Vector group
CT-91
Star with neutral solidly earthed

----------------do---------------YYO
4.2.8 Tapping
On load tappings at neutral end of 220

Kv side for variation +10 % to -10% in
steps of 1.25% each.
4.2.9 Rated short duration Power frequency withstand Voltage

a)
HV Side
395Kv rms
b)
LV Side
70Kv rms
c)
Neutral
70Kv rms
4.2.10 Rated lightning impulse withstand Voltage
a)
HV Side
b)
LV Side
c)
Neutral
4.2.11 %age Impedance
12.5% at 100MVA base
4.2.12 B.I.L for Bushings

a)
HV Side
b)
LV Side
c)
Neutral
1050Kv Peak/460Kv rms

170 Kv Peak/ 70 Kv rms
170 Kv Peak/ 70 Kv rms
4.2.13 Creepage:
a) Total
25mm per Kv corresponding to highest

system voltage
50% of the total creepage distance
b) Protected
5.00
950Kv Peak
170Kv Peak
170 Kv Peak
GENERAL DESIGN OF TRANSFORMER:

5.1
The transformer and accessories shall be so designed as to facilitate
inspection, cleaning and repairs. The requirement of Indian Electricity Rules
shall be kept in view.
5.2
The design shall ensure satisfactory operation under severe working
conditions due to fluctuating load of steel furnaces and voltage variations in the
system including those, due to short circuits. The transformer shall be designed
as to minimize the risk of accidental short circuits caused by animals, birds or
vermins.
The design shall incorporate every reasonable precaution and provision for the
safety of all those concerned in the operation and maintenance of the equipment
keeping in view the requirements of Indian Electricity Rules.
5.3
All material used shall be of the best quality and of class most suitable for
working under specified conditions and shall withstand the atmospheric
CT-92
5.4
5.5
5.6
conditions and temperature variations without undue deterioration or distortion or

setting up of undue stress in any part thereof.
All taper pins to be used in the mechanism shall be split types as per latest
edition of IS: 2393.
CT-93
5.7
5.8
5.9
5.10
5.11
5.12
5.13
5.14
5.15
5.16
5.17
5.20
The construction shall be such as to avoid air or water pockets. Special care
shall be exercised to reduce noise and vibration to the minimum level.
Steel bolts of suitable finish will be used for diameters above 6mm. Brass bolts
or studs used for electrical connections shall not be of less than 6mm diameter.
On outdoor equipment, all bolts, nuts & washers in contact with current carrying
non-ferrous parts shall be phosphor bronze.
All nuts, bolts and pins shall be locked except those, which are external to the
transformer. If bolts and nuts are so placed as to be inaccessible by means of
ordinary spanners, the Contractor shall provide suitable special spanners.
Labels shall be provided for all apparatus like relays, switches, fuses, etc.
housed in any cubicle or marshalling kiosks. These shall be of incredible material
with matt/satin finish and permanent lettering. Labels mounted on black surface
shall have white letters and danger notices shall have red lettering on a white
background. The labels shall be secured by means of brass screws or rust
protected steel screws.
Before painting, all un galvanised parts shall be cleaned, made free from rust,
scale and grease and external rough surfaces smoothened (filled with metal
deposition). The interior of the tank and other oil filled chambers shall be cleaned
by shot blasting or any other suitable method.
All external surfaces shall be given three coats of paints except for nuts, bolts
and washers which may be given one coat after assembling of transformer at
works. The final coat shall be a glossy oil and weather proof, non-fading paint of
shade 631 of IS: 5
The interior of mechanism chambers and kiosks shall be given 3 coats of paint,
the final coat being of a light coloured anti-condensation mixture.
The outer most radial spacers of the winding shall be locked in position by means
of vertical strips so that the same cannot fall off/get displaced.
The manufacturers must ensure proper & complete tightening of the nuts of the
coil clamping bolts. The nuts of all the coil clamping bolts will be tightened to
designed value & the job be carried out with torque spanners.
The devices used for locking the nuts of coil clamping bolts must be of such a
quality and such care should be taken first in tightening. The nuts and next in
locking them in position that the arrangement does not become loose due to
stresses caused by short circuits and fluctuating loads etc.
5.18 The noise level shall not be more than 80 db.
5.19 The transformers shall be designed to have short circuit rating of five
seconds as per IS: 2026. The thermal ability to withstand short circuit shall be
judged by calculation to be supplied above in the tender. The dynamic ability to
with stand short circuit shall be demonstrated by test and their calculation will
also be supplied with drawings.
Foundation bolts and nuts shall be supplied along with the transformer
(Preferably at the time of call for inspection) so that transformer plinth is ready by
the time transformer is received by the consignee.
CT-94
10.3
The core shall be built up with thin laminations of high grade. Non-ageing, low
loss, high permeability cold rolled super grain oriented silicon steel. Known as
MOH High B Grade or superior grade CRGO steels of maximum 0.27 mm or
low lamination thickness especially suitable for transformer core.
10.4(a) (i)Bidder should have in house core cutting facility for proper monitoring & control
on quality and also to avoid any possibility of mixing of prime material with
defective/second grade material. The purchaser may witness the core-cutting
operation. In case the in house core cutting facility for core cutting
is
not
available
then the same shall be carried out in the presence of the
representative of
HVPN.
a)
b)
c)
d)
e)
(ii)Inspection call notice for the purpose should be accompanied with the
following documents as applicable as a proof toward use of Prime core
materials:Invoice of supplier.
Mills test certificates.
Packing list.
Bill of loading.
Bill of entry certificates by customs.
Core material shall be directly procured either from the manufacturer or through
their accredited marketing ressurized of repute and not through any agent.
10.4(b) After being sheared, the laminations shall be treated to remove all burrs. They
shall be coated with a baked enamel insulation coating. The insulation shall be
inert to the action of hot transformer oil and shall be perfectly adhesive. Paper
and varnish insulation shall not be accepted. Particulars of proposed insulation
shall be stated in the tender. Laminations shall be checked for burrs during
stage inspection.
10.5
The core shall be rigidly clamped and/or bolted to ensure adequate

mechanical strength and to prevent vibrations during operation. The bolts used in
the assembly of the core shall be suitably insulated and the clamping structure
shall be constructed that the eddy currents will be minimum.
10.6
Construction of the core shall be such that number of steps in the limb and
yoke shall be matching and dimensionally identical to minimize the effect of
cross fluxing and better mechanical strength.
10.7
The core shall be provided with Lugs suitable for lifting the complete core and
coil assembly of transformer. The Core & coil shall be fixed in the tank such
that its shifting will not occur when the transformer is moved or when a short
circuit occurs.
10.8
The design of magnetic circuit shall be such as to avoid static discharge

development of short circuit paths within itself or to the earthing clamping
structure and the production of flux components at right angles to the plane of
the lamination which may cause local heating.
CT-96
6.00
7.00
8.00
9.00
10.0
INSULATING OIL:
Sufficient insulating oil of Napthenic type (made from Napthenic crude) in which
paraffinic content should be less than 50% and aromatic content 4 to 12%
conforming to BS: 148/IEC:296 class-1 shall be supplied for first filling of each
transformer. Particular attention shall be paid to deliver the oil at site free from
moisture and of uniform quality through out in non-returnable steels drums. The
quantity of oil for first filling of each transformer shall be stated in tender alongwith trade mark of the oil to be supplied. Use of inhibitors in oil
shall not be
resorted to. 10% extra oil of the total quantity of oil shall be supplied along with
the transformer.
LIMIT OF TEMPERATURE RISE
7.1
With the above climatic conditions, given in clause-3 each transformer
shall be capable of operating continuously on any tap at their normal rating
without exceeding following temperature rises:
i)
50o C in oil by thermometer.
ii)
55o C in winding by resistance.
iii)
Temperature of hot spot in winding not to exceed 98oC when calculated
over max. annual weighted average temperature of 32o C.
7.2
manufacturer by carrying out the heat run test at the lowest negative tap. This
test shall be carried out by feeding 1.1 times the total losses at 75o C at highest
current tap.
7.3
OVERLOAD CAPACITY & CONTINUOUS RATING.
The safe over load capacity of the transformer and the duration of overload under
maximum temperature conditions without any damage to the winding or harmful
effects on the insulation shall be clearly stated in the tender which must be as per
IEC-354/IS: 6600, guide for loading of oil immersed transformer.
IMPEDANCE:
The transformer shall have 12.5% impedance on 100 MVA base with tolerance as per
IS: 2026/Part-1 (1983). Impedance shall include positive and zero sequence and shall
be expressed in terms of the branches of the star connected equivalent diagram, all on
the same KVA base and range shall be given for each branch of the equivalent circuit in
turn. Percentage tolerance allowed at extreme tap should be as applicable to normal tap.
FREQUENCY:
The transformer shall be suitable for continuous operation with a +/- 5% frequency
variation from a normal of 50 Hz without exceeding the temperature rise as specified in
Clause 7.1 above.
FLUX DENSITY, CORE CONSTRUCTION AND INSPECTION
10.1
The transformer should be so designed that the working flux density should
not exceed1.60 Tesla at normal voltage, frequency.
10.2
CT-95
10.9
Every care shall be exercised in the selection treatment and handling of core
steel to ensure that the laminations are flat and that finally assembled core is
free from distortions.
10.10
The supporting frame work of the core shall be so designed as to avoid the
presence of pockets which would prevent complete emptying of the tank
through the drain valve or cause trapping of air during filling.
10.11
Oil ducts where necessary should be formed across the plane of the
lamination and be given a suitable slope to assist oil circulation. The overall
design of core and winding should be such that free flow of oil is not
obstructed.
10.12
The frame work and clamping arrangement shall be earthed by connecting to

the tank body through a copper strip. Yoke bolt area should be compensated if
bolts are used for fastening of the core.
10.13
The insulation of core to bolts and core to clamp plates shall be able to
withstand a voltage of 2KV RMS for one minute.
10.14
Core and windings shall be capable of withstanding shocks during transport,

installation, service and adequate provision shall be made to prevent
movement of core and winding relative to tank during these conditions.
10.15
All steel sections used for supporting the core shall be thoroughly sand blasted
after cutting drilling and welding.
10.16
considered.
10.17
The tenderers should indicate the maximum flux density allowable continuously
as well as for time intervals of 1 minute and 5 seconds and the limit of flux density
at which core material used by them saturates.
10.18 The name of the core material must be mentioned in the tender. The
successful tenderer shall be required to furnish magnetization curves of the
core material/design calculations and such other data/documents deemed fit
by the Purchaser for being satisfied that flux density is as desired.
10.19
Purchaser shall inspect the built-up core for verification of flux density for which
all facilities shall be provided. The purchaser shall inspect/test the core material
for various tests as per relevant IEC/IS to ensure quality. Core may also be
inspected during horizontal assembly, built-up assembly.
NOTES:
i) The above flux density has been specified to meet with the over fluxing of the
core due to temporary over voltage of the order of 31% for l min, 44% for 5
seconds that may appear abnormal conditions such as those following sudden
loss of large loads.
CT-97
ii)
Yoke bolt area and flitch plate areas shall not be counted in the net core area
if these are provided for fastening core.
iii)
The design of limb and yoke shall be so co-ordinate that there is no cross fluxing
at the joints.
iv) The tenderer shall ensure that the CRGO supplier should have BIS certification.
11.00 SUPPRESSION OF HARMONICS:
The transformer shall be so designed as to withstand thermal and electro-magnetic
stress under severe short-circuits where the fault level on 220 KV & 33 KV bus are of
the order of 20,000 and 2,500 MVA respectively.
12.00 WINDING:
12.1 The 220/33 KV windings shall have graded insulation whereas the neutral points
shall be insulated as amended in IS:2026.
12.2 The transformers shall be capable of operation without danger on any particular tapping
at the rated KVA when the voltage may vary by 10% of the voltage corresponding to
the tapping.
12.3 The windings and connections as well as the insulating material shall not soften ooz,
shrink or collapse during service.
12.4 No strip conductor wound on edge shall have a width exceeding six times its thickness.
The conductors shall be transposed at sufficient intervals to minimize eddy currents and
equalize the current and temperature distribution along the windings.
12.5 The windings and connections shall be properly brazed to withstand shocks during
transportation or transient conditions during service.
12.6 Adequate pre-shrinkage of the coil assembly using pre-compressed press board
material having low moisture content for the radial spacer blocks shall be ensured by the
manufacturers so that there is no displacement of the radial spacer blocks due to
frequent short circuits on the transformers.
construction of the transformer shall be dried under vacuum and impregnated with hot
oil.
In addition to this the drying process be sufficiently extended for proper stabilization of
the coil assembly. More than one cycle of soaking in oil followed by retightening of the
coil assembly should be adopted.
12.8 The coil clamping rings wherever used shall preferably be of flat insulated steel
laminations. Axial laminated material except bakelised paper shall not be used.
12.9 The clamping arrangement shall exert equal pressure on all columns of spacers of the
transformer windings built of sections or disc-coils separated by spacers. In no case,
spiral winding will be used either for HV or LV windings.
12.10 The radial spacer blocks must be made of pre-compressed pressboard material,
which will not soften while in contact with oil or fray out into fibers or edges. The slots
should be so dimensioned that the blocks will not come out of the slots.
CT-98
Uniform distribution of coil clamping force shall be designed by using an adequately

large number of coil clamping bolts and by transferring the clamping force from clamping
bolts to the clamping plates through intermediate members which can spread the
clamping force over a large area.
12.11 All joints shall be brazed/crimped considering the vibrations due to short circuits and
load fluctuations.
13.00 CURRENT DENSITY:
The HVPNL shall be at liberty to inspect built-up winding for its quality, weight of copper,
insulation and overall weight of coil assembly. The size of conductor used for different
windings shall also be checked during stage inspection to check the current density .
The transformer shall be so designed that the current density of all the windings and the
regulating winding at the lowest tap should not exceed 250 A/cm.Sq.
14.1 TANK CONSTRUCTION
14.1.1 The tank shall be fabricated of a suitable grade steel and strong enough to allow the
lifting of complete transformer with oil by means of a crane or jacks and transported to
site without over-straining the joints etc.
14.1.2 The main tank body shall be capable of withstanding a vacuum of 100.64 Kn/m2
(760mm of Hg.)
14.1.3 The base shall be so designed as to allow the transformer to be moved by skidding
without any injury.
14.1.4 All channeled constructions and stiffeners shall be designed to avoid retention of
water.
14.1.5 The transformer shall preferably be of bell type tank with the joint 500 mm above the
bottom of tank.
14.1.6 The tank construction shall be free of air pockets. Where such pockets cannot be
avoided, vent pipes of 15 mm internal diameter shall be provided to vent gases into the
main expansion pipes. In case of short branch pipes, however, minimum diameter
may be taken as 6mm.
required they shall be double welded. All bolted joints to the tank shall be fitted with
suitable oil tight gaskets, which shall give satisfactory service under the operating
conditions and guaranteed temperature rise conditions. Special attention shall be
given to the methods of making hot oil tight joints between the tank and the cover and
also, between the cover and the bushings and all other out-lets to ensure that the
joints can be remade satisfactorily at site and with ease by semi-skilled labour.
14.1.8 Suitable lifting lugs for lifting the transformer filled with oil shall be provided on the
tank.
14.1.9 Four jacking lugs shall be provided to enable the transformer complete with oil to be
lifted or lowered by means of jacks. The lugs shall be fitted at a minimum height
(excluding under base if detachable) of 300mm for transformer up to 10 tons weight
and of 500mm for transformer above 10 tons weights.
14.1.10 The transformer shall be provided with detachable steel flanged wheels of 380mm
diameter and suitable for moving transformer complete with oil. These shall be suitable
for 2 rails of 1676 mm gauge along with longer axis and 2 rails of 3353 mm along with
shorter axis.
CT-99
14.2
14.2.1
14.2.2
14.2.3
14.3
14.3.1
14.3.2
14.3.3
14.3.4
14.3.5
14.3.6
14.4
14.4.1
14.4.2
14.4.3
14.4.4
14.4.5
14.5
TANK COVER
The tank cover shall be of bolted type and of adequate strength so as not to distort,
when lifted. Suitable inspection cover shall be provided with lifting arrangements to
give access to bushings, winding connections or testing the earth connections. The
weight of each inspection cover shall not exceed 25 Kg.
Pockets shall be provided in the position of Max. oil temperature at CMR for fitting a
thermometer and for bolts of oil and winding temperature indicators. The thermometer
pockets shall be fitted with a captive screwed cap to prevent ingress of water.
Suitable No. of jacking bolts shall be provided on tank cover, inspection
covers/windows including OLTC.
CONSERVATOR TANK, OIL GAUGE AND BREATHER
An adequate conservator tank complete with sump and drain valves shall be provided
in such a position as not to obstruct the electrical connections to the transformer.
If the sump is formed by extending the feed pipe inside the conservator, this extension
shall be at least 25mm.
One end of the conservator shall be bolted type to facilitate cleaning.
The conservator shall be provided with a magnetic oil level gauge.
The oil connections from the transformer tank to the conservator shall be at rising
angle of 3 to 9 degrees to the horizontal up to Buchholz relay. The inside diameter of
the pipe shall be 80mm. The Buchholz relay will have suitable valves on its both side
so as to facilitate its testing at site as well as cut off oil supply to the transformer.
The conservator shall be provided with oil preservation system, which may not allow
direct contact of atmospheric air with oil during operation, in addition to silica
gel-breather.
VALVES:
The transformers shall be provided with 2 No. filter valve each of 50 mm size one
mounted close to the top of the main tank & the other close to bottom of the tank oil
circulation and one drain valve of 80mm size with plug. The conservator shall have
drain plug of 25mm size.
Two robust sampling valves with spouts suitable for taking samples of top, and bottom
oil. The top sampling valves shall be brought down by internal pipe connections.
Suitable name plates shall be affixed to the sampling valves. The sampling device
shall not be fitted on the filter valve.
Two air release plug of 15mm shall be provided.
Plugs shall be supplied for all valves opening to atmosphere.
All valves shall be of gun metal and comply with the latest edition of IS: 3639.
PRESSURE RELIEF DEVICES:
A suitable pressure relief device shall be provided for rapid release of any pressure in
transformer which may endanger the equipment. The device (s) shall operate at static
opposite side of first PRD be provided.
CT-100
14.6
EARTHING TERMINALS:
14.6.1 Two earthing pads suitable for connecting 50x8mm mild steel flat shall be provided at
provided each on marshalling box and any other equipment mounted separately. The
earthing terminal should be capable of carrying full low voltage short circuit current of
transformer for four seconds.
14.7
JOINTS AND GASKETS: 14.7.1 All gaskets used for making oil tight joints shall be of granulated cork bonded with
14.8
vector relationship of different windings, plan view of the transformer showing physical
relationship of the terminals and no load voltage and corresponding current for each
tap.
14.8.2 Each transformer shall be provided with a rating plate data as specified in IS: 2026 or
equivalent international standard.
14.8.3 The transformer shall carry a valve schedule plate shorting the location and function of
all values and air release cock on plugs. This plate shall warn operators to refer to the
maintenance instructions before applying the vacuum treatment for drying.
14.8.4 I.R. values along with oil temperature at the time of testing at manufacturers works
shall be indicated on rating plate or separate plate, to be provided on transformer.
14.9

Thermosyphon filter arrangement shall be provided on the transformer for preserving
the quality of Transformer Oil. The filter assembly shall be mounted on the
Transformer as well as ground supported and connected with pipes and shut off
valves. Suitable instructions required to be followed for commissioning, dismantlement
& maintenance of the filter arrangement, re-generation and storage of the adsorbent
etc. must be included in the instruction manual. A detailed drawing showing internal
arrangement shall also be required to be submitted. Suitable capacity pump (along
with motor) shall also be provided to boost circulation of oil. The pump and motor
should not be in main pipe line. It should be in bypass pipe line having suitable valve to
isolate from main pipe line. The main pipe line should have two shut off valves at the
bottom.
NOTE : -
The pump and motor should be weather proof(Flow well Type).
The oil & absorbent capacity required in the Thermosyphon Filter is as under : (i)
(ii)
Quantity of oil
Quantity of absorbent
CT-101

15.0
15.1
NITROGEN INJECTION FIRE PROTECTION CUM EXTINGUISHING SYSTEM FOR

100 MVA TRANSFORMER
The Contractor shall provide the nitrogen injection fire protection cum extinguishing
system. The fire protection system using nitrogen as fire quenching medium is required
for the 100 MVA 220/33kV T/F NIFPES shall act as fire preventer by preventing
transformer oil tank explosion and possible fire in case of internal faults. In the event of
fire by external causes such as busing fire, OLTC fires, fire from surrounding equipment
etc, it shall act as a fast and effective fire fighter. NIFPES shall accomplish its role as fire
preventer and extinguisher without employing water and/or carbon dioxide. Fire shall be
put out within max. 3 minutes of system activation and within max. 30 seconds of
commencement of nitrogen injection.
Activation of NIFPES
Mal-functioning of fire prevention/extinguishing systems is their major shortcoming which leads
to interruption in power supply. The Contractor shall ensure that the chances of malfunctioning of
NIFPES are practically nil. To achieve this objective, the Contractor shall work out his scheme of
activating signals which, while preventing mal- operation, should not be too rigorous to make the
operation of NIFPES impracticable in case of actual need. Transformer isolation shall be the
mandatory pre-requisite for activation of the system in automatic mode or remote mode in the
control room. In addition, at least following electrical-signals shall be provided in series for
activating NIFPES.
15.1.1 Auto Mode

a)
For prevention of fire:
iv) Differential relay operation
v) Buchholz relay paralleled with pressure relief valve
vi) Tripping of all connected breakers is a pre-requisite for initiation of system activation.
c)
i)
ii)
iii)
For extinguishing fire:

Fire detector
Buchholz relay paralleled with pressure relief valve
Tripping of all connected breakers is a pre-requisite for initiation of system
activation.
15.1.2 Manual Mode (Local/Remote):

activation.
15.1.3 Manual Mode (Mechanical)
Tripping of all connected breakers is a
CT-102

activation.
15.2
General description of NIFPES
15.2.1 Schematic of the system

NIFPES should be a stand alone dedicated system for oil filled transformer. It should have a fire
extinguishing (F.E.) cubicle placed on a plinth at a distance of 6-10 mtrs. From the transformer.
The F.E. cubicle may be connected to the transformer oil tank (near its top) and to the oil pit (of
capacity approx. equal to 10% of transformer oil tank) from its bottom through oil pipes with gate
valves. The F.E. cubicle should house a ressurized nitrogen cylinder connected to the
transformer oil tank (near its bottom). Cable connections are to be provided from signal box
placed on the transformer to the control box in the control room and from control box to F.E.
cubicle. Fire detectors placed at the top of transformer 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 to be connected to relay panel in control
room for system activation signals.
15.2.2 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, stirring the oil thus bringing the temperature of top oil layer
down. Nitrogen occupies the space created by oil drained out and acts as an insulating
layer between the tank oil and fire on top cover. Pre-stressed non-return valve blocks oil
flow from conservator tank, thus isolating it & preventing aggravation of fire.
15.2.3 System components
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 and effective working of NIFPES shall be considered within the scope of
supply.
15.2.4 Fire Extinguishing cubicle
CT-103
It shall be made of 3 mm thick steel sheet, painted dark red from inside and 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
transformer.
Panel lighting (CFL type)
Oil drain pipe extension of suitable sizes for connecting pipes to oil pit.
15.2.5 Control box

Control box for monitoring system operation, automatic control and remote operation,
with following alarms indication, light switches, push buttons, audio signal, line fault
detection suitable for tripping and signaling on 110V DC/220V DC supply.
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 progress^
Cylinder pressure low^
Differential relay trip^
PRV operated^
Transformer trip^
System out of service
Line fault fire detector
Line fault differential relay
Line fault buchholz relay
Line fault PRV
Line fault transformer trip
Line fault PNRV
Auto / Manual/Off
Extinction release on
Extinction release off
Lamp test
Visual/Audio alarm
Visual/Audio alarm
CT-104
Visual/audio alarm for DC supply fail
The signals marked (*) shall be in the top most row of control box panel. The signals
marked (^) shall follow next.
15.2.6 Pre-stressed non return valve (PNRV)
PNRV is to be fitted in the conservator pipe line between conservator and 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 consequence as its closing leads to stoppage of breathing of
transformer.
15.2.7 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 141 degree C for heat sensing each fitted
with two no. cable glands (water proof/weather proof).
15.2.8 Signal box
It shall be fitted on the transformer for terminating cable connections form PNRV and fire
detectors and for further connection to the control box.
15.2.9 Cables
Fire survival cables, able to withstand 750 degree C, 4 core x 1.5 mm sq. for connection
of fire detectors in parallel shall be used.
Fire retardant low smoke (FRLS) cable 12 core x 1.5 mm sq. for connection between
transformer signal box/marshalling box to control box and control box to fire
extinguishing cubicle shall be used.
Fire retardant low smoke 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/marshalling box to
pre-stressed non return valve connection on transformer shall be used.
15.2.10 Pipes
Pipes, complete with connections, flanges, bends tees etc. shall be supplied along with
the system.
15.3
l.
Other items
oil drain and nitrogen injection openings with gate valves on transformer tank at suitable
locations.
CT-105
m. Flanges with dummy piece in conservator pipe between Buchholz relay and conservator
tank for fixing PNRV.
n. Fire detector brackets on transformer top cover.
o. Spare potential free contacts for system activating signals i.e. differential relay buchholz
relay, pressure relief valve, transformer isolation (master trip relay).
p. Pipe connections between transformer to fire extinguishing cubicle and fire extinguishing
cubicle to oil pit.
q. Cabling on transformer 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.
r. Mild steel oil tank with moisture proof coating and sheet thickness of minimum 5 mm,
with watertight cover, to be placed in the oil pit. 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.
The capacity of tank shall be 10,000 ltrs. And shall be provided as each S/Stn. The
location of the tank shall be approved by the HVPNL. All the Transformers to be fitted
with NISPEF at that S/Stn. shall be connected through suitable piping arrangement to
this common tank.
s. DC-DC converter 220-110V DC (optional, incase 110V, supply is not available.)
t. Gate valves on oil drain pipe and nitrogen injection pipe should be able to withstand full
vacuum. A non-return valve shall also be fitted on nitrogen injection pipe between
transformer and gate valve.
u. 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 be painted with enameled paint.
v. Civil works of F.E. cubicle and oil pit are in the scope of bidder.
15.4
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.
15.5
Technical particulars
15.5.1 Fire extinction period

On commencement of nitrogen injection : Max. 30 secs.
From the moment of system activation to : Max. 3 mins.
Complete cooling.
Fire detectors heat sensing temperature
:1410C
Heat sensing area
:800mm radius
Pre-stressed non return valve setting for
: minimum 60 ltr. Per operation.min.
Capacity of nitrogen cylinder
: minimum 68 ltr. Water cap.
And shall hold minimum 10 cubic mete
gas to 150 bar pressure.
Power Source
:
Control Box
: 110V DC/220V DC
Fire extinguishing cubicle for lighting
: 230V AC
CT-106
16.00
COOLING PLANT:
16.1 The cooling equipment shall consist of the following:
d. 2-50 percent tank
e. 2-100% pumps one of these being stand by
f. 2-stand by fans one in each 50% Bank
16.2
connections to each cooler. Thermometer pockets with captive screwed cap at inlet
and outlet of each separate cooler, filter valve at top and bottom and air release plug of
15mm.
16.3
The motor blowers shall be direct driven suitable for continuous out door operation and
16.4
MOTORS:
16.4.1 The motor shall be squirrel cage totally enclosed weatherproof type suitable for direct
starting and for continuous running from 415/240 volts, three-phase/single phase 50
HZ supply. The motors shall comply with IS as applicable for continuous rated
machine.
5% and 415/240 V AC 10% variation of the normal voltage without injurious over
heating.
16.4.3 All motors shall have ball or roller bearing with hexagonal nipples for greasing. In case
of vertical spindle, motor shall have bearing capable of withstanding thrust, due to
weight of the moving parts.
16.4.4 Varnished cambric or glass insulator shall be used for connections from stator winding
to the terminal suitable for external wiring. The motor terminals shall be of stud type
and totally enclosed.
16.5
COOLER CONTROL:
16.5.1 Each motor or group of motors shall be provided with a 3 pole electrically operated
connector with control gear for motor operation by hand and automatically through
16.5.2 All connection shall be so arranged as to allow either individual or collective operation
of the motors. Alarm indication (audio and visual) for failure of fans and to indicate
failure of power supply shall be provided.
16.5.3 The control equipment shall be installed in the marshaling box as specified in Cl.22 in
a readily accessible position.
16.5.4 The alarm indication for failure of power supply and failure of individual fans be
provided through independent non trip alarm scheme to be wired on the remote tap
charger control cubicle conforming to the following. : G:\REC-138 New\Technical specification 21.04.15.doc
CT-107
i)
17.00
17.1
17.2
17.2.1
17.2.2
17.2.3
17.2.4
17.2.5
17.2.6
17.3

ii)
The closing of an initiating contact shall glow a lamp, which will not reset until
the fault has been cleared.
iii)
It shall be possible to silence the buzzer by pressing Accept push button. If,
after canceling the alarm but before resetting the visual signal, the same fault
persists the buzzer shall be suppressed.
iv)
If after canceling the alarm but before resetting the visual signal, some other
fault takes place, the alarm accompanied by flag indication on appropriate
auxiliary relay shall take place.
v)
If after canceling the alarm and after resetting the visual signal, the same fault
appears or some other fault takes place, the alarm, flag indication and non-trip
lamp indication shall reappear as usual.
vi)
The non-trip alarm acceptance shall be by means of push button and resetting
of visual signal may also preferably be done through a push button.
vii)
Means shall be provided for test checking the lamp and alarm circuit at
frequent intervals.
viii)
Static facia aunnuciator conforming to the foregoing requirements of non-trip
VOLTAGE CONTROL (ON LOAD TYPE):
The transformer shall by provided with OLTC which apart from being suitable for local
manual/electrical operation & remote electrical operation.
Equipment for local and remote electrical and local' manual operation shall be
in use.
operations.
The local control switches shall be mounted, in the drive gear housing.
CT-108
17.4
17.4.1
17.4.2
17.5
17.6
17.7
17.8
17.9
17.10
17.11
17.12
17.13
17.14
Thermostatically controlled heaters shall be provided in the driving mechanism
fungi etc.
relay. A separate buchholz relay may be provided for this compartment.
be provided with adequate breathing arrangement. The tap changer shall be mounted
in such a way that the cover of the transformer can be lifted without removing
connections between windings and tap changer.
be standard 415 Volts, three-phase, 3 wire, 50 Hz. alongwith 240 Volts single phase,
2 wire 50 Hz, subject to a variation of 5 percent so that the equipment offered can
CT-109
17.15
17.16
17.17
17.18
17.19
17.20
17.21
18.0
18. 1
18.2
18.3
19.0
19.1

The indigenous make OLTC having voltage rating as 132 kV & current rating 300
Amp. should be duly type tested from CPRI or other Govt. test house or reputed lab
from abroad to the extent the facilities of type test available with CPRI.
PARALLEL OPERATION:
In addition to individual control of tap changer, provision shall be made to enable
transformer.
step.
Transformer shall be fitted with bushing insulators as follows: HV bushing: 245 kV class, condenser bushing of 800 Amp. rating without arcing
horns.
L.V. Bushing: 72.5/36 kV class condenser bushing of 1000/2000 Amp. rating without
arcing horns.
Neutral Bushing: 36 kV class oil communicating type porcelain bushing of 1000/2000
Amp. rating without arcing horns.
3347.
copper shall be connected to the connector in the helmet of the 220/33 KV
CT-110
20.00
20.1
20.2
20.3
20.4
20.5
20.6
20.7
air.
Bi-metallic terminal connectors shall be supplied suitable for single Tarantulla
conductor for HV side & twin AAC Tarantulla conductor for LV side and neutral
side. The take off for H.V. & L.V. connectors will be Vertical and for Neutral it
should be suitable for horizontal take off.
conform to designation Grade 4600 of IS: 617-1975. The steel bolts, nuts washers
and check nuts shall be hot dip galvanized marked with ISI certification mark or of
GKW make.
CT-111
21.00
21.1
21.2
21.3
21.4
21.5
22.00
22.1
22.2
22.3
22.4
22.5
23.00
23.1
23.2
23.3
23.4
vent.
MARSHALING BOX: A sheet steel (of 10 SWG size) vermin proof well ventilated and weather proof
trench.
CT-112
23.5
23.6
23.7
24.00
The losses at principal tap of each transformer shall be stated in the tender. The
manufacture shall state separately no load, load and Auxiliary losses at rated
frequency & voltage and load losses corresponding to OFAF rating (at full load at
750C) for fair comparison of difference of losses. It is essential that tenderers quote
firm losses.
shall be capitalized as per formula given below:
=3,86,700 (Wi + 0.45 Wc + 0.45Wp)
Where
Wi
Wc
Wp
=
=
=
Iron (No. Load ) Losses

Copper (Load) Losses
Auxilary Losses
25.00 and no positive tolerance shall be allowed on these values.
within three years from the date of commissioning the capitalized value of excess
losses, as compare to the specified value shall be recovered as per following
capitalization formula:Amount recoverable (Rs.)= 3,86,700(Wi + 0.45 Wc + 0.45Wp)
25.00
Losses:The losses of each transformer shall be stated in the tender for OFAF at principal tap
rating (at full load at 75 deg. C) which shall be less than:Sr.
No.
1
2
3
4
25.1
Type of Losses
100 MVA 220/33KV T/F
No load losses
Load Losses
Auxiliary Losses
overall average wt. losses (based on
capitalisation formula of W i+0.45 (W p+W c)
54 KW (Max)
274 KW (Max)
8KW (Max)
163KW (Max.)
Noise level
Max. 80 dB
Transformer offers shall be rejected if audible sound level is higher than max. 80 dB.
CT-113
26.00
TESTS:
26.1
ROUTINE TESTS:
All routine test shall be carried out on each transformer as

presence of HVPNL's representative.
per IS-2026 in the
26.2
TYPE TESTS :
The following type tests shall be carried out on one transformer as per ISS:2026 in
the presence of HVPNL's representative.
vi)
Temperature rise test (along with DGA)
vii)
Impulse voltage withstand test as per clause 13 of ISS-2026/1981 Part-III on one
limb.
There will not be any separate schedule for type test charges. The charges if any may
be included in bid price.
26.2.1
OIL LEAKAGE TEST:
occur.
26.2.2
26.2.3
26.2.4
Following tests shall be carried out on each transformer as reference test:

vii)
10 kV.
viii)
ix)
x)
Measurement of percentage impedance at all taps at low voltage.
xi)
Partial discharge test.
xii)
Noise level test.
TRANSFORMER OIL:
SHORT CIRCUIT TEST
CT-114
26.3
26.4
The HVPNL reserves the right to have any other, reasonable test carried out at his
STAGE INSPECTION:
radiators shall be carried-out as detailed below:a.
i)
ii)
viii)
CORE:Measurement of flux Density.

Tests of CRGO sample taken from the core shall be carried-out for Carlite test
Tests.
ix) Physical inspection for quality of workmanship.
x)
b.
WINDINGS:
i.
ii.
iii.
The purity test of copper shall be got conducted on sample of copper for
c.
TANK:
i)
Vacuum Test:
100.64 kN (760 mm of hg). The tanks to be designed for full vacuum shall be
tested at an internal pressure of 3.33 KN/M2 (25mm of Hg.) for one hour.
The permanent deflection of flat plates after the vacuum has been released shall
not exceed the values given below without affecting the performance of the
Transformer.
----------------------------------------------------------------------------------------------------------------Horizontal length of flat plate(mm).
Permanent deflection(mm).
----------------------------------------------------------------------------------------------------------------Upto & including 750
5.0
751-1250
6.5
1251-1750
8.0
1751-2000
9.5
2001-2250
11.0
2251-2500
12.5
2501-3000
16.0
above 3000
19.0
---------------------------------------------------------------------------------------------------------------ii) PRESSURE TEST:
CT-115
One transformer tank out of the lot shall be subject to the pressure corresponding to
twice the normal head of oil or normal pressure plus 35KN/M2 (which ever is lower)
measured at the base of the tank and maintained for one hour. The permanent
deflection of flat plates after removal of excess pressure shall not exceed the figures
specified as above.
d. RADIATORS:
Radiator shall be routine and type tested at sub Contractors' work as per relevant
NOTE:
a.

VIGNOLE MAKE). The polarisation index values (ratio of 120/20 sec. value)
will be accordingly calculated and recorded in the test certificates and it should
not be less than 1.5.
b.
Dissolved gas analysis test shall be got carried-out before and after heat run
test at CPRI.
c.
Capacitance and Tan Delta values for each transformer and condenser
d.
Lightening impulse test with the chopped wave applications as per clause 13 of
e.
Contractor shall submit in-house test certificate at least 15 days in advance for final
testing of transformer. For testing T/F, all measuring instruments shall be of highest
efficiency and best quality. These shall be got calibrated from NPL/ Govt. Agency
and be got sealed by calibrating agency. HVPN reserves the right to calibrate the
instruments in the manner it desires.
Losses shall be measured with 3-wattmeter method only. Resistance shall be taken
with Double-Kelvin Bridge. Losses can be measured directly from CTs and PTs and
not through the panel. Ratio of the measuring instrument shall be such that the
multiplying factor is the minimum.
All tests shall be carried out in the presence of the HVPNL before dispatching the
material. Test certificates in quadruplicate will be submitted to the HVPNL for
approval. No material shall be despatched without prior inspection and approval of
test certificates unless otherwise agreed to. Type and routine test certificates of all
bought out items from recognised testing agency shall be submitted for approval
before commencing supplies. OLTC scheme including the master follower
functioning shall also be checked. Only fully assembled transformer including
mounting of radiators shall be put-up for inspection.
27.00
27.1
27.1.1
DRAWINGS:
CT-116
27.1.2
27.2

The bidder shall submit four sets of final version of all the above drawings for
HVPNL's approval along with the tender in a separate seal cover. These drawings
will be opened in the event of order. The HVPNL shall communicate his
comments/approval on the drawings to the Contractor within four weeks of the issue
of LOI. The manufacturer shall, if necessary, modify the drawings and resubmit the
same for HVPNL's approval within two weeks of receipt of comments. Such duly
revised drawings will be approved by the HVPNL within two weeks of their receipt.
After receipt of HVPNL's approval to drawings, the manufacturer will submit a set of
reproducible of all the approved drawings and will also supply five sets of all
approved drawings and five sets of manual of instructions per transformer to
Substation Design Directorate HVPNL Panchkula.
ONE SET OF ALL THE APPROVED DRAWINGS AND MANUAL OF INSTRUCTIONS WILL BE
SUPPLIED ALONGWITH EACH TRANSFORMER WITHOUT WHICH THE SUPPLY WILL NOT
BE CONSIDERED AS COMPLETE SUPPLY.
27.2.1
Outline general arrangement drawings showing plan, front elevation & side elevation
with all fittings and accessories etc. The following information must be specifically
included on the drawings.
a.
b.
c.
d.
e.
f.
g.
h.
Weight of oil, bare copper weight windings, core, un-tanking mass,
transportation mass and dimensions etc.
27.2.2
Detailed of bushings showing plan, elevation, terminal details, mounting details make
and type number incorporating electrical characteristics, description of various parts,
total creepage/ & protected creepage distance, weight of oil, total weight of bushing ,
dimensions, short time current rating etc.
27.2.3
connections.
27.2.4
Schematic control and wiring diagram for auxiliary equipment like OLTC control gear,
cooler control gear, Marshaling Kiosk. Detailed write-up for schematic shall also be
supplied
27.2.5
27.2.6
15.3.1
27.2.8
kiosk.
27.2.9
Detailed calculations showing short circuit withstand capacity due to radial and axial
forces during short circuit and calculation for thermal withstand capability during
short circuit shall also be supplied.
27.2.10
CT-117
27.2.11
27.2.12
28.00
29.00
Detailed drawing of NIFPES system along with its detailed write up.
LIST OF SPARES
As per schedule of requirement.
SPARE WINDING
It will be obligatory on the part of the firm to supply spare winding, if needed,
during the normal life of the transformer.
30.0
ERECTION TESTING AND COMMISSIONING AT SITE:The employer intends to carry-out the erection, testing and commission of the
equipment, covered by this specification departmentally with or without the
supervisory services off the contractor. Accordingly the successful bidder shall
furnish sufficient copies of complete erection drawings and instruction manuals
containing all relevant date to enable the employer to arrange the requirement tools.
Plant and instruments and to successfully install test and commission the
equipment. Complete details for filling of insulating oil, hot oil circulation, vacuum
treatment, venting of air if trapped during oil filling etc. shall be specifically covered
in the manuals. Full details of commissioning tests shall also be furnished.
The employer may at his option avail the services of contractor engineer(s) for
supervision of erection, testing and commissioning of the equipment for which
bidder should indicate the charges separately.
These charges and other terms and conditions shall be valid for one and a half
years after the supply of the equipment. The contractor shall also furnish, if
necessary, special erection, tools and plant instruments on rental basis.
32.0
SCHEDULE OF GUARANTEED AND OTHER TECHNICAL PARTICULARS.

These particulars shall be furnished by the tenderers along with their tenders strictly.
CT-118
SECTION-3
CHAPTER-3
TECHNICAL SPECIFICATION FOR 20/25 MVA 132/33kV
POWER TRANSFORMERS
1.0
2.0
SCOPE:
a)
This specification covers the Design, Engineering, manufacture, testing, supply
on CIP basis, transportation to site, insurance, storage, testing and
commissioning of 20/25 MVA 132/33 kV Power Transformers.
b)
of all accessories and hardware shall be subject to purchasers approval.
CODES & STANDARDS:
of bid. The following standards and codes shall be applicable: IS:5
IS:325
IS:335
BS:148/IEC-296
IS:375
Marking & arrangement of Switch-gear bus bars main connections and
auxiliary wiring.
IS:1866
IS:2026
&IEC:76
IS:2099
& 3347
IS:2147
Degree of protection provided by enclosures for low voltage switchgear &
control gear.
IS:2705
Current transformer
IS:3637
Gas operated relay.
IS:3639
CT-119
IS:6600
&IEC-354
IS:8468
&IEC:214
IS:5561
IS:617
IS:2629
IS:8478
IS:8603
3.0
4.0

Electric power connectors.

Dimensions for porcelain transformer bushings for use in heavily polluted
atmosphere(36 kV Class). Dimensions for oil filled porcelain transformer
bushings for use in medium polluted atmosphere.
IS:9434
equipment.
IS:10028
Code of practice for selection, installation and
maintenance of
transformers.
IS:12676
CBIP
Manual on transformer.
Equipment complying with other internationally accepted standards will also be
CLIMATIC CONDITIONS:
The transformers are required to operate satisfactorily under the following site
conditions:
3.1
Max. temperature
50 C
3.2
Min. temperature
-2.5 C
3.3
100%
3.4
26 %
3.5
Nearly120 days
3.6
900mm
3.7
Average number of dust storm days per annum.
35
3.8
Isoceraunic level
45
3.9
Max. Wind pressures
195 kg/sqmt.
3.10 Altitude above mean sea level
Less than 1000 mt.
TYPE AND RATING :
4.1
The transformer shall be of two winding, 3 phase oil immersed core type with
ONAN/ONAF cooling suitable for outdoor service as step down transformers.
The transformer shall not be provided with the tertiary delta winding.
4.2
The ratings and other characteristics which are not covered elsewhere shall be,
as detailed in following clauses:
a)
ONAN
20 MVA
CT-120
4.2.2
4.2.3
4.2.4
4.2.5
5.0
5.1
5.2
5.3
5.4
b)
ONAF
Number of phases
Frequency
Rated Voltage :
a)
HV side
b)
LV side
Connections :
a)
HV side
b)
LV side
Vector group
%age Impedance
25 MVA
3
50 Hz
(5%)
132kV
33kV
Star
Star
4.2.6
YYO
4.2.7
10% at
25 MVA base
4.2.8 ON load taps on HV side +5% to -15% in steps of 1.25% each
4.2.9 a)
Insulation level
132 kV
33 kV
i)
Lighting withstand
550 kV
170kV
ii)
Power frequency
230 kV
70 kV
withstand voltage
(rms)
(rms)
b)
Insulation level of Bushings
i)
Lighting Impulse
650 kV
170kV
voltage
ii)
Power frequency
275 kV
70 kV
voltage
(rms)
(rms)
4.2 10 Total Creepage Distance :
a)
Total: 25mm per kV corresponding to highest system voltage i.e.
145 kV, 36 kV, 12 kV.
b)
Protected: 50% of the total Creepage distance
GENERAL DESIGN OF TRANSFORMER: The transformer and accessories shall be so designed as to facilitate inspection,
cleaning and repairs. The requirement of Indian Electricity Rules shall be kept in view.
The design shall ensure satisfactory operation under severe working conditions due to
fluctuating load of steel furnaces and voltage variations in the system including those,
due to short circuits. The transformers shall be designed as to minimize the risk of
accidental short circuits caused by animals, birds or vermins.
The design shall incorporate every reasonable precaution and provision for the safety of
all those concerned in the operation and maintenance of the equipment keeping in the
view the requirement of Indian Electricity Board.
All material used shall be of the best quality and of class most suitable for working under
specified conditions and shall withstand the atmospheric conditions and temperature
variations without undue deterioration or distortion or setting up of undue stress in any
part thereof.
CT-121
5.5
5.6
5.7
5.8
5.9
5.10
5.11
5.12
5.13
5.14
5.15
5.16
5.17

All taper pins to be used in the mechanism shall be split types as per latest edition of IS:
2393.
The construction shall be such as to avoid air or water pockets. Special care shall be
exercised to reduce noise and vibration to the minimum level.
Steel bolts of suitable finish will be used for diameters above 6mm. Brass bolts or studs
used for electrical connections shall not be of less than 6mm dia. On outdoor
equipment, all bolts, nuts & washers in contact with current carrying non-ferrous parts
shall be phosphor bronze:
All nuts bolts and pins shall be locked except those which are external to the
transformer. If bolts and nuts are so placed as to be inaccessible by means of ordinary
spanners, suitable special spanners shall be provided by the supplier.
Labels shall be provided for all apparatus like relays, switches, fuses, etc. housed in any
cubicle or marshaling kiosks. These shall be of incorrodible material with matt/satin
finish and permanent lettering. Labels mounted on black surface shall have white
letters & danger notices shall have red lettering on a white background. The labels shall
be secured by means of brass screws or rust protected steel screws.
Before painting, all ungalvanised parts shall be cleaned made free from rust, scale and
grease and external rough surfaces smoothened filled with metal deposition. The
interior of the tank and other oil filled chambers shall be cleaned by shot blasting or any
other suitable method.
All external surfaces shall be given three coats of paints except for nuts, bolts and
washers which may be given one coat after erection. The final coat shall be a glossy oil
and weather proof, non-fading paints of shade 631 of IS:5.
The interior of mechanism chambers and kiosks shall be given 3 coats of paint, the final
coat being of a light coloured anti-condensation mixture.
LOCKING OF OUTER RADIAL SPACERS:The outer most radial spacers of the winding shall be locked in position by means of
vertical strips so that the same can not fall off/got displaced.
TIGHTENING OF THE NUTS OF THE COIL CLAMPING BOLTS:The proper & complete tightening of the nuts of the coil clamping bolts must be ensured
by the manufacturers. The tightening of the nuts to the designed value and that the nuts
of all the coils clamping bolts are tightened to same extent, should be carried out with
torque spanners.
The devices used for locking the nuts of coil clamping bolts must be of such a quality and such
care should be taken first in tightening the nuts and next in locking them in position that the
arrangement does not work loose due to vibrations caused by short circuits and fluctuating loads
etc.
5.18
The noise level shall not be more than 5db above NEMA standard publication TR-1.
CT-122
5.19
6.0
7.0
7.1
7.2
7.3
The transformers shall be designed to have short circuit rating of two seconds as per
ISS-2026.
INSULATING OIL:Sufficient insulating oil of Napthenic type (made from Naphthenic crude) in which
paraffinic content should be less than 50% and aromatic content 4 to 12% conforming to
BS: 148/IEC:296 class-1 shall be supplied for first filling of each transformer. Particular
attention shall be paid to deliver the oil at site free from moisture and of uniform quality
through out in non-returnable steels drums. The quantity of oil for first filling of each
transformer shall be stated in tender along-with trade mark of the oil to be supplied. Use
of inhibitors in oil shall not be resorted to. 10% extra oil of the total quantity of oil shall be
supplied along with the transformer.
LIMIT OF TEMPERATURE RISE:With the above climatic conditions given in clause-3 each transformer shall be capable
of operating continuously on any tap at their normal rating without exceeding the
following temperature rises
(i)
50 deg C in oil by thermometer
(ii)
55 deg C in winding by resistance
(iii)
Winding Gradient i.e the difference between average winding average oil
temperature not to exceed 13 deg C.
(iv)
Temperature of hot spot in windings not to exceed 98 deg C when calculated
over max annual weighted average temperature of 32 deg C.
manufacturer by carrying out the heat run test at the lowest negative tap. This test shall
be carried out by feeding 1.1 times the total losses at 75 deg C at highest current tap.
OVERLOAD CAPACITY & CONTINOUS RATING
The safe overload capacity of the transformer and the duration of overload under maximum
temperature conditions without any damage to the winding or harmful effects on the insulation
shall be clearly stated in the tender which must be asper IEC-354/IS6600,guide for loading of oil
immersed transformer.
8.0
9.0
IMPEDANCE
The transformer shall have 10% impedance on 25 MVA base respectively with tolerance
as per IS:2026/Part-I(1983). Impedance shall include positive and zero sequence and
shall be expressed in terms of the branches of star connected equivalent diagram, all on
the same kVA base and range shall be given for each branch of the equivalent circuit in
turn.
FREQUENCY:The transformer shall be suitable for continuous operation with a 5% frequency variation from a
normal of 50 HZ without exceeding the temperature rise as specified in clause-7.1 above.
CT-123
10.0
FLUX DENSITY, CORE CONSTRUCTION and INSPECTION
10.1
The transformer should be so designed that the working flux density should not exceed
1.57 Tesla at normal voltage, frequency.
10.2
10.3
The core shall be built up with thin laminations of high grade. non-ageing, low loss, high
permeability cold rolled super grain oriented silicon steel. Known as MOH High B Grade
or superior grade CRGO steels of maximum 0.27 mm or low lamination thickness
especially suitable for transformer core.
10.4(a) (i)Bidder should have in house core cutting facility for proper monitoring & control on
quality and also to avoid any possibility of mixing of prime material with defective/second
grade material. The purchaser may witness the core-cutting operation. In case the in
house core cutting facility for core cutting is not available then the same shall be carried
out in the presence of the representative of HVPN.
(ii)Inspection call notice for the purpose should be accompanied with the following
documents as applicable as a proof toward use of Prime core materials :a) Invoice of supplier.
b) Mills test certificates.
c) Packing list.
d) Bill of loading.
e) Bill of entry certificates by customs.
Core material shall be directly procured either from the manufacturer or through their
accredited marketing organisation of repute and not through any agent.
10.4(b) After being sheared, the laminations shall be treated to remove all burrs. They shall be
coated with a baked enamel insulation coating. The insulation shall be inert to the
action of hot transformer oil and shall be perfectly adhesive. Paper and varnish
insulation shall not be accepted. Particulars of proposed insulation shall be stated in the
tender. Laminations shall be checked for burrs during stage inspection.
10.5
The core shall be rigidly clamped and/or bolted to ensure adequate mechanical strength
and to prevent vibrations during operation. The bolts used in the assembly of the core
shall be suitably insulated and the clamping structure shall be constructed that the eddy
currents will be minimum.
10.6
Construction of the core shall be such that number of steps in the limb and yoke shall
be matching and dimensionally identical to minimize the effect of cross fluxing and
better mechanical strength.
10.7
The core shall be provided with Lugs suitable for lifting the complete core and coil
assembly of transformer. The Core & coil shall be fixed in the tank such that its shifting
will not occur when the transformer in moved or when a short circuit occurs.
10.8
The design of magnetic circuit shall be such as to avoid static discharge development
of short circuit paths within itself or to the earthing clamping structure and the
production of flux components at right angles to the plane of the lamination which may
cause local heating.
CT-124
10.9
Every care shall be exercised in the selection treatment and handling of core steel to
ensure that the laminations are flat and that finally assembled core is free from
distortions.
10.10 The supporting frame work of the core shall be so designed as to avoid the presence
of pockets which would prevent complete emptying of the tank through the drain valve
or cause trapping of air during filling.
10.11 Oil ducts where necessary should be formed across the plane of the lamination and be
given a suitable slope to assist oil circulation. The overall design of core and winding
should be such that free flow of oil is not obstructed.
10.12 The frame work and clamping arrangement shall be earthed by connecting to the tank
body through a copper strip. Yoke bolt area should be compensated if bolts are used
for fastening of the core.
10.13 The insulation of core to bolts and core to clamp plates shall be able to withstand a
voltage of 2 KV RMS for one minute.
10.14 Core and windings shall be capable of withstanding shocks during transport,
installation, service and adequate provision shall be made to prevent movement of
core and winding relative to tank during these conditions.
10.15
All steel sections used for supporting the core shall be thoroughly sand blasted after
cutting drilling and welding.
10.16
considered.
10.17 The tenderers should indicate the maximum flux density allowable continuously as
well as for time intervals of 1 minute and 5 secs. and the limit of flux density at which
core material used by them saturates.
10.18
10.19
The name of the core material must be mentioned in the tender. The successful
tenderer shall be required to furnish magnetization curves of the core material/design
calculations and such other data/documents deemed fit by the Purchaser for being
satisfied that flux density is as desired.
Purchaser shall inspect the built-up core for verification of flux density for which all
facilities shall be provided. The purchaser shall inspect/test the core material for
various tests as per relevant IEC/IS to ensure quality. Core may also be inspected
during horizontal assembly, built-up assembly.
NOTES :
i)
The above flux density has been specified to meet with the over fluxing of the core
due to temporary over voltage of the order of 31% for l min, 44%for 5 sec. that may
appear abnormal conditions such as those following sudden loss of large loads.
ii)
Yoke bolt area and flitch plate areas shall not be counted in the net core area if these
are provided for fastening core.
iii)
The design of limb and yoke shall be so co-ordinate that there is no cross fluxing at
the joints.
The tenderer shall ensure that the CRGO supplier should have BIS certification.
iv)
11.
SUPPRESSION OF HARMONICS:
CT-125
12.
12.1
12.2

WINDINGS:The 132kV windings shall have graded insulation whereas all other windings shall be
fully insulated and the neutral points shall be insulated as amended in IS:2026.
The transformers shall be capable of operation without danger on any particular tapping
at the rated kVA when the voltage may vary by 10% of the voltage corresponding to the
tapping.
12.3
The windings and connections, insulation material shall not soften, ooze out, shrink or
collapse during service.
12.4
No strip conductor wound on edge shall have a width exceeding six times its thickness.
The conductors shall be transposed at sufficient intervals to minimize eddy currents and
equalize the current and temperature distribution along the windings.
The windings and connections shall be properly brazed to withstand shocks during
transportation or transient conditions during service.
12.5
12.6
The adequate pre-shrinkage of the coil assembly using pre-compressed press board
material having low moisture content for the radial spacer blocks shall be ensured by the
manufacturers so that there is no displacement of the radial spacer blocks due to
frequent short circuits on the transformers.
construction of the transformer shall be dried under vacuum and impregnated with hot
oil.
In addition to this the drying process be sufficiently extended for proper stabilization of
the coil assembly. More than one cycle of soaking in oil followed by retightening of the
coil assembly should be adopted.
12.8 The coil clamping rings wherever used, shall preferably be of flat insulated steel
laminations. Auxiliary laminated material except bakelised paper shall not be used.
12.9 The clamping arrangement shall exert equal pressure on all columns of spacers of the
transformer windings built of sections or disc-coils separated by spacers. In no case,
spiral winding will be used either for HV or LV windings.
12.10 The radial spacer blocks must be made of pre-compressed pressboard material,
which will not soften while in contact with oil or fray out into fibers or edges. The slots
should be so dimensioned that the blocks will not come out of the slots.
Uniform distribution of coil clamping force shall be designed by using an adequately
large number of coil clamping bolts and by transferring the clamping force from clamping
bolts to the clamping plates through intermediate members which can spread the
clamping force over a large area.
12.11 All joints shall be brazed/crimped considering the vibrations due to short circuits and
load fluctuations.
13.
CURRENT DENSITY:
The purchaser shall be at liberty to inspect built-up winding for its quality, weight of
copper, insulation and overall weight of coil assembly. The size of conductor used for
different windings shall also be checked during stage inspection to check the current
density. The transformer shall be so designed that the current density of all the windings
and the regulating winding at the lowest tap should not exceed 250 A/cm.Sq.
CT-126
14.
TANK CONSTRUCTION:14.1.1 The tank shall be fabricated of a suitable grade steel and strong enough to allow the
lifting of complete transformer with oil by means of a crane or jacks and transported to
site without over-straining the joints etc.
14.1.2 The main tank body shall be capable of withstanding a vacuum of 100.64 KN/m2
(760mm of Hg.)
14.1.3 The base shall be so designed as to allow the transformer to be moved by skidding
without any injury.
14.1.4 All channeled constructions and stiffeners shall be designed to avoid retention of water.
14.1.5 The tank construction shall be free of air pockets, where such pockets cannot be avoided vent
pipes of 15 mm internal dia shall be provided to vent gases into the main expansion pipes. In case
of short branch pipes, however, minimum diameter may be taken as 6mm.
required they shall be double welded. All bolted joints to the tank shall be fitted with
suitable oil tight gaskets, which shall give satisfactory service under the operating
conditions and guaranteed temperature rise conditions. Special attention shall be given
to the methods of making hot oil tight joints between the tank and the cover and also,
between the cover and the bushings and all other out-lets to ensure that the joints can
be remade satisfactorily at site and with ease by semi-skilled labour.
14.1.7 Suitable lifting lugs for lifting the transformer filled with oil shall be provided on the tank.
14.1.8 Four jacking lugs shall be provided to enable the transformer complete with oil to be
lifted or lowered by means of jacks. The lugs shall be fitted at a minimum height
(excluding under base if detachable) of 300mm for transformer upto 10 tonnes weight
and of 500mm for transformer above 10 tonnes weights.
14.1.9 The transformer shall be provided with detachable steel flanged wheels of 250mm dia
and suitable for moving transformer complete with oil. These shall be bi-directional and
mounted on swivels which may be turned through 90o when the tank is jacked up and
capable of being locked in position parallel to and at right angles to the longitudinal axis.
The wheel be suitable for standard gauge track of 1676mm.
14.2 TANK COVER
14.2.1 The tank cover shall be of bolted type and of adequate strength so as not to
distort, when lifted. Suitable inspection cover shall be provided with lifting arrangements
to give access to bushings, winding connections or testing the earth connections. The
weight of each inspection cover shall not exceed 25 Kg.
14.2.2 Pockets shall be provided in the position of Max. oil temperature at CMR for
fitting a thermometer and for bolts of oil and winding temperature indicators. The
thermometer pockets shall be fitted with a captive screwed cap to prevent ingress of
water.
14.2.3 Suitable No. of jacking bolts shall be provided on tank cover, inspection covers/windows
including OLTC.
14.3 CONSERVATOR TANK, OIL GAUGE AND BREATHER
14.3.1 An adequate conservator tank of air cell type complete with sump and drain valves shall
be provided in such a position as not to obstruct the electrical connections to the
transformer.
14.3.2 If the sump is formed by extending the feed pipe inside the conservator, this extension
shall be atleast 25mm.
CT-127
14.3.3 One end of the conservator shall be bolted type to facilitate cleaning.
14.3.4 The conservator shall be provided with a magnetic oil level gauge.
14.3.5 The oil connections from the transformer tank to the conservator shall be at rising
angle of 3 to 9 degrees to the horizontal upto Buchholz relay. The inside diameter of
the pipe shall be 80mm. The Buchholz relay will have suitable valves on its both side
so as to facilitate its testing at site as well as cut off oil supply to the transformer.
14.3.6
The conservator shall be provided with oil preservation system, which should be
suitable either to remove moisture continuously from air entering the air space with
which they are connected or may not allow direct contact of atmospheric air with oil
during operation, in addition to silicagel-breather.
14.4
VALVES:
14.4.1 The transformers shall be provided with 2 No. filter valve each of 50 mm size one
mounted close to the top of the main tank & the other close to bottom of the tank oil
circulation and one drain valve of 80mm size with plug. The conservator shall have
drain plug of 25mm size.
14.4.2 Two robust sampling valves with spouts suitable for taking samples of top, and bottom
oil. The top sampling valves shall be brought down by internal pipe connections.
Suitable name plates shall be affixed to the sampling valves. The sampling device
shall not be fitted on the filter valve.
14.4.3 Two air release plug of 15mm shall be provided.
14.4.4 Plugs shall be supplied for all valves opening to atmosphere.
14.4.5 All valves shall be of gun metal and comply with the latest edition of IS: 3639.
14.5
PRESSURE RELIEF DEVICES:
A suitable pressure relief device of 6" diameter shall be provided on the main tank and
of 3" diameter shall be provided on OLTC for rapid release of any pressure in
transformer, which may endanger the equipment. The device (s) shall operate at static
opposite side of the first PRD be provided.
14.6
EARTHING TERMINALS:
14.6.1 Two earthing pads suitable for connecting 50x8mm mild steel flat shall be provided at
provided each on marshalling box and any other equipment mounted separately.
14.7
JOINTS AND GASKETS: 14.7.1 All gaskets used for making oil tight joints shall be of granulated cork bonded with
14.8
vector relationship of different windings, plan view of the transformer showing physical
relationship of the terminals and no load voltage and corresponding current for each
tap.
CT-128
14.8.2
14.8.3
Each transformer shall be provided with a rating plate data as specified in IS: 2026.
I.R. values alongwith oil temperature at the time of testing at manufacturer's works
shall be indicated on rating plate or separate plate, to be provided on transformer.
14.9

Thermosyphon filter arrangement shall be provided on the transformer for preserving
the quality of Transformer Oil. The filter assembly shall be mounted on the
Transformer as well as ground supported and connected with pipes and shut off
valves. Suitable instructions required to be followed for commissioning, dismantlement
& maintenance of the filter arrangement, re-generation and storage of the adsorbent
etc. must be included in the instruction manual. A detailed drawing showing internal
arrangement, shall also be required to be submitted. Suitable capacity pump
(alongwith motor) shall also be provided to boost circulation of oil. The pump and
motor should not be in main pipe line. It should be in bypass pipe line having suitable
valve to isolate from main pipe line. The main pipe line should have two shut off valves
at the bottom.
NOTE: The pump and motor should be weather proof (Flow well Type).
The oil & sorbent capacity required in the Thermosyphon Filter is as under: (i)
Quantity of oil
(ii)
Quantity of adsorbent
15.
15.1
COOLING PLANT:Detachable radiators shall be fitted on the main tank with machined flanged outlet and
inlet. Each radiator shall be provided with 19mm drain plug at Bottom and 19mm air
release plug at the top. Valves shall be provided on the tank at each point of
connection to radiators.
15.2
connections to each cooler. 25 mm drain valve. Thermometer pockets with captive
screwed cap at inlet and outlet of each separate cooler, filter valve at top and bottom
and air release plug of 15mm.
15.3 The motor blowers shall be direct driven suitable for continuous out door operation and
15.4 MOTORS:15.4.1 The motor shall be squirrel cage totally enclosed weather proof type suitable for direct
starting and for continuous running from 415-240 volts, three phase/single phase 50 C/S
supply. The motors shall comply with IS as applicable for continuous rated machine.
5 % and 415/240 V AC 10 % variation of the normal voltage without injurious over
heating.
CT-129
15.4.3 All motors shall have ball or roller bearing with hexagonal nipples for greasing. In case of
vertical spindle, motor shall have bearing capable of withstanding thrust, due to weight of
the moving parts.
15.4.4 Varnished cambric or glass insulator shall be used for connections from stator winding to
the terminal suitable for external wiring. The motor terminals shall be of stud type and
totally enclosed.
15.5 COOLER CONTROL:15.5.1 Each motor or group of motors shall be provided with a 3 pole electrically operated
contactor with control gear for motor operation by hand and automatically through
15.5.2 All connection shall be so arranged as to allow either individual or collective operation of
the motors, Alarm indication (audio and visual) for failure of fans and to indicate failure of
power supply shall be provided.
15.5.3 The control equipment shall be installed in the marshaling box as specified in Cl.20 in
readily accessible position.
15.5.4 The alarm indication for failure of power supply and failure of individual fans be provided
through independent non trip alarm scheme conforming to the following:i)
ii)
The closing of an initiating contact shall glow a lamp, which will not reset until the
fault has cleared.
iii)
It shall be possible to silence the buzzer by pressing 'Accept' push button. If after
canceling the alarm but before resetting the visual signal, the same fault persists
the buzzer shall be suppressed.
iv)
If after canceling the alarm but before resetting the visual signal, some other fault
takes place, the alarm accompanied by flag indication on appropriate auxiliary
relay shall taken place.
v)
If after canceling the alarm and after resetting the visual signal, the same
fault appears or some other fault take place, the alarm, flag indication and
non-trip lamp indication shall reappear as usual.
vi)
The non-trip alarm acceptance shall be by means of push button and resetting of
visual signal may also preferably be done through a push button.
vii)
Means shall be provided for test checking the lamp and alarm circuit at frequent
intervals.
viii)
Static facia aunnuciator conforming to the foregoing requirements of non trip
16.
VOLTAGE CONTROL (ON LOAD TYPE):16.1
The transformer shall be provided with voltage control equipment of the tap changing
type for varying its effective transformation ratio while the T/Fs are on load and without
producing phase displacement.
16.2
Equipment for 'local' and 'remote' electrical and 'local' manual operation shall be
CT-130
16.2.1
16.2.2
16.2.3
16.2.4
16.2.5
16.3
16.4
16.4.1
16.4.2
16.5
16.6
16.7
16.8
16.9
in use.
operations.
Thermostatically controlled heaters shall be provided in the driving mechanism
fungi etc.
relay. A separate buchholz relay may be provided for this compartment.
CT-131
16.10
16.11
16.12
16.13
16.14
16.15
16.16
16.17
16.18
16.19
16.20
16.21
17.0
17. 1
be provided with adequate breathing arrangement. The tap changer shall be mounted
in such a way that the cover of the transformer can be lifted without removing
connections between windings and tap changer.
be standard 415 Volts, three-phase, 3 wire, 50 Hz. alongwith 240 Volts single phase, 2
wire 50 Hz, subject to a variation of 5 percent so that the equipment offered can
The indigenous make OLTC suitable for 132 KV voltage class insulation (graded) but
the voltage class insulation should not be less than 66 KV and current rating as 300
Amp. The OLTC should be type tested from CPRI or other Govt. test house or from
reputed Lab. Abroad to the extent the facilities of type test are available with CPRI.
PARALLEL OPERATION In addition to individual control of tap changer, provision shall be made to enable
similar unit of same rating.
CT-132
17.2
17.3
18.0
18.1
step.
Transformer shall be fitted with bushing insulators as follows: HV bushing: 145 kV class, condenser bushing of 800 Amp. rating with arcing
horns.
L.V. Bushing: 36 kV class, oil communicating type porcelain bushing of 1000 Amp.
rating but with suitable arcing horns.
L.V.-N Bushing: 36 kV class, oil communicating type porcelain bushing of 1000 Amp.
rating but without arcing horns.
H.V-N Bushing: 36 kV class, oil communicating type porcelain bushing of 630 Amp.
rating but without arcing horns.
3347.
The bushing insulators except for neutral bushing shall be provided with adjustable
arcing horns and the bidder shall furnish calibration gap to decide actual gap
setting.
copper shall be connected to the connector in the helmet of the 220/132 kV
air.
Bi-metallic terminal connectors shall be supplied suitable for single 0.4 Sq. inch
ACSR Zebra conductor for HV, LVN & HVN and twin ACSR Zebra conductor for
LV side . The take off for H.V. & L.V. connectors will be Vertical and for Neutral it
should be suitable for horizontal take off.
conform to designation Grade 4600 of IS: 617-1975. The steel bolts, nuts washers
and check nuts shall be hot dip galvanized marked with ISI certification mark or of
GKWmake.
CT-133
19.0
19.1
19.2
19.3
19.4
19.5
19.6
19.7
20.0
20.1
20.2
20.3
20.4
20.5
21.0
21.1
21.2
21.3

vent.
MARSHALING BOX:
A sheet steel (of 10 SWG size) vermin proof well ventilated and weather proof
CT-134
21.4
21.5
22.0
22.1
22.2
22.3
22.4
22.5
22.6
22.7
23.0
trench.
The losses at principal tap of each transformer shall be stated in the tender ONAF
rating at full load at 750C.
shall be capitalised as per capitalization formula given below:
=3,86,700( Wi + 0.45 Wc + 0.45 Wp)
Where
Wi
=
Iron (No load) Losses
Wc
=
Copper (Load Losses)
Wp
=
Auxiliary Losses
24.0 and no positive tolerance shall be allowed on these values
CT-135
within three years from the date of commissioning the capaitalized value of excess losses,
as compare to the specified value shall be recovered as per following capitalization
formula:Amount recoverable (Rs.)= 3,86,700 (Wi + 0.45 Wc + 0.45Wp).
24.0
24.1
Losses:The losses of each transformer shall be stated in the tender for OFAF rating at
principal tap (at full load at 75 deg. C) which shall be less than:Sr. No.
1
2
Type of Losses
No Load Losses
Load Losses
25 MVA, 132/33 KV T/F

23 KW (Max)
100 KW(Max)
3
4
Auxiliary Losses
Maximum weighted average losses
2.2 KW (Max)
62 KW
Noise level
80 dB
Transformer offers shall be rejected if audible sound level is higher than max.80 dB.
25.
25.1
25.2
25.3
25.3.1
25.3.2
TESTS:
ROUTINE TESTS:
All routine test shall be carried out on each transformer as per IS-2026/ IEC-76. In the
presence of purchasers representative.
TYPE TEST
Following type test shall be carried out on one transformer as per ISS 2026 in the
presence of purchasers representative.
(i) Temperature rise test (along with DGA).
(ii) Impulse voltage withstand test as per clause 13 of ISS-2026 /1981 Part-III on one
limb.
OIL LEAKAGE TEST:
occur.
Following tests shall be carried out on each transformer as reference test
i.
10 kV.
ii.
iii.
iv. Measurement of percentage impedance at all taps at low voltage.
CT-136
25.3.3
TRANSFORMER OIL:
25.3.4
SHORT CIRCUIT TEST

The warranty in case of Power Transformer shall be 18 months from the date of
commissioning or 24 months from the date of receipt whichever is earlier. All
other stipulations of Warranty Clause as per Schedule-D of purchase regulation
shall remain same.
25.4
The purchaser reserves the right to have any other, reasonable test carried out at his
25.5
STAGE INSPECTION:
radiators shall be carried-out as detailed below:a.
i)
ii)
iii)
iv)
v)
b.
i.
ii.
iii.
CORE:
Measurement of flux Density.
Tests of CRGO sample taken from the core shall be carried-out for Carlite test
Tests.
Physical inspection for quality of workmanship.
WINDINGS:
The purity test of copper shall be got conducted on sample of copper for
CT-137
c.
NOTE:
TANK:
i) Vacuum Test:
100.64 kN (760 mm of hg). The tanks to be designed for full vacuum shall be
tested at an internal pressure of 3.33 KN/M2 (25mm of Hg.) for one hour.
The permanent deflection of flat plates after the vacuum has been released shall
not exceed the values given below without affecting the performance of the
Transformer.
-----------------------------------------------------------------------------------------------------------------------Horizontal length of flat plate(mm).
Permanent deflection(mm).
-----------------------------------------------------------------------------------------------------------------------Upto & including 750
5.0
751-1250
6.5
1251-1750
8.0
1751-2000
9.5
2001-2250
11.0
2251-2500
12.5
2501-3000
16.0
above 3000
19.0
---------------------------------------------------------------------------------------------------------------------ii) PRESSURE TEST:
One transformer out of the lot shall be subject to the pressure corresponding to
twice the normal head of oil or normal pressure plus 35KN/M2 (which ever is
lower) measured at the base of the tank and maintained for one hour. The
permanent deflection of flat plates after removal of excess pressure shall not
exceed the figures specified as above.
d. RADIATORS:
Radiator shall be routine and type tested at sub suppliers' work as per relevant
a.
VIGNOLE MAKE). The polarisation index values (ratio of 120/20 sec. value) will
be accordingly calculated and recorded in the test certificates and it should not
be less than 1.5.
b. Dissolved gas analysis test shall be got carried-out before and after heat run
test at CPRI.
c. Capacitance and Tan Delta values for each transformer and condenser
d. Lightening impulse test with the chopped wave applications as per clause 13 of
CT-138
e.
26.
26.1
26.1.1
26.1.2.1
26.2
26.2.1
a.
b.
c.
d.
e.
Supplier shall submit in house test certificates at least 15 days in advance for
final testing of T/F. For testing T/F, all measuring instruments shall be of highest
efficiency and best quality. These shall be got calibrated from NPL/ Govt. Agency
and be got sealed by calibrating agency. HVPN reserves the right to calibrate
the instruments in the manner it desires.
Losses shall be measured with 3-wattmeter method only. Resistance shall be
taken with Double-Kelvin Bridge. Losses can be measured directly from CTs and
PTs and not through the panel. Ratio of the measuring instrument shall be such
that the multiplying factor is the minimum.
All tests shall be carried out in the presence of the Purchaser before dispatching
the material. Test certificates in quadruplicate will be submitted to the Purchaser
for approval. No material shall be despatched without prior inspection and
approval of test certificates unless otherwise agreed to. Type and routine test
certificates of all bought out items from recognised testing agency shall be
submitted for approval before commencing supplies. OLTC scheme including the
master follower functioning shall also be checked. Only fully assembled
transformer including mounting of radiators shall be put-up for inspection.
DRAWINGS:
The successful bidder shall submit final version of drawings complete in all
respects in quadruplicate within 15 days of placement of order for purchaser's
approval. The purchaser shall communicate his comments/ approval on the
drawings to the supplier within one month of their receipt. The manufacturer
shall, if so required by the purchaser, modify the drawings and resubmit the
same for purchaser's approval within two weeks of receipt of comments. Such
duly revised drawings will be approved by the purchaser within two weeks of their
receipt.
After receipt of purchaser's approval to drawings, the manufacturer will submit
five sets of all approved drawings and five sets of manual of instructions to our
Design Office.
One set of all the approved drawings and manual of instructions will be
supplied along with each equipment without which the supply will not be
considered as complete supply.
Outline general arrangement drawings showing plan, front elevation & side
elevation with all fittings and accessories etc. The following information must be
specifically included on the drawings.
CT-139
f.
g.
h.
26.2.2
26.2.3
26.2.4
26.2.5
26.2.6
26.2.7
26.2.8
26.2.9
26.2.10
26.2.11

Weight of oil, bare copper weight windings, core, un-tanking mass, transportation
mass and dimensions etc.
Detailed of bushings showing plan, elevation, terminal details, mounting details

make and type number incorporating electrical characteristics, description of
various parts, total creepage/ & protected creepage distance, weight of oil, total
weight of bushing , dimensions, short time current rating etc.
connections.
Schematic control and wiring diagram for auxiliary equipment like OLTC control
gear, cooler control gear, Marshaling Kiosk. Detailed write-up for schematic shall
also be supplied
kiosk.
Detailed calculations showing short circuit with stand capability due to radial and
axial forces during short circuit. Also calculation for thermal withstand capability
during short circuit.
CT-140

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SECTION-3

On load tap changer.

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Aluminium Alloy grade.

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Star auto with neutral solidly earthed

Power frequency withstand voltage

Insulation level of Bushings

25mm per kV corresponding to

GENERAL DESIGN OF TRANSFORMER:

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Corresponding parts liable to replace shall be interchangeable.

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The design of magnetic circuit shall be such as to avoid static discharge

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structure and the production of flux components at right angles to the

Core and windings shall be capable of withstanding shocks during transport,

11.00 SUPPRESSION OF HARMONICS:

THERMOSYPHON FILTER ARRANGEMENT

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2.0% of total oil by weight.

NITROGEN INJECTION FIRE PROTECTION CUM EXTINGUISHING SYSTEM

15.1.1 Auto Mode

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

For extinguishing fire:

15.1.2 Manual Mode (Local/Remote):

Tripping of all connected breakers is

15.1.3 Manual Mode (Mechanical)

Tripping of all connected breakers is

pre- requisite for initiation of system

General description of NIFPES

15.2.1 Schematic of the system

15.2.5 Control box

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System out of service

15.2.6 Pre-stressed non return valve (PNRV)

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15.5.1 Fire extinction period

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BUSHING INSULATORS AND TERMINALS:

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The temperature indicators shall be housed in marshaling box.

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Iron (No. Load ) Losses

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100 MVA, 220/132

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The insulation resistance values of the transformer windings will be recorded at

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SCHEDULE OF GUARANTEED AND OTHER TECHNICAL PARTICULARS.

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Electricity power connectors.

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4.2.5 Max. System Voltage

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