CMD Ii (L) Dgo - 15012015

BIS/DGO( 428 )/2015
15 January 2015
BUREAU OF INDIAN STANDARDS
OFFICE ORDER
Subject: Preparation of Product Manuals by RO/BOs by Custodian BOs
Attention of RO/BOs is drawn towards Cl.10.1 of DGO(404) whereupon it was informed that the
structure of Product Manual was under consideration.
The structure of Product Manual has now been approved by Competent Authority and is available at
Annexure-A. The format is to be used by custodian BOs in preparing the Product Manuals.
A typical Product Manual based on the structure of the format approved by the Competent Authority
for Transformers as per IS 1180 (Part 1) has been drafted by CMD-II and enclosed at Annexure-B for
perusal and guidance of RO/BOs (the same however needs to be modified by the Custodian BO and
approval sought as per the office order).
It has further been decided that all Product Manuals (under preparation/already prepared) shall be re-
structured using format given under Annexure-A and finalized after following the procedure given in
DGO(404). The responsibility for preparation of Product Manual for new products under certification
shall be done as per DGO(404). As and when the software is made operational by ITS, necessary
inputs should be done in the software by the Custodian BOs.
All Product Manuals for existing products under Certification Marks scheme are to be hosted on
Intranet/Website latest by 30 June 2015. The responsibility adhering to the deadline shall lie with
custodian BO and this should be monitored by PCO of the Region. RO is requested to forward the
BO-wise list of IO assigned the responsibility of preparation of product Manual by 20 Jan 2015. Any
difficulty encountered shall be brought to the notice of concerned DDGR. A compliance report in this
regard shall be sent to CMD-II by the concerned PCO(ROs) on 01 July 2015.
This is for information and necessary action by all concerned.
This issues with the approval of Competent Authority
Sd/- 15 01 2015
(V.K. Diundi )
Sc.F & Head
Ref.:CMD-II(L)/7
Circulated to all Custodian BOs
Copy to : 1. All DDGRs
2. PCO(RO)s
3. ITS - for hosting on Intranet and for preparation of software for

preparation of Product Manual.
PRODUCT MANUAL
(First Version)
TITLE:
IS NO:
No. of Amendments:
Custodian BO:
Date of Issue:

MANAK BHAWAN, 9, BAHADUR SHAH ZAFAR MARG,
NEW DELHI – 110002
DISCLAIMER
The use of Standard Mark is governed by the provisions of the Bureau of Indian Standards
Act, 1986 and the Rules and Regulations made thereunder. The details of conditions under
which the licence for the use of the Standard Mark may be granted to manufactures or
producers may be obtained from the Bureau of Indian Standards.
This Product Manual document is provided for informational purposes and should be used
for reference purposes only. The document may be used by prospective applicants desirous
of obtaining BIS certification licence. This Product Manual shall also be used as reference
material by all Regional / Branch Offices & licensees to ensure coherence of practice and
transparency in operation of BIS certification licence.
1. Title of the latest Indian Standard, IS Number & Total number of Amendments
TITLE:
IS NO:
No. of Amendments:
2. LIST OF REFERRED STANDARDS
IS No. Title
3. INTRODUCTION
Objective:
This Product Manual on “Indian Standard IS 1180 (Pt1): 2014 - Outdoor Type Oil Immersed
Distribution Transformers Up to And Including 2 500 KVA, 33KV provides all important
information / elements needed for grant of a product certification licence and its continued
operation and can be used by prospective applicants desirous of obtaining BIS certification
licence. This Product Manual shall also be used as reference material by all Regional /
Branch Offices to ensure coherence of practice and transparency. This will also help in
having a uniform and transparent approach in processing of application for grant of licence
and its operation
The Product Manual will serve as an important guide for all stakeholders including licensees
& applicant desirous of obtaining BIS Certification licence.
General :
A brief description of the Indian Standard applicable for the product and other provisions of
relevance shall be indicated..
Important provisions which are of significance shall also be provided.
.
4. REQUIREMENTS OF THE STANDARD
4.1 Grade /Class/ Rating/ Variety/ Size as per Standard
Grade
Class
Rating
Variety
Size
Any other
4.2 Clause Wise Requirements
4.2.1 Clause wise Requirements for Type/ Grade/ Variety - --------------
Sl.N Clause No. Test Method Critical/ Remarks

o. (Clause/Reference) Non Critical
RAW MATERIALS Raw Material
GENERAL Tests
ROUTINE TESTS
TYPE TESTS
SPECIAL TESTS / ADDITIONAL TESTS/ OPTIONAL TESTS / MUTUALLY

AGREED TEST
Critical/non-critical to be decided for operation of BIS licence, irrespective of whether the

Critical/non-critical parameters are defined in product standards or not.
4.2.2 Add on provisions for more type/grade/variety/ etc , if required
4.2.3 Hygienic Conditions (applicable to food products)
In case of food industries the hygienic conditions required as per the relevant clause of the
standard to be to be maintained by the firm shall be given.
5. GROUPING GUIDELINES
Sl no Grade / variety Type/Class Rating Size Group Remark 2 Justification3

as per Standard 1 as per Standard 1 as per Standard 1 as per Standard 1
1 Group1
2 ….. Group 2
3 …… ……. ……. ……. ……..
Note :
1. All Type/Grade / Class / Rating / variety as per Standard has to be covered
2. Any specific instruction (if any) shall be given in remark column e.g relaxation for covering less
stringent grade/variety / Size / thickness if more stringent grade / variety / higher / lower size /
thickness is drawn.
3. Justification shall be given for grouping the types/Grades / Class / Rating / variety / sizes
4. Intention shall be to draw less number of sample and cover maximum numbers of grade / variety / size
based on criteria of most stringiest.
5. Grade/Size/Class/variety other than specified in standards or non standard size (e.g- which may be
supplied as per mutual agreement between manufacturer and purchaser) shall not be endorsed in
licence and hence shall not form part of grouping guideline.
6. SCOPE OF THE LICENCE
A description of what should be in a typical licence document shall also be clearly spelt out.
Specimen contents of a typical licence documents shall be given.
Details of the scope of licence to be indicated, mentioning that
“Licence shall be granted with the following scope:
Name of the Product

Type
Class
Grade
Sizes
Any other aspect
required as per the
Standard
As per IS-----
7. Infrastructure for Production
7.1 Description of Plant & Machinery
A typical list of manufacturing machinery and equipment is given below for guidance as a
minimum requirement. Alternative machinery may be used based on advancement of
technology by various manufacturers which may be built into this manual from time to time".
PROCESS 1
Sl No Description of Machinery Capacity Remarks
PROCESS 2
PROCESS -----
7.2 Manufacturing Process
A brief write-up of a typical manufacturing process indicating the involvement of

machineries and its utility in the process, in-process controls exercised at various stages, etc
to be provided.
7.3 Manufacturing Process Flow Chart
A flow diagram for manufacturing process to be provided

8. Infrastructure for Testing
Complete test facility for all the requirements covered under ‘Routine Tests’ shall be available with the firm. For other tests, test report
of conformity from BIS recognized/Group-2 category of laboratories as per the frequency of STI shall be produced by the licensee to BIS (where
in-house test facilities are not available for these tests and relaxation as given by BIS).
A typical list of test equipment is given below for guidance as a minimum requirement. Alternative test equipment may be used based on
advancement of technology which may be built into this manual from time to time based on revision / amendment in Indian Standard.
Requirement Clause of Frequency Importance Test Least Count & Frequency of Approx Cost of test In-house arrangement
Standard per Control of test Equipment Range Calibration equipment Or
Unit requirement Outside Laboratory
General Requirements
Routine Test
Type Test
Special Tests / Additional Tests/ Optional Tests / Mutually Agreed Test

9. CONTROL UNIT :
The control unit shall be defined depending upon the type of process. This shall be suitably
defined for level of controls to be exercised for the production.
10. TEST RECORDS TO BE MAINTAINED BY FIRM
Format I
Class / Type Group / Rating/ Size Important Parameters
Date of Control Quantity Quantity Parameter Parameter Parameter Parameter Parameter Parameter Parameter Parameter Parameter
manufacture Unit Under the marked x1 x2 x3 x4 x5 x6 x7 x8 xn
Control Unit with Frequency Frequency Frequency Frequency Frequency Frequency Frequency Frequency Frequency
Standard
Test result Test result Test result Test result Test result Test result Test result Test result Test result
Mark
Other Parameters
Date of Control Quantity Quantity Parameter Parameter Parameter Parameter

manufacture Unit Under the marked with x1 x2 x3 x4
Control Standard Frequency Frequency Frequency Frequency
Unit Mark Test result Test result Test result Test result
Format 2
S.No Batch No & Date Total Quantity Total Quantity Quantity found Segregation / Dispatch details
of Manufacture Manufactured Marked under Non conforming Disposal of Non
under the the Control Conforming
Control Unit Unit product
Bill No Date Name and Quantity (with Balance in

address Batch No.) stock
of the Dispatched with
consignee(s) Standard Mark
Format 3 RAW MATERIAL (Outside testing)
Sl Date of Name Source In case ISI marked In case Testing done from In case Non ISI Results Remarks
No receipt of the raw material -No of Outside Laboratory raw material &
Raw the corresponding IS accompanied by
Material Number & Licence No Test Certificate-
Test Certificate
No & Date
Name of Sample TR No &
Lab sent On date
Format 4 RAW MATERIAL (In house Testing)
Sl Date of Name Source Test Results of In house Testing Remarks

No receipt of the
Raw
Material
Date of IS No Clause Result
Testing
11. MARKING AND LABELLING REQUIREMENTS
Marking & labeling shall be defined as per the requirement of standard and Scheme
of Testing & Inspection.
12. PRODUCT SAMPLE SIZE AND TEST REQUEST
Quantity of sample Qty of sample required for testing to be indicated.
Manner of packing (to avoid

contamination/ damage during
transit)
Details to be Indicated in test 1. Size / Class / Grade/ Rating …

Request 2. Keeping Quality , Shelf life, Type of killing
etc..
3. Declaration / manufacturer specified value
4. Drawings
5. Special Test/Optional Test (if any) or any any
other requirement required to be tested
Instruction to Lab Any specific instruction or information to lab

regarding testing of sample may be given here
Manner of sealing
Instruction for re removing /

defacing label and/or
manufacturer's identification
Mechanism for dealing with the

remnants of sample to be indicated-
In case sample is required to be
returned back to certified body/
applicant, the same shall be
indicated
12. 2 RAW MATERIAL SAMPLE SIZE AND TEST REQUEST

transit)

etc..
4. Drawings

Manner of sealing
indicated
13. PRODUCT SPECIFIC GUIDELINES (If any)
Product specific guidelines if issued shall be provided under this item
14. GUIDELINES FOR ASCERTAINING CONFORMITY OF PRODUCT AT THE TIME OF

GRANT OF LICENCE
15. GUIDELINES FOR ASCERTAINING CONFORMITY OF PRODUCT BY WAY OF

INDPENDENT TESTING DURING OPERATION OF LICENCE
GENERAL
Clause Requirement Periodicity of testing the requirement in Independent Testing
ROUTINE TEST
Clause Requirement
TYPE TESTS: To be carried out at the first instance and whenever there is any change in design
Clause Requirement
SPECIAL TEST (If applicable, as agreed between purchaser and manufacturer)
16. GUIDELINES FOR OPERATION OF LICENCE IN CASE LICENCE BEING

OPERATED BASED ON FACTORY TESTING
17. GUIDELINES TO ENSURE CONFORMITY OF RAW MATERIAL DURING GRANT

OF LICENCE
18. GUIDELINES TO ENSURE CONFORMITY OF RAW MATERIAL DURING

OPERATION OF LICENCE
In cases where licences are being operated based on factory testing only, guidelines to be
provided .
19 MARKING FEE#
Unit
Unit rate
Marking Fee (Minimum) Large scale
Marking Fee (Minimum) Small scale
MF Rates effective from
20. TEST REPORT –
20.1 TEST(S) TO BE CARRIED OUT DURING REGULAR SURVEILLANCE –All

requirements as far possible to be tested during regular surveillance is to be indicated.
20.2 TEST(S) TO BE CARRIED OUT DURING ROM VISIT – All requirements as far possible
and requirements which has failed.
20.3 TEST REPORT PERFORMA (To be linked with test report format of T &C)
21. SCHEME OF TESTING & INSPECTION

PRODUCT MANUAL
(First Vesion)
TITLE: OUTDOOR TYPE OIL IMMERSED DISTRIBUTION

TRANSFORMERS UPTO AND INCLUDING 2500 KVA,
33KV – SPECIFICATION - (PART 1) MINERAL OIL
IMMERSED
IS NO: 1180 (Part 1):2014
No. of Amendments: NIL
Custodian BO:
Date of Issue:

MANAK BHAWAN, 9, BAHADUR SHAH ZAFAR MARG,
NEW DELHI – 110002
DISCLAIMER
The use of Standard Mark is governed by the provisions of the Bureau of Indian Standards
Act, 1986 and the Rules and Regulations made thereunder. The details of conditions under
which the licence for the use of the Standard Mark may be granted to manufactures or
producers may be obtained from the Bureau of Indian Standards.
This Product Manual document is provided for informational purposes and should be used
for reference purposes only. The document may be used by prospective applicants desirous
of obtaining BIS certification licence. This Product Manual shall also be used as reference
material by all Regional / Branch Offices & licensees to ensure coherence of practice and
transparency in operation of BIS certification licence.
1. Title of the latest Indian Standard, IS Number & Total number of Amendments
TITLE: Outdoor Type Oil Immersed Distribution Transformers upto and

including 2500 KVa, 33Kv – Specification - (Part 1) Mineral Oil
Immersed
IS NO: 1180 (Part 1):2014
No. of Amendments: NIL

2. LIST OF REFERRED STANDARDS
IS No. Title
191: 2007 Copper
335 : 1993 New insulating oils
554 : 1999 Pipe Threads Where Pressure-Tight Joints are Made on the Threads -
Dimensions, Tolerances and Designation
1576 : 1992 Solid pressboard for electrical purpose
1608 : 2005 Mechanical testing of metals – tensile Testing
1747 : 1972 Nitrogen
1885 (Part 38) : 1993 Electrotechnical vocabulary: Part 38 Power transformers and reactors
1897 : 2008 Copper strip for electrical purpose
2026 Power transformers :

(Part 1) : 2011 General
(Part 2) : 2010 Temperature rise
(Part 3) : 2009 Insulation levels, dielectric tests and external clearances in air
(Part 5) : 2011 Ability to withstand short circuit
(Part 8) : 2009 Application guide
(Part 10) : 2009 Determination of sound levels
2099 : 1986 Bushings for alternative voltages above 1 000 volts
3024 : 2006 Grain oriented electrical steel sheets and strips
3347 Dimensions for porcelain transformer bushings for use in lightly

Polluted Atmospheres
(Part 1/Sec 1) : 1979 Part 1: Up to and including 1 kV: Section 1 Porcelain parts
(Part 1/Sec 2) : 1979 Part 1: Up to and including 1 kV: Section 2 Metal parts
(Part 2/Sec 1) : 1979 3.6 kV Bushings : Section 1 Porcelain parts
(Part 2/Sec 2) : 1979 3.6 kV Bushings: Section 2 Metal parts
(Part 3/Sec 1) : 1988 17.5 kV Bushings: Section 1 Porcelain parts
(Part 3/Sec 2) : 1988 17.5 kV Bushings: Section 2 Metal parts
(Part 4/Sec 1) : 1988 24 kV Bushings: Section1 Porcelain parts
(Part 4/Sec 2) : 1982 24 kV Bushings: Section 2 Metal parts
(Part 5/Sec 1) : 1979 36 kV Bushings: Section 1 Porcelain parts
(Part 5/Sec 2) : 1979 36 kV Bushings: Section 2 Metal parts
3639 : 1966 Fittings and accessories for power transformers
4253 (Part 2) : 2008 Cork composition sheet- Part 2 Cork and Rubber
6162 Paper-covered aluminum conductors Round conductors
(Part 1) : 1971
6162 (Part 2) : 1971 Rectangular conductors
7404(Part1) : 1991 Paper covered copper conductors: Part 1 Round conductors
7421 : 1988 Porcelain bushings for alternating voltages up to and including 1000 V
8999 : 2003 Pipe Threads where Pressure-Tight Joints are Made on the Threads -
Verification by Means of Limit Gauges
9335 Cellulosic papers for electrical purposes:Definitions and general
(Part 1) : 1979 requirements
(Part 2) : 1998 Methods of test
(Part 3/Sec 1) : 1984 Specifications for individual materials, Section 1 General purposes
electrical paper
(Part 3/ Sec 3) : 1984 Specifications for individual materials, Section 3 Crepe paper
(Part 3/ Sec 5) :1985 Specifications for individual materials, Section 5 Special papers
11149 : 1984 Specification for rubber gaskets
12444 : 1988 Continuously cast and rolled electrolytic copper wire rods for electrical
Conductors
13730(Part 0/Sec 3) : Specification for particular types of winding wires: General
2012 requirements Section 3: Enameled round copper wire
( Part 17) : 1996 Polyvinyl acetal enameled rectangular copper wire, Class 105
(Part 27) : 1996 Paper covered rectangular copper wire
16081 : 2013 Insulating liquids - Specification for unused synthetic organic esters for
electrical purposes
3. INTRODUCTION
Objective:
This Product Manual on “Indian Standard IS 1180 (Pt1): 2014 - Outdoor Type Oil Immersed
Distribution Transformers Up to And Including 2 500 KVA, 33KV provides all important
information / elements needed for grant of a product certification licence and its continued
operation and can be used by prospective applicants desirous of obtaining BIS certification
licence. This Product Manual shall also be used as reference material by all Regional /
Branch Offices to ensure coherence of practice and transparency. This will also help in
having a uniform and transparent approach in processing of application for grant of licence
and its operation
The Product Manual will serve as an important guide for all stakeholders including licensees
& applicant desirous of obtaining BIS Certification licence.
General :
Transformers are the crucial and key power system equipments in the electricity distribution
network. The reduction in total load loss and constant no-load electrical loss assume
importance, considering the fact that total number of distribution transformers in the
electricity network is quite large and these equipments are constantly under operation. Apart
from this energy conservation aspect, another critical facet is the reliability of the equipment
in ensuring uninterrupted power supply. Thus, the longevity of the distribution transformer is
quite an important attribute to realise the goal of having a reliable power system network.
Distribution Transformer Industry in the country has progressed a lot over the years. In view
of the importance of conservation of energy, minimum energy performance standards for
distribution transformers right up to 2500 KVA 3 phase ratings as well as single phase high
voltage distribution transformers up to 25 kVA has been specified in certain regulation.
Indian Standard IS 1180 (Pt1): 2014 - Outdoor Type Oil Immersed Distribution
Transformers Up to And Including 2 500 KVA, 33KV — Specification specifies the
requirements and tests which include standard loss levels of mineral oil immersed, natural
air-cooled, outdoor type, and double wound distribution transformers for use in power
distribution systems with nominal system voltages up to and including 33 kV and of
following types and ratings:
a) Three phase ratings up to and including 200 KVA both non-sealed type and sealed
type.
b) Three phase ratings higher than 200 KVA, up to and including 2 500 KVA both non-
sealed type and sealed type.
c) Single phase ratings up to and including 25 KVA sealed type.

This standard recommends multiple rating with regard to Energy Efficiency that is, three
energy efficiency levels: level 1, level 2 and level 3 of transformers based on the “maximum
total loss”. It is expected that transformers shall conform to at least energy efficiency level 1.
In due course of time with improvements in technology and materials, higher levels of energy
efficient transformers shall be progressively used.
.
4. REQUIREMENTS OF THE STANDARD
4.1 Grade /Class/ Rating/ Variety/ Size as per Standard
Nominal System Voltage kVA Rating

Three Phase Sealed Type and Up to and including 11 kV 6.3, 10, 16, 20, 25, 40, 63, 100,
Non sealed type (up to and 160 and 200
including 200kVA)
Above 11 kV &Up to & including 22 kV 63, 100, 160 and 200

Above 22 kV & Up to & including 33 kV 100, 160 and 200
Three Phase Sealed Type and Up to and including 11 kV 250, 315, 400, 500, 630,1000,
Non sealed type (above 200 1250, 1600, 2000 and 2500
kVA up to and including Above 11 kV &Up to & including 22 kV 250, 315, 400, 500, 630, 1000,
2500kVA) 1250, 1600, 2000, and 2500
Above 22 kV & Up to & including 33 kV 250, 315, 400, 500, 630, 1000,
1250, 1600, 2000, and 2500
Single phase transformer 11kV 5, 10, 16 and 25
(Sealed Type)
22kV 10, 16 and 25
33kV 16 and 25
Note 1: Rated Basic Insulation Level shall be as per Table 2, 5 & 8 of IS 1180 (Part 1)
Note2: Maximum Total Losses up to 11KV Class Transformer shall be as per Table 3, 6 and
9 of of IS 1180 (Part 1)
4.2 Clause Wise Requirements
4.2.1 Clause Wise Requirements Three Phase Sealed Type and Non sealed type (up to
and including 200kVA)
Sl.N Clause No. Test Method Critical/ Remarks

o. (Clause/Reference) Non Critical
1. 9.1 CRGO electrical steel IS 3024
Copper/Aluminium conductor IS 191, IS 1897, IS
7404, IS 12444, IS
13730/IS 6162 series
Kraft paper IS 9335 series
Press board IS 1576
Mineral oil IS 335
Bushings IS 2099 /7421 & IS
3347
GENERAL Tests
1. 6.9.1 & 6.9.2 Permissible flux density and IS 1180 (Part 1)
7.9.1 & 7.9.2 over fluxing
8.9.1 & 8.9.2
2. 11 Minimum clearances in Air -do-
3. 15.1 Construction of transformer -do-
tank
4. 15.5 Painting of Transformer Tank -do-
5. 16 Conservator for non sealed type -do-
transformers
ROUTINE TESTS
1. 21.2 a) Measurement of Winding IS 2026 (Part-1)
Resistance
2. 21.2 b) Measurement of Voltage Ratio IS 2026 (Part-1)
and check of Phase
Displacement
3. 21.2 c), 6.8 Measurement of Short Circuit IS 2026 (Part-1)
7.8, 8.8 Impedance (principal tapping,
when applicable) and load loss
at 50 percent and 100 percent
load
4. 21.2 d) Measurement of no load loss IS 2026 (Part-1)
and current
5. 21.2 e) Measurement of insulation IS 2026 (Part-1)
resistance
6. 21.2 f) Induced overvoltage withstand IS 2026 (Part-3)
test
7. 21.2 g) Separate source voltage IS 2026 (Part-3)
withstand test
8. 15.2 & Pressure test Cl. 21.5 of IS
21.2 h) 1180(Part-1):2014
9. 15.2 & Oil Leakage test Cl. 21.5 of IS
21.2 j) 1180(Part-1):2014
TYPE TESTS
1. 21.3 a) Lightning Impulse Test IS 2026 (Part-3)
2. 21.3 b), 6.10 Temperature rise test IS 2026 (Part-2)
7.10, 8.10
3. 21.3 c) Short Circuit withstand test IS 2026 (Part-5)
(up to 200kVA)
4. 21.3 d) Pressure Test Cl. 21.5 of IS 1180
(Part-1):2014
SPECIAL TESTS
1. 21.4 a) Determination of Sound Levels IS 2026 (Part-10)
2. 21.4 c) No load current at 112.5% Cl. 5.9.3 of IS 1180
voltage (P-1):2014
3. 21.4 d) Paint adhesion test ASTM D 3359
4. 21.4 e) BDV & Moisture Content of IS 335
Transformer Oil
4.2.2 Clause Wise Requirements Three Phase Sealed Type and Non sealed type (above 200
kVA up to and including 2500kVA)
Sl.No. Clause No. Test Method

(Clause/Reference)
Copper/Aluminium conductor IS 191, IS 1897, IS 7404,
IS 12444, IS 13730/IS
6162 series
Press board IS 1576
Mineral oil IS 335
Bushings IS 2099 /7421 & IS 3347
GENERAL Tests
1. 6.9.1 & 6.9.2 Permissible flux density and over fluxing IS 1180 (Part 1)
7.9.1 & 7.9.2
8.9.1 & 8.9.2
3. 15.1 Construction of transformer tank -do-
5. 16 Conservator for non sealed type transformers -do-
ROUTINE TESTS
1. 21.2 a) Measurement of Winding Resistance IS 2026 (Part-1)
2. 21.2 b) Measurement of Voltage Ratio and check of IS 2026 (Part-1)
Phase Displacement
3. 21.2 c), 6.8 Measurement of Short Circuit Impedance IS 2026 (Part-1)
7.8, 8.8 (principal tapping, when applicable) and load
loss at 50 percent and 100 percent load
4. 21.2 d) Measurement of no load loss and current IS 2026 (Part-1)
5. 21.2 e) Measurement of insulation resistance IS 2026 (Part-1)
6. 21.2 f) Induced overvoltage withstand test IS 2026 (Part-3)
7. 21.2 g) Separate source voltage withstand test IS 2026 (Part-3)
8. 15.2 & Pressure test Cl. 21.5 of IS 1180(Part-
21.2 h) 1):2014
9. 15.2 & Oil Leakage test Cl. 21.5 of IS 1180(Part-
21.2 j) 1):2014
TYPE TESTS
7.10, 8.10
(up to 200kVA)
(Part-1):2014
SPECIAL TESTS
2. 21.4 b) Short Circuit withstand test IS 2026 (Part-5)
(above 200kVA)
3. 21.4 c) No load current at 112.5% voltage Cl. 5.9.3 of IS 1180
(P-1):2014
5. 21.4 e) BDV & Moisture Content of Transformer Oil IS 335
4.2.3 Clause Wise Requirements Single phase transformer (Sealed Type)
Sl.No. Clause No. Test Method

(Clause/Reference)
Copper/Aluminium conductor IS 191, IS 1897, IS 7404,
IS 12444, IS 13730/IS
6162 series
Press board IS 1576
Mineral oil IS 335
Bushings IS 2099 /7421 & IS 3347
GENERAL Tests
1. 6.9.1 & 6.9.2 Permissible flux density and over fluxing IS 1180 (Part 1)
7.9.1 & 7.9.2
8.9.1 & 8.9.2
3. 15.1 Construction of transformer tank -do-
5. 16 Conservator for non sealed type transformers -do-
ROUTINE TESTS
1. 21.2 a) Measurement of Winding Resistance IS 2026 (Part-1)
2. 21.2 b) Measurement of Voltage Ratio and check of IS 2026 (Part-1)
Phase Displacement
3. 21.2 c), 6.8 Measurement of Short Circuit Impedance IS 2026 (Part-1)
7.8, 8.8 (principal tapping, when applicable) and load
loss at 50 percent and 100 percent load
4. 21.2 d) Measurement of no load loss and current IS 2026 (Part-1)
5. 21.2 e) Measurement of insulation resistance IS 2026 (Part-1)
6. 21.2 f) Induced overvoltage withstand test IS 2026 (Part-3)
7. 21.2 g) Separate source voltage withstand test IS 2026 (Part-3)
8. 15.2 & Pressure test Cl. 21.5 of IS 1180(Part-
21.2 h) 1):2014
9. 15.2 & Oil Leakage test Cl. 21.5 of IS 1180(Part-
21.2 j) 1):2014
TYPE TESTS
7.10, 8.10
(up to 200kVA)
(Part-1):2014
SPECIAL TESTS
2. 21.4 c) No load current at 112.5% voltage Cl. 5.9.3 of IS 1180
(P-1):2014
4. 21.4 e) BDV & Moisture Content of Transformer Oil IS 335
Critical/non-critical to be decided for operation of BIS licence, irrespective of whether the

Critical/non-critical parameters are defined in product standards or not.
5. GROUPING GUIDELINES
Type/Class Grade / Rating Size Group Reason / Justification of

As per Standard grouping
Nominal System kVA Rating For Certification purpose
Voltage
Three Phase 3.3 kV Up to and One sample of highest rating Group X1 Basic Insulation Level is
(Sealed including 200 and the highest energy same for the same nominal
Type)/ (Non kVA efficiency offered by the system voltage.
Sealed Type) applicant to cover all the Compliance to higher energy
efficiency level ensures
ratings and energy efficiency compliance to lower energy
levels up to that highest value. efficiency levels
Separate
6.6 kV -do- Group X2 -do-
samples
shall be 11 kV -do- Group X3 -do-
drawn for
sealed and
Above 11 kV -do- Group X4 -do-
non-sealed
&Up to &
type
including 22 kV
Above 22 kV & -do- Group X5 -do-
Up to &
including 33 kV
3.3 kV Above 200kVA -do- Group X6 -do-
and up to &
6.6 kV -do- Group X7 -do-
including 2500
11 kV kVA, 3 Phase -do- Group X8 -do-
Above 11 kV -do- Group X9 -do-
&Up to &
including 22 kV
Above 22 kV & -do- Group -do-
Up to & X10
including 33 kV
Single phase 11kV Up to and -do- Group -do-
transformer including 25 X11
(Sealed 22kV kVA -do- Group -do-
Type) X12
33kV -do- Group -do-
X13
6. SCOPE OF THE LICENCE
“Licence shall be granted with the following scope:
Name of the OUTDOOR TYPE OIL IMMERSED DISTRIBUTION

Product TRANSFORMERS
Type (Sealed or
Non sealed Type)
Nominal System
Voltage
kVA Ratings All kVA ratings to mentioned individually as per the standard
Energy Efficiency
Levels
Any other aspect

required as per the
Standard
7. Infrastructure for Production
7.1 Description of Plant & Machinery
A typical list of manufacturing machinery and equipment is given below for guidance as a
minimum requirement. Alternative machinery may be used based on advancement of
technology by various manufacturers which may be built into this manual from time to time".
PROCESS 1
PROCESS 2
PROCESS -----
7.2 Manufacturing Process
On the basis of Guaranteed Technical Parameters (Customers Requirement), a design is

prepared. Based on the design, raw-materials are chosen.
The major raw material is CRGO Steel used for manufacturing the Core of the transformer.
The LV and HV windings are prepared using coil winding machines. Insulations are cut into
different dimensions based on the design.
The HV and LV coils are placed on the limbs of the core. The assembly is then put into an
oven for removal of moisture – this process referred to as baking.
The tank of the transformer is fabricated on the basis of the design and the electrical and
mechanical stress it has to withstand. This tank is shot blasted and primer coated. Mineral oils
used in the transformer are centrifuged- which is generally termed as oil filtration.
The assembled core with the windings on its limbs is placed in the transformer tank, the
process which is called as ‘tanking’ or ‘box-up’. Then, the transformer is tested to verify its
compliance to the requirements. Oil leakage test is also performed to ensure no-leakage of the
mineral oil from any of the joints.
The transformer is painted, and made ready for dispatch.

7.3 MANUFACTURING PROCESS FLOW CHART - DISTRIBUTION
TRANSFORMER
GURANTEED TECHNICAL
PARAMETERS
DESIGN OF
TRANSFORMER
LV WINDING HV WINDING
CRGO CORE COIL INSULATION

STEEL ASSEMBLY ASSEMBLY CUTTING
PROCESSING
AND BAKING
OIL OIL TANKING / SHOT TANK

TANKER CENTRIFIGUI BOX-UP BLASTING & FABRICATION
NG PRIMING
TESTING
LEAKAGE
TEST
PAINTING
DESPATCH
8. Infrastructure for Testing
Complete test facility for all the requirements covered under ‘Routine Tests’ shall be available with the firm. For other tests, test report
of conformity from BIS recognized/Group-2 category of laboratories as per the frequency of STI shall be produced by the licensee to BIS (where
in-house test facilities are not available for these tests and relaxation as given by BIS).
A typical list of test equipment is given below for guidance as a minimum requirement. Alternative test equipment may be used based on
advancement of technology which may be built into this manual from time to time based on revision / amendment in Indian Standard.
Requirement Clause of Frequency Importance Test Least Count & Frequency of Approx Cost of test In-house arrangement
Standard per Control of test Equipment Range Calibration equipment Or
Unit requirement Outside Laboratory
General Requirements
Permissible flux 6.9.1 & One sample Measuremen

density and 6.9.2 each of t of
over fluxing 7.9.1 & identical magnetizatio
7.9.2 design/constr n of core
8.9.1 & uction and of
8.9.2 same nominal
system
voltage and
rating once in
five years.
Minimum 11 Each Electrical Vernier 0.01mm,
clearances in transformer Safety 0-150mm
Air
Calipper
Construction of 15.1 Each Electrical & Visual

transformer transformer Mechanical
tank Safety
Painting of 15.5 Each Corrosion Visual
Transformer transformer Protection
Tank
Conservator for 16 Each Electrical & Visual
non sealed type transformer Mechanical
transformers Safety
Routine Test
Measurement 21.2 a) Each Performance  Digital µ- 1µΩ, 199 µΩ -
of winding transformer requirement ohm meter 19.99KΩ
resistance IS  Kelvin 0.002mΩ, 0-
2026 (Part 1). Bridge 11Ω
 Wheatston 0.001Ω, 0-
e Bridge 106Ω
Measurement of 21.2 b) Each Compatibilit  Transform 0.01%,
voltage ratio transformer y and er Ratio 0.9-900
and check of Meter
phase
displacement IS
2026 (Part 1).
Measurement of 21.2 c) Each Loss  Current 5-10-25-50-
short-circuit 6.8 transformer Calculation Transform 100/5 A
impedance 7.8 er
(principal 8.8  Potential 2000-1800/
tapping, when Transform 600V
applicable) and er
load loss at 50  Portable 1W, 150-300-
percent and 100 Wattmeter 600V, 5-10A
percent load IS  Portable
2026 (Part 1). AC 1/2/4V, 150-
Voltmeter 300-600V
Measurement of 21.2 d) Each To find out  Current 5-10-25-50-
no-load loss and transformer the circuit transforme 100/5 A
current IS 2026 parameters r
(Part 1).  Potential 2000-1800/
transforme 600V
r
 Portable 1W, 150-300-
wattmeter 600V, 5-10A
 Portable
AC 1/2/4V, 150-
voltmeter 300-600V
 Frequenc
y meter 0.5Hz, 45-
 Digital 55Hz
Power
Analyzer 600V/20A
Measurement of 21.2 e) Each To test the  Insulation 0.1mΩ, 0-

insulation transformer insulation Tester 5000 mΩ/
resistance IS resistance 2500V
2026 (Part 1). between HV
and LV
windings,
HV winding
and
Ground, LV
winding
and Ground,
Induced over- 21.2 f) Each To test the  Double

voltage transformer insulation of Voltage
withstand test each Double
IS 2026 (Part winding Frequency
3). between the Generator
turns and with DC
between Drive
winding to  Stop 0-5min, 0.1Sec
winding. Watch
Separate-source 21.2 g) Each To test the  High
voltage transformer insulation Voltage
withstand test between HV Power
IS 2026 (Part and LV side, Transformer
3). HV side and  Stop Watch
GND, LV 0-5min, 0.1Sec
side and
GND
Pressure Test 15.2 & Each To check  Compress
21.2 h) transformer any bulging or
of the tank
 Pressure
Gauge
Oil Leakage 15.2 & Each To check  Oil

Test 21.2 j) transformer any leakage Conservat
in the
or tank
transformer
tank
Type Test
Lightning 21.3 a) One sample  Impulse Generally from Outside

Impulse Test each of Generator Laboratory, considering the
identical Circuit specialized nature of test
design/constr  Impulse
uction and of recorder
same nominal
system
voltage and
rating once in
five years.
Temperature 21.3 b) One sample To check the Temperature 0-100oC, 1OC Generally from Outside
rise test 6.10 from every lot actual temp. Sensors Laboratory, considering the
7.10 of 50 rise during specialized nature of test
8.10 transformers operation of
(of identical transformer
design/constr
uction and of
same nominal
system
voltage and
rating) or part
thereof.
Short Circuit 21.3 c) One sample To check the Power Generally from Outside
withstand test each of actual short Source, AC Laboratory, considering the
identical circuit Generator, specialized nature of test
design/constr SC breaker
withstand
uction and of
same nominal capacity
system
voltage and
rating once in
five years.
Pressure Test 21.3 d) One sample To check  Compress In house test
from every lot any bulging or
of 50 of the tank  Pressure
transformers
(of identical Gauge
design/constr
uction and of
same nominal
system
voltage and
rating) or part
thereof.
SPECIAL TESTS / ADDITIONAL TESTS/ OPTIONAL TESTS / MUTUALLY AGREED TEST
Determination 21.4 a) As agreed

of Sound Levels between
purchaser and
manufacturer
Short Circuit 21.4 b) -do-
withstand test
No load current 21.4 c) -do-
at 112.5%
voltage
Paint adhesion 21.4 d) -do-
test
BDV & 21.4 e) -do- To check the  Oil 0-100kV, 2kV In house test facility
Moisture di-electric insulation
Content of strength &
test set
Transformer Oil moisture
content
9. CONTROL UNIT & BATCH
Control Unit : Control Unit : For the purpose of type tests, 50 transformers (of
identical design / construction and of same nominal system voltage
and rating) or part there of shall constitute one lot.
For other tests, appropriate control as mentioned in STI shall be

applicable.
10. TEST RECORDS TO BE MAINTAINED BY FIRM
Format I
Class / Type Group / Rating/Size Important Parameters
Date of Control Quantity Quantity Measurement Measurement of Measurement of Measurement Measurement Induced Separate- Pressure Test Oil Leakage
manufacture Unit Under the marked of Winding Voltage Ratio Short Circuit of no load of insulation overvoltage source Test
Control Unit with Resistance and check of Impedance loss and resistance withstand voltage
Phase (principal tapping, current test withstand
Standard
Displacement when applicable) test
Mark and load loss at 50
percent and 100
percent load
Each Each Each transformer Each Each Each Each Each Each
transformer transformer transformer transformer transformer transform transformer transformer
er
Test result Test result Test result Test result Test result Test result Test Test result Test result
result
Other Parameters
Date of Control Quantity Quantity Lightning Impulse Test Temperature rise test Short Circuit withstand Pressure Test
manufacture Unit Under the marked with test
Control Standard
Unit Mark One sample each of One sample from every lot of One sample each of One sample from every lot of
identical design / 50 transformers (of identical identical design / 50 transformers (of identical
construction and of same design/construction and of construction and of same design/ construction and of
nominal system voltage same nominal system voltage nominal system voltage same nominal system voltage
and rating once in five and rating) or part thereof. and rating once in five and rating) or part thereof.
years. years.
Test result Test result Test result Test result
Date of Control Quantity Quantity Permissible flux density and Minimum Construction of Painting of Conservator for non sealed
manufacture Unit Under the marked with over fluxing clearances in Air transformer tank Transformer type transformers
Control Standard Tank
One sample each of identical Each transformer Each transformer Each transformer Each transformer
Unit Mark
design/construction and of
same nominal system
voltage and rating once in
five years.
Test result Test result Test result Test result
Format 2
S.No Control Unit & Total Quantity Quantity found Segregation / Dispatch details
Date of Marked under Non conforming Disposal of Non
Manufacture the Control Conforming
Unit product
Bill No Date Name and Quantity (with Balance in stock

address Batch No.)
S.No Batch No & Date Total Quantity Total Quantity Quantity found Segregation / Dispatch details
of Manufacture Marked under Marked under Non conforming Disposal of Non
the Control Unit the Batch Conforming
product
Bill No Date Name and Quantity (with Balance in

address Batch No.) stock
Format 3 RAW MATERIAL (Outside testing)
Sl Date of Name Source In case ISI marked In case Testing done from In case Non ISI Results Remarks
No receipt of the raw material -No of Outside Laboratory raw material &
Raw the corresponding IS accompanied by
Material Number & Licence No Test Certificate-
Test Certificate
No & Date
Name of Sample TR No &
Lab sent On date
Format 4 RAW MATERIAL (In house Testing)
Sl Date of Name Source Test Results of In house Testing Remarks

No receipt of the
Raw
Material
Date of IS No Clause Result
Testing
11. MARKING AND LABELLING REQUIREMENTS
Marking & labeling shall be defined as per the Clause 13 of standard
Rating Plate - Each transformer shall be provided with rating plate made of anodized
aluminium/stainless steel material securely fixed on the outer body, easily accessible,
showing the information given in Fig. 1 of IS 1180 (Pt1) for 3 phase transformers and Fig. 2
of IS 1180 (Pr1) for single phase transformers. The entries on the rating plate shall be
indelibly marked for example, by etching, engraving or stamping.
Terminal Marking Plate- Each transformer shall be provided with a terminal marking plate
in accordance with Fig. 3 to Fig. 5 of IS 1180 (Pt1) whichever is applicable.
Energy Efficiency Level -Each transformer shall also be clearly marked with its Energy
Efficiency Level rating
BIS Certification Mark- Each transformer shall also be clearly marked with and BIS
Certification Mark.
12. PRODUCT SAMPLE SIZE AND TEST REQUEST

transit)

etc..
4. Drawings

Manner of sealing


indicated
12. 2 RAW MATERIAL SAMPLE SIZE AND TEST REQUEST

transit)

etc..
4. Drawings

Manner of sealing
indicated
13. PRODUCT SPECIFIC GUIDELINES (If any)
Document : Ref: CMD1(BD)/IS 1180 dated 27 Nov 2014 , Guidelines for Certification of
Outdoor Type Distribution Transformers as per IS 1180
IS 1180 (Part 1):2014 (Outdoor Type Oil Immersed Distribution Transformers Up to and
Including 2500kVA, 33kV – Specification Part 1 Mineral Oil Immersed) has been published,
amalgamating IS 1180 (Part 1):1989 and IS 1180 (Part 2):1989. This version of IS 1180 has come into
force with effect from 19.07.2014. All applications shall be recorded as per IS 1180 (Part 1):2014.
This revised ISS covers both sealed and non-sealed type distribution transformers up to 2500
kVA and nominal system voltage up to and including 33kV and also, single phase sealed type
distribution transformer up to 25 kVA rating and nominal system voltage up to and including 33kV.
Moreover, in this revised version, the distribution transformers have been grouped under three
different categories namely – ‘Energy Efficiency Level 1’, ‘Energy Efficiency Level 2’ and ‘Energy
Efficiency Level 3’ based on the maximum total loss.
Transformers are designed based on the Basic Insulation Level (BIL) consideration.
Accordingly, other parameters are also set for the transformer of a particular rating to achieve the
desired performance. Therefore, the existing guidelines have been reviewed and the following
guidelines have been proposed for certification of Outdoor Type Distribution Transformers as per IS
1180 (Part 1):2014.
Application for GOL as per IS 1180 (Part 1):2014 shall be processed as follows:
A Type of Tests
According to Cl.21 of IS 1180 (Part 1):2014, the tests on the transformers are classified into Routine
test, Type test and Special test as given below:
Routine Test Type Test Special Test

(As agreed between
Manufacturer and purchaser)
a) Measurement of winding resistance IS a) Lightning impulse test IS a) Determination of sound

2026 (Part 1). 2026 (Part 3). levels IS 2026 (Part 10)
b) Measurement of voltage ratio and check b) Temperature-rise test IS b) Short-circuit withstand
of phase displacement IS 2026 (Part 1). 2026 (Part 2). test IS 2026 (Part 5)
c) Measurement of short-circuit impedance c) Short-circuit withstand test (above 200 kVA)
(principal tapping, when applicable) and IS 2026 (Part 5) (up to 200 c) No load current at
load loss at 50 percent and 100 percent kVA). 112.5 percent voltage
load IS 2026 (Part 1). d) Pressure test d) Paint adhesion tests.
d) Measurement of no-load loss and current The test is performed
IS 2026 (Part 1). as per ASTM D3359
e) Measurement of insulation resistance IS (Standard Test
2026 (Part 1). Methods for measuring
f) Induced over-voltage withstand test IS adhesion by Tape test).
2026 (Part 3). e) BDV and moisture
g) Separate-source voltage withstand test content of oil in the
IS 2026 (Part 3). transformer (IS 335).
h) Pressure Test
i) Oil Leakage Test
B For Grant of Licence

I. The applicant shall clearly indicate in the application, the ratings of the transformers for which
BIS licence is required. Relevant drawings and technical parameters of the transformers of the
said ratings shall also be submitted to BIS. In addition, an undertaking shall also be submitted
by the applicant that whenever there is any change in technical design of the transformer,
prior intimation would be given to BIS. The following shall be taken as a change in the
design of the transformer, which would require type testing again:
 Change in flux density  Change in current density and type  Change in tank design
of winding material (Cu/Al)
 Type of construction (core  Change in type of connection  Total loss and method of
type/shell type) (star/delta) & Vector Group cooling
The applicant is mandatorily required to have testing facilities in-house for all routine tests.
In-house testing facilities for type tests i.e. ‘Lightning Impulse Test’, ‘Short Circuit Test’,
‘Temperature Rise Test’ &’Permissible Flux Density & Overfluxing Test’, are desirable.
However, considering the facts of specialized nature of tests and costly testing equipments,
testing facilities of BIS recognized/Group-2 category of laboratories may be availed by the
applicant. Presently, CPRI (Bangalore and Bhopal) and ERDA (Vadodara) are having
complete testing facilities as informed by PP&C(T&C).
II. Conformity of Raw Material:
a. Compliance of CRGO Electrical Steel as per IS 3024(Clause 9.1 a) which is under compulsory
BIS certification shall be ensured through test certificate of supplier.
b. Compliance of Copper/Aluminium conductor (Clause 9.1 c) shall be ensured through a Test
Certificate from supplier or applicant firm getting the same tested from BIS
recognized/Group-2 category of laboratories.
c. Compliance of Kraft Paper (Cl. 9.1 d), Press Board (Cl. 9.1 e) and Gasket (Cl. 15.4) shall be
ensured through a Test Certificate from supplier.
d. Compliance of Transformer Oil (clause 10) as per IS 335 shall be ensured through a Test
Certificate from supplier/ISI Marked material with TC or applicant firm getting the same
tested from a BIS recognized lab.
e. Compliance of Bushings (clause 12) as per IS 2099 /7421 & relevant part of IS 3347 shall be
ensured through a Test Certificate from supplier or applicant firm getting the same tested from
BIS recognized/Group-2 category of laboratories.
III. Drawl of Samples and Conformity of Product:

a. During Preliminary Inspection, samples shall be drawn from the following group to
cover all the ratings of Three Phase Transformers:
Standard Ratings
Nominal System Voltage Up to and including 200 kVA, Above 200kVA and up to &
3 Phase including 2500 kVA, 3 Phase
3.3 kV One sample of highest rating One sample of highest rating
6.6 kV -do- -do-
11 kV -do- -do-
Above 11 kV &Up to & -do- -do-
including 22 kV
Above 22 kV & Up to & -do- -do-
including 33 kV
b. For Single phase transformers, samples shall be drawn as per the following to cover
all the ratings:
Nominal System Voltage Standard Ratings
11kV One sample of highest rating
22kV -do-
33kV -do-
c. During Preliminary Inspection, one sample of highest rating, offered by the firm
shall be drawn to cover the entire range for which licence has been applied for, as per
the above table. The relevant drawings of the samples of transformer shall also be
collected and sent to the laboratory with the samples. Separate samples shall be drawn
for sealed and non-sealed type transformers, wherever applicable. The conformity
of the raw materials as per the requirements of the relevant standards shall be verified
while drawl of samples.
d. All tests shall be carried out at BIS recognized/Group-2 category of laboratories. The
licence shall be granted once the product passes in both the type tests and the routine
tests as indicated above.
e. If transformers with higher energy efficiency level is drawn for testing and found
passing, the scope of licence shall also cover transformers with lower energy
efficiency levels, as specified in the ISS.
f. The energy efficiency levels shall be clearly indicated in the licence document.
B. For Operation of Licence
1. While operation of licence, surveillance inspections shall be carried out as per the renewal
policy of the BIS licensees. During each such surveillance inspection, sample shall be drawn
for independent testing at BIS recognized/Group-2 category of laboratories for all parameters
under Routine Tests. The licensee shall inform BIS its production schedule in advance for
timely planning of surveillance inspection.
2. The requirements of Type Tests shall also be carried out, periodically, from a BIS
recognized/Group-2 category of laboratories. (The frequency of type test is to be decided in
consultation with Ministry of Power.)
3. For inclusion of new rating of the transformer, licensee shall submit a complete test report
indicating conformity of the product from BIS recognized/Group-2 category of laboratories,
along with the certified drawings and technical parameters. The scope of licence shall be
extended to cover all the ratings, up to the highest rating tested so far, in the group as
mentioned in the above tables, without any further type test/ routine test. However, when the
highest rating is to be certified, the procedure as specified in III (c)/(e) above shall be fulfilled.
These tests shall be valid for a period as stated above.
4. For Market Samples, any one of the following may be adopted, in consultation with Ministry
of Power:
a. Buyers (Electricity Utilities) to send samples directly to BIS recognized laboratory
for testing
b. BIS recognized Laboratory can draw samples on behalf of the Electricity Utilities and
get them tested
c. BIS can draw samples as per the current practice prevailing in case of other products
14. GUIDELINES FOR ASCERTAINING CONFORMITY OF PRODUCT AT THE TIME OF

GRANT OF LICENCE
Document : Ref: CMD1(BD)/IS 1180 dated 27 Nov 2014 , Guidelines for Certification of Outdoor
Type Distribution Transformers as per IS 1180
15. GUIDELINES FOR ASCERTAINING CONFORMITY OF PRODUCT BY WAY OF

INDPENDENT TESTING DURING OPERATION OF LICENCE
GENERAL
Clause Requirement Periodicity of testing the requirement in Independent Testing
6.9.1 & Permissible flux density and over
6.9.2 fluxing
7.9.1 & All requirements for every sample drawn for independent testing
7.9.2
8.9.1 &
8.9.2
11 Minimum clearances in Air
15.1 Construction of transformer tank
15.5 Painting of Transformer Tank
16 Conservator for non sealed type
transformers
ROUTINE TEST
Clause Requirement
21.2 a) Measurement of Winding
Resistance
21.2 b) Measurement of Voltage Ratio All requirements for every sample drawn for independent testing
and check of Phase
Displacement
21.2 c) Measurement of Short Circuit
6.8 Impedance (principal tapping,
7.8 when applicable) and load loss
8.8 at 50 percent and 100 percent
load
21.2 d) Measurement of no load loss
and current
21.2 e) Measurement of insulation
resistance
21.2 f) Induced overvoltage withstand
test
21.2 g) Separate source voltage
withstand test
15.2 & 21.2 h) Pressure test
15.2 & 21.2 j) Oil Leakage test
Clause Requirement
21.3 a) Lightning Impulse Test Once in five years or and whenever there is any change in
design
21.3 b) 6.10 Temperature rise test Every sample drawn for independent testing
7.10, 8.10
21.3 c) Short Circuit withstand test Once in five years or and whenever there is any change in
design
21.3 d) Pressure Test Every sample drawn for independent testing
SPECIAL TEST (If applicable, as agreed between purchaser and manufacturer)

21.4 a) Determination of Sound Levels All requirements for every sample drawn for independent testing
21.4 b) Short Circuit withstand test , if applicable (As agreed between purchaser and
21.4 c) No load current at 112.5% voltage manufacturer)
21.4 d) Paint adhesion test
21.4 e) BDV & Moisture Content of
Transformer Oil
16. GUIDELINES FOR OPERATION OF LICENCE IN CASE LICENCE BEING

OPERATED BASED ON FACTORY TESTING
NA
17. GUIDELINES TO ENSURE CONFORMITY OF RAW MATERIAL DURING GRANT
OF LICENCE
18. GUIDELINES TO ENSURE CONFORMITY OF RAW MATERIAL DURING

OPERATION OF LICENCE
19 MARKING FEE#
Unit One kVA

Unit rate
Marking Fee (Minimum) Large scale
Marking Fee (Minimum) Small scale
MF Rates effective from
20. TEST REPORT –
201.1 TEST(S) TO BE CARRIED OUT DURING REGULAR SURVEILLANCE –All

requirements as far possible to be tested during regular surveillance is to be indicated.
201.2 TEST(S) TO BE CARRIED OUT DURING ROM VISIT – All requirements as far
possible and requirements which has failed.
20.3 TEST REPORT PERFORMA (To be linked with test report format of T &C)
21. SCHEME OF TESTING & INSPECTION
(attached)
Draft
Doc: STI 1180 (Part 1)
SCHEME OF TESTING AND INSPECTION FOR OUTDOOR TYPE OIL IMMERSED

DISTRIBUTION TRANSFORMERS UP TO AND INCLUDING 2500 KVA, 33kV
AS PER IS 1180 (Part 1):2014
1.0 LABORATORY/TESTING STATION: A laboratory/testing station shall be maintained, which

shall be suitably equipped and staffed, to carry out different tests and inspections according to the
Standard.
1.1 Environmental conditions wherever applicable shall be maintained.
2.0 TEST RECORDS: All records of tests and analysis shall be kept in suitable formats
2.1 Copies of any records or connected papers that may be required by BIS shall be made available at
any time on request.
2.2 For all stages of manufacture, the factory shall maintain appropriate controls and checks to ensure
that their product conforms to the various requirements of the Standard
3.0 QUALITY CONTROL: It is recommended that, as far as possible, Statistical Quality Control
(SQC) methods may be used for controlling the quality of the product during production as envisaged
in this Scheme. See IS 397(Part 1), IS397(Part 2), IS 397(Part 3) and IS 397(Part 4)].
3.1 In addition, efforts should be made to gradually introduce Quality Management System in
accordance with IS/ISO 9001.
4.0 CALIBRATION: Testing instruments/equipments shall be carried out periodically from NABL
accredited calibration laboratories wherever they are available in the same city. In case where such
laboratories are not available, traceability to a National Measurement System (NPL) to be ensured. All
records of such calibrations to be kept.
5.0 STANDARD MARK: The standard mark as given in column 1 of the First Schedule of the
license shall be applied clearly and indelibly by stencilling/screen or ink jet
printing/embossing/etching/engraving on the rating plate, provided that the distribution transformers
conform to specified requirements of the Indian Standard.
5.1 RATING PLATE : The rating plate shall be according to Clause 13 of IS 1180(Part 1):2014 and
shall be fitted in a visible position.
5.2 MARKING: In addition, the BIS Certification Mark Licence No. (CM/L XXXXXXX) shall be
clearly and indelibly marked on the rating plate:
5.3 TERMINAL MARKING PLATE: Each transformer to be provided with a terminal marking
plate as per Clause 13.2 of IS 1180 (Part 1):2014
6.0 LEVELS OF CONTROL: The tests, as indicated in Table 1 and at the levels of control specified
therein, shall be carried out on the whole production of the factory which is covered by this Scheme
and appropriate records and charts maintained in accordance with paragraph 2.0 above.
6.1 The criterion of acceptance/rejection of production will be as given below.:
6.1.1 Each transformer when tested shall pass the routine tests. If a transformer fails in any one or
more of the requirements it shall be unfit for the purpose of marking.
6.1.1.1 The transformer rejected in 6.1.1 may however, be suitably repaired and the defects rectified.
Such repaired transformers when tested again shall conform to all the routine tests.
6.2 For the purpose of type tests (Table 1), 50 transformers (of identical design/construction and of
same nominal system voltage and rating) or part there of shall constitute one lot.
6.3 In respect of all other clauses of the Indian Standard, appropriate control and checks to be
maintained in order to ensure that the product conforms to the various requirements of the Indian
Standard.
6.4 All the production which conforms to the Indian Standard and covered by this License shall be
marked with the Standard Mark.
7.0 REJECTION: A separate record shall be maintained giving information relating to the rejection
of products which do not conform to the Indian Standard and the method of their disposal. Such
products shall in no case be stored together with those conforming to the Indian Standard.
8.0 SAMPLES: The licensee shall supply free of charge, the sample or samples required in
accordance with Bureau of Indian Standards (Certification ) Regulation, from his factory or godown.
BIS shall pay for the samples taken by it from the open market.
9.0 REPLACEMENT: Whenever a complaint is received soon after the product with Standard Mark
have been purchased and used, and if there is adequate evidence that the product has not been
misused, defective product shall be replaced or repaired free of cost by the licensee in case the
complaint is proved to be genuine and the warranty period (where applicable) has not expired. The
final authority to judge conformity of the product to the Indian Standard shall be with BIS. The firm
shall have own complaint investigation system as per IS/ISO 10002
9.1 In the event of any damages caused by the product bearing the Standard Mark, or claim being filed
by the consumers against BIS Standard Mark and “ not conforming” to the relevant Indian Standard,
entire liability arising out of such non conforming product shall be of the licensee and BIS shall not in
any way be responsible in such cases
10.0 STOP MARKING: The marking of the product shall be stopped under intimation to BIS, if at
any time, there is some difficulty in maintaining the conformity of the product to the Standard, or the
testing equipment goes out of order. The marking may be resumed as soon as the defects are removed
under intimation to BIS.
The marking of the product shall be stopped immediately if directed by BIS for any reason.
The markingmay then be resumed only after permission by BIS. The information regarding
resumption of marking shallalso be sent to BIS.
11.0 PRODUCTION DATA: The licensee shall send to BIS as per the enclosed Proforma-1
authenticated by a Chartered Accountant, a statement of quantity produced, marked and exported by
them and the trade value thereof at the end of each operative year of the license.
SCHEME OF TESTING AND INSPECTION FOR OUTDOOR TYPE OIL IMMERSED

DISTRIBUTION TRANSFORMERS UP TO AND INCLUDING 2500 KVA, 33kV
AS PER IS 1180 (Part 1):2014
TABLE-1: LEVELS OF CONTROL
LEVELS OF CONTROL
TEST DETAILS REMARKS
No. of Frequency
Samples
Clause No. Requirements Test Method Frequency
(Clause/Reference)
RAW MATERIALS
9.1 a) CRGO Electrical Steel Shall be ISI marked Each consignment of a
particular grade as received
9.1 b) Amorphous core
material
9.1 c) Copper/Aluminium ISI marked or Test Each consignment
Conductor certificate of
conformity to the
relevant ISS as per
Annex A of IS 1180
(Part-1), from the
manufacturer/ BIS
recognized OSL
9.1 d) Kraft Paper -do- -do-
9.1 e) Press board -do- -do-
9.1 f) Mineral Oil -do- Each Drum of Oil received
15.3 Bolts, Nuts & Washers -do- Each consignment
15.4 Gasket -do- -do-
GENERAL
6.9.1 & 6.9.2 Permissible flux IS 1180 (Part 1) One sample each of identical
7.9.1 & 7.9.2 density and over design/construction and of
8.9.1 & 8.9.2 fluxing same nominal system
voltage and rating once in
five years.
11 Minimum clearances -do- Each transformer
in Air
15.1 Construction of -do- Each transformer
transformer tank
15.5 Painting of -do- Each transformer
Transformer Tank
16 Conservator for non -do- Each transformer
sealed type
transformers
ROUTINE TESTS
21.2 a) Measurement of IS 2026 (Part-1) Each transformer
Winding Resistance
21.2 b) Measurement of IS 2026 (Part-1) Each transformer
Voltage Ratio and
check of Phase
Displacement
21.2 c) Measurement of Short IS 2026 (Part-1) Each transformer
6.8 Circuit Impedance
7.8 (principal tapping,
8.8 when applicable) and
load loss at 50 percent
and 100 percent load
21.2 d) Measurement of no IS 2026 (Part-1) Each transformer
load loss and current
21.2 e) Measurement of IS 2026 (Part-1) Each transformer
insulation resistance
21.2 f) Induced overvoltage IS 2026 (Part-3) Each transformer
withstand test
21.2 g) Separate source IS 2026 (Part-3) Each transformer
voltage withstand test
15.2 & Pressure test Cl. 21.5 of IS Each transformer
21.2 h) 1180(Part-1):2014
15.2 & Oil Leakage test Cl. 21.5 of IS Each transformer
21.2 j) 1180(Part-1):2014
21.3 a) Lightning Impulse IS 2026 (Part-3) One sample each of identical design/construction
Test and of same nominal system voltage and rating
once in five years.
21.3 b) Temperature rise test IS 2026 (Part-2) One sample from every lot of 50 transformers (of
6.10 identical design/construction and of same nominal
7.10 system voltage and rating) or part thereof.
8.10
21.3 c) Short Circuit IS 2026 (Part-5) One sample each of identical design/construction
withstand test (up to 200kVA) and of same nominal system voltage and rating
once in five years.
21.3 d) Pressure Test Cl. 21.5 of IS One sample from every lot of 50 transformers (of
1180(Part-1):2014 identical design/construction and of same nominal
system voltage and rating) or part thereof.
SPECIAL TESTS: To be carried out on mutual agreement between manufacturer and purchaser
21.4 a) Determination of IS 2026 (Part-10) As agreed between
Sound Levels purchaser and manufacturer
21.4 b) Short Circuit IS 2026 (Part-5) -do-
withstand test (up to 200kVA)
21.4 c) No load current at Cl. 5.9.3 of IS -do-
112.5% voltage 1180(P-1):2014
21.4 d) Paint adhesion test ASTM D 3359 -do-
21.4 e) BDV & Moisture IS 335 -do-
Content of
Transformer Oil
PROFORMA - 1
PROFORMA FOR YEARLY PRODUCTION DETAILS
Period covered *
Name of Licensee
CM/L No.
Name of Articles (s) IS No.
Grade/Type/Size
1.1 Brand/Trade/Name(s) of BIS Certification Marked Products
2. Total production of the articles(s) licensed for certification marking

2.1 Total production of the article(s) conforming to Indian Standard
3. Production covered with BIS Certification Mark and its approximate value
a) Quantity
b) Invoice sale price
3.1 Brand Name used on production covered under BIS Certification Mark
3.2 Calculation of marking fee on unit rate basis: Marking Fee per unit
a) Unit
b) Quantity covered with BIS Certification Mark
------------------------------------------------------------------------------------------------------------
*Information to be filled up by BO before forwarding to the licensee.
Note : In case a clause is not applicable, suitable remarks may be given against it.
c) Marking fee rounded off in whole rupees as obtained by applying unit rates given in
(a) on quantity given in (b)
4. Quantity not covered with BIS Certification Mark. If any, and the reasons for such non-
coverage
4.1 Brand Name under which non-certified goods were sold
5.0 Quantity Exported with BIS Standard Mark and its value
5.1 Brand Name under which BIS Certified goods are exported
6.0 Authentication by Chartered Accountant

CMD Ii (L) Dgo - 15012015

Hochgeladen von

Dokumentinformationen

Originaltitel

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

CMD Ii (L) Dgo - 15012015

Hochgeladen von

Copyright:

Verfügbare Formate

BIS/DGO( 428 )/2015

BUREAU OF INDIAN STANDARDS

Subject: Preparation of Product Manuals by RO/BOs by Custodian BOs

This is for information and necessary action by all concerned.

This issues with the approval of Competent Authority

Circulated to all Custodian BOs

Copy to : 1. All DDGRs

3. ITS - for hosting on Intranet and for preparation of software for

BUREAU OF INDIAN STANDARDS

Important provisions which are of significance shall also be provided.

4.1 Grade /Class/ Rating/ Variety/ Size as per Standard

4.2 Clause Wise Requirements

4.2.1 Clause wise Requirements for Type/ Grade/ Variety - --------------

Sl.N Clause No. Test Method Critical/ Remarks

SPECIAL TESTS / ADDITIONAL TESTS/ OPTIONAL TESTS / MUTUALLY

Critical/non-critical to be decided for operation of BIS licence, irrespective of whether the

4.2.3 Hygienic Conditions (applicable to food products)

Sl no Grade / variety Type/Class Rating Size Group Remark 2 Justification3

6. SCOPE OF THE LICENCE

Details of the scope of licence to be indicated, mentioning that

“Licence shall be granted with the following scope:

Name of the Product

7.1 Description of Plant & Machinery

A brief write-up of a typical manufacturing process indicating the involvement of

7.3 Manufacturing Process Flow Chart

A flow diagram for manufacturing process to be provided

Special Tests / Additional Tests/ Optional Tests / Mutually Agreed Test

Class / Type Group / Rating/ Size Important Parameters

Date of Control Quantity Quantity Parameter Parameter Parameter Parameter

Bill No Date Name and Quantity (with Balance in

Format 3 RAW MATERIAL (Outside testing)

Sl Date of Name Source Test Results of In house Testing Remarks

12. PRODUCT SAMPLE SIZE AND TEST REQUEST

Quantity of sample Qty of sample required for testing to be indicated.

Manner of packing (to avoid

Details to be Indicated in test 1. Size / Class / Grade/ Rating …

Instruction to Lab Any specific instruction or information to lab

Instruction for re removing /

Mechanism for dealing with the

12. 2 RAW MATERIAL SAMPLE SIZE AND TEST REQUEST

Quantity of sample Qty of sample required for testing to be indicated.

Manner of packing (to avoid

Details to be Indicated in test 1. Size / Class / Grade/ Rating …

Instruction to Lab Any specific instruction or information to lab

Product specific guidelines if issued shall be provided under this item

14. GUIDELINES FOR ASCERTAINING CONFORMITY OF PRODUCT AT THE TIME OF

15. GUIDELINES FOR ASCERTAINING CONFORMITY OF PRODUCT BY WAY OF

SPECIAL TEST (If applicable, as agreed between purchaser and manufacturer)

16. GUIDELINES FOR OPERATION OF LICENCE IN CASE LICENCE BEING

17. GUIDELINES TO ENSURE CONFORMITY OF RAW MATERIAL DURING GRANT

18. GUIDELINES TO ENSURE CONFORMITY OF RAW MATERIAL DURING

20. TEST REPORT –

20.1 TEST(S) TO BE CARRIED OUT DURING REGULAR SURVEILLANCE –All

21. SCHEME OF TESTING & INSPECTION

TITLE: OUTDOOR TYPE OIL IMMERSED DISTRIBUTION

IS NO: 1180 (Part 1):2014

No. of Amendments: NIL

BUREAU OF INDIAN STANDARDS

TITLE: Outdoor Type Oil Immersed Distribution Transformers upto and

IS NO: 1180 (Part 1):2014

No. of Amendments: NIL

2026 Power transformers :

3347 Dimensions for porcelain transformer bushings for use in lightly