BUS (SHUNT)REACTOR:

Technical Parameters:

Shunt Reactor : 125 MVAR

Rated Voltage : 420kV (1.0pu)
System Fault level : 50 kA (1 Sec.) Or 2Sec.
Duration of short circuit without : 2 seconds
Exceeding temperature of 250 Deg C : Star with neutral brought out
Connection

Insulation level (for winding): Line: Neutral:

(a) Lightning impulse 1.2/50 µ Sec withstand voltage 1300 kVp 550

(b) 250/2500µ Sec rated Switching surgewith stand voltage 1050 kVp NA

(c) One minute power frequency with stand voltage 630kV (RMS) 230kV RMS

(d) Insulation : Graded Insulation

Maximum temp rise over an ambient temp of 50 0 C and at 420kV voltage

(a) of winding measured by resistance method 45 0 C

(b) of top oil measured thermometer 40 0 C
(c) The temperature of the hottest spot shall be as per relevant standards.

Note: The temperature rise should be guaranteed when the reactor is operating at 420kV
( highest voltage for equipment) i.e., at 5% higher voltage the reactor shall be capable
of operating continuously without injuries heating.
Cooling System: Natural Oil circulation (ONAN)
(a) Type of cooling medium Mineral Oil as per IS: 335 latest revision.

Insulation level of neutral

(a) Impulse withstand voltage 550 kVp

(b) Power frequency voltage 230 kV (rms)

(c) Whether neutral is to be brought out Yes (through 145kV class

Oil filled condenser bushings)

Ratio of zero sequence reactance to positive between 0.9 & 1.0.

sequence reactance (X0/X1)

Page 1 of 38
 Range of Constant Impedance. Up to 1.5 p.u. voltage (the
Bidder shall furnish complete
saturation characteristics of
the Reactors upto 2.5 pu
Voltage

Tolerance on current 0 to +5%

Harmonic content in phase current The crest value of the third

harmonic component in phase
current not to exceed 3% of the
crest value of fundamental when
reactor is energized at rated voltage
with sinusoidal wave form.

Permissible current unbalance among + 2%

different phases.

Minimum clearance in air Phase to phase Phase to ground

Rated voltage of 420 kV 4000mm 3500 mm
145 kV 1220 mm 1050 mm

Noise level at rated voltage and frequency 81db (As per NEMA-TR-I)

Line Terminal 420kV oil filled condenser bushings with test taps and without arcing horns and
neutral terminal is 145kV oil –filled condenser bushing and neutral is brought out.

Bushing Line side Neutral sides

(a) Rated voltage 420 kV 145 kV

(b) Creepage distance

For Highly polluted areas 13020 mm 4495mm

(c) Mounting Tank cover Tank cover

(d) 1.2/50 micro sec. lightning 1425 650

impulse withstand voltage (kVp)

(e) Switching impulse 1050 -

(250/2500 micro seconds)
withstand voltage (kVp)

(f) One minute power frequency

withstand voltage (kV rms) 695 305

Page 2 of 38
(g) Rated current (A) 800/1250 800/1250

Vibration and stress level at Not more than 200 microns peak to peak
rated voltage and frequency Average vibrations shall not exceed 60 microns peak
to peak. Tank stresses shall not exceed 2.0kg/sq.mm
at any point on the tank.

R.I. Voltage 1000 micro volts at 305kV (rms)

Partial discharge 500 Pico Coulomb
Corona Extinction
Voltage Not less than 320kV (rms)

1.0 STANDARDS:
1.1 All equipment’s provided under this specification shall in general conform to the latest
issues including amendments of the following standards.

Indian Title Internationally recognized

Standards standards
IS : 2026 Power Shunt reactors IEC – 6076
IS : 3639 Fittings and Accessories for Power Shunt
reactors
IS : 5553 Shunt Reactors
Part – I
Part – III Neutral earthing reactor and arc suppression IEC – 60289
coil.
IS : 335 Insulating oils for shunt reactors and IEC – 60296, BS – 148
switchgears
IS : 1866 Code of practice for maintenance and
supervision of mineral insulating oil in a
equipment
IS : 9434 Guide for sampling and analysis of free and IEC – 60567
dissolved gas and oil from oil filled electrical
equipment.
IS : 2099 Bushing for alternating voltage above 1000 IEC – 137
volts
IS : 3347 Specification for dimensions of porcelain
bushings.
IS : 2705 Current Transformers. IEC – 185
IS : 3070 Lightning Arrestor IEC –99-1 IEC –TC-37
WG4
IS : 2147 Degree of protection provided by enclosures for IEC –60144
low voltage switchgear and control
IS : 5 Colour for ready mixed paints
IS : 375 Internal wiring of marshalling box
IS : 3637 Gas operated relays

Page 3 of 38
 TECHNICAL SPECIFICATION

GENERAL:

1.0 General
Intent of Specification:
This specification covers the design, engineering, manufacturing, type testing,
packing, handling, delivery at site, erection, testing and commissioning of 420 kV,
125MVAR Shunt reactors (BUS) for 400KV 1X800MW (KTPS), 4X270MW (BTPS)
and 5X800MW (YTPS) in Telangana state,complete with all accessories and fittings
terminal connectors, erection & maintenance tools, tools & tackles, Gas-in-oil incipient
fault monitors along with first fill of oil etc.
.
2.0 Scope of offer:
The scope of offer covers the design, engineering, manufacturing, type testing,
packing, handling, delivery at site, erection, testing and commissioning of 125MVAR, 400
kV Shunt Reactors for 400KV Substations.
It is not the intent to specify completely all details of design and construction of
the equipment. However, the equipment shall conform, in all respects, to high standards
of design, engineering and workmanship and be capable of performing in continuous
commercial operations

The bidder shall acquaint himself of the application and working condition of the
equipment offered for supply in the TSGENSCO system and mere complying with the
specification does not relieve the supplier from the contractual obligation. The supplier shall
ensure successful operation of the equipment in TSGENCO System without any
modification for the intended purpose.
The schedule of requirement of under this specification and desired deliveries are given at
Annexure – I.

3.0 GENERAL REQUIREMENT:

(a) The requirement, conditions, appendices etc., stated in the relevant clauses, shall
apply to all and shall be considered as part of this volume as if bound together.

(b) The design and workmanship shall be in accordance with the best engineering
practices to ensure satisfactory performance throughout the service life of the
equipment offered.

(c) All drawings, schedules and annexure appended to this specification shall form
part of the specification.

(d) The equipment offered by the bidder shall be complete in all respect. Any material
and component not specifically stated in this specification and which is necessary

Page 4 of 38
 for trouble free operation of the equipment and accessories specified in this
specification shall deemed to be included unless specifically excluded. All such
equipments and accessories shall be supplied without any extra cost.

(e) All equipment furnished shall conform to type tests and shall be subjected to
acceptance and routine tests in accordance with the requirements stipulated in
respective equipment heads and relevant standards. Owner reserves the right for
getting any or all the type tests conducted on the equipment. No equipment or
material should be dispatched until the test reports duly approved by the purchaser
or authorized representative.

(f) The price for conducting all the type tests in accordance with the relevant
standards shall be included in bid price

(g) Unless brought out clearly, the bidder shall be deemed to conform to the
specification scrupulously. All deviations from the specification shall be clearly
brought out .Any discrepancy between the specification and the catalogue of bid if
not brought out in the relevant deviation schedule, will not be considered as valid
deviation and in case of award, bidder will have to perform exactly in accordance
with the specification.
(h) Special Tools and Tackles

The bidder shall include in his proposal any special erection and maintenance tools
required according to the specification of the equipment. The list of such special
tools shall be given in the BPS

(i) Design and manufacturing shall be such that equipment / accessories of same type
and rating are interchangeable.

(j) Components having identical rating shall be in changeable.

SHUNT REACTOR LOSSES:

(a) The bidder shall indicate values of load losses (copper losses). He shall indicate
whether losses are firm or subject to tolerance. In case losses are subject to
tolerance, ceiling shall be indicated for tolerance. In case no ceiling is specified it
will be taken as per IS: 2026 and the losses shall be capitalized accordingly.

Measurement of losses on first reactor shall be carried both by calorimetric

and bridge methods for achieving the correction factor. Losses measurement
on subsequent reactors can carried out by bridge method and losses thus
obtained shall be corrected by multiplying with correction factor achieved as
above for the purpose of loss evaluation.

Page 5 of 38
Construction Details

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

3.1 Tank and Tank Accessories

3.1.1 Tank
a) Tank shall preferably be of welded construction and fabricated from tested quality
low carbon steel of adequate thickness. The quality of steel shall be as per IS 2062. The
tank bottom shall be of one plane and heavy registructure. The components and fitting
associated with reactor are subject to Owner’s approval and design review.

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

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

d) The shunt reactor tank may be of bell type tank with the joint at about 500mm above the
bottom of tank or conventional tank with welded cover at top. In case the joint is welded
it shall be provided with flange suitable for repeated welding. The joint shall be provided
with a suitable gasket to prevent weld splatter inside the tank. Proper tank shielding shall
be done to prevent excessive temperature rise of the joint.

e) Each tank shall be provided with

(i) Four symmetrically placed lifting lugs shall be provided so that it will be possible to
lift the complete reactor when filled with oil without structural damage to any part
of the reactor. The factor of safety at any one point shall not be less than 2. The
lifting lugs shall be so arranged and located as to be accessible for use when the reactor is
loaded on the transport vehicle.

(ii) A minimum of four jacking pads in accessible position to enable the reactor
complete with oil, to be raised or lowered using mechanical/hydraulic screw jacks.Each
jacking pad shall be designed to support with an adequate factor of safety for at least half
of the total mass of the reactor filled with oil allowing in addition for maximum
possible misalignment of the jacking force to the centre of the working surface.

(iii) Suitable haulage holes shall be provided.

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

Page 6 of 38
g) The base of each tank shall be so designed that it shall be possible to move the complete
reactor unit by skidding in any direction without injury when using plates or rails.

h) Wherever possible the reactor tank and its accessories shall be designed without pockets
wherein gas may collect. Where pockets cannot be avoided (bushing turrets etc.,) pipes
shall be provided to vent gas into the main expansion pipe. The vent pipes shall have
minimum inside diameter of 25mm.

i) Adequate space shall be provided of the bottom of the tank for the collection of sediments.

j) Tank shields shall be such that no magnetic field shall exist outside the tank. They shall
be of magnetically permeable material. If required impermeable shields shall be provided
at the coil ends. Tank shield shall not resonate when excited at the natural frequency of
the reactor. Bidder shall confirm use of tank shields to the schedule of additional
information

k) Suitable guides shall be provided in tank for positioning of the core and coil assembly.

3.1.2 Tank Cover

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

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

c) The tank cover shall be fitted with pockets at the position of maximum oil temperature at
maximum continuous rating for bulbs of oil and winding temperature indicators. It shall
be possible to remove these bulbs without lowering the oil in the tank. The thermometer
shall be fitted with a captive screw to prevent the ingress of water.
d) Bushing turrets, covers of inspection openings, thermometer pockets etc. shall be designed
to prevent ingress of water into or leakage of oil from the tank.

e) All bolted connections shall be fitted with weather proof, hot oil resistant, resilient
gasket in between for complete oil tightness. If gasket is compressible, metallic
stops/other suitable means shall be provided to prevent over compression. Groove
provided to accommodate round nitrile rubber cord for rectangular openings shall be
milled. Details of all gasket joints shall be submitted for approval

f) Current flowing in tank cover and bushing turrets.

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

Page 7 of 38
 g) The reactor shall be provided with a 100mm nominal diameter pipe flange with
bolted blanking plate, gasket and shall be fitted at the highest point of the reactor for
maintaining vacuum in the tank.

h) If bell type tank is offered, suitable projecting guides shall be promoted on core assembly
to facilitate removal of tank. Design shall be such that Tank Cover can be lifted
independently without lifting active part of care, Winding etc.

3.1.3 Axles and Wheels

a) The shunt reactor is to be provided with flanged bi-directional wheels and axles. They
shall be designed not to deflect excessively to interfere with the movement of the shunt
reactor Wheels shall be provided with suitable bearings, which shall be corrosion
resistant. Fittings for lubrication shall also be provided.

Suitable locking arrangement along with foundation bolts shall be provided for
the wheels to prevent accidental movement of shunt reactor.

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

c) The rail track gauge shall be 4 rails with 1676 mm between adjacent rails on shorter axis
and two rails with 1676 mm between rails on longer axis.

3.1.4 Foundation and Anti Earthquake clamping Device

To prevent reactor movement during earthquake, suitable a clamping device shall

be provided for fixing the reactor to the foundation.

3.1.5 Conservator & Oil Preservation System

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

a) Conservator tank and pipe work

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

Page 8 of 38
ii) The conservator shall be fitted with integral lifting lugs in such a position so that it can
be removed for cleaning purposes. Suitable provision shall be kept to replace air cell and
cleaning of the conservator, wherever applicable.

iii) Conservator shall be positioned so as not to obstruct any electrical connection to

reactor. Pipe work shall not obstruct the opening of inspection or manhole covers.

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

v) The feed pipe to the reactor tank shall enter the reactor cover plate at its highest
point and shall be straight for a distance not less than five times its internal diameter
on the reactor side of the Buchholz relay, and straight for not less than three times
that diameter on the conservator side of the relay.
vi) This pipe shall rise towards the oil conservator, through the Buchholz relay, at an angle of
not less than 5 degree.
b) Oil Preservation Equipment:

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

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

ii) The temperature of oil is likely to rise up to 1000C during operation. As such air
cell used shall be suitable for operating continuously at least at 1000C.
iii) Air cell of conservator shall be able to withstand the vacuum during
installation/maintenance periods. Otherwise provision shall be kept to isolate the
conservator from the main tank when the latter is under vacuum by providing a
vacuum sealing valve or other suitable means in the pipe connecting main tank
with the conservator.

iv) The connection of air cell to the top of the conservator is by air proof seal
preventing entrance of air into the conservator. Air cell shall be monitored by using
rupture relay.

c) Dehydrating Filter Breather:

The conservator vessel shall be fitted with two parallel breathers in which only blue
silicagel (pink coloured when wet) has been filled as a dehydrating agent. The containers
for the dehydrating agent and the oil trap shall be of transparent plastics.

The parallel breathers shall be connected to the air-expansion pipes via two-position three-
way valves with captive screwed caps. The three-way valves shall control the breathers in
such a manner that each of the two parallel breathers can be in service while the other
breather is in stand-by position, i.e. it must be possible to switch off each of the two

Page 9 of 38
 parallel silica gel breathers of the same group individually while the other one is still in
operation. Any position other than specified above shall be mechanically interlocked. An
universal spanner for removing of the cap and operation of the valve shall be fitted to the
tank by a fly-nut on a rigidly fixed bolt of stainless steel at an accessible position in a
convenient floor height.

In view of excessive humidity the breathers shall be larger in size and shall be provided
with oil trap. The silica gel filling capacity of each breather shall be dependent on the size
of the reactor (each having a silica gel filling capacity of minimum 5kg shall be
provided).The silica gel breathers and the three-way valves shall be rigidly fastened at an
accessible position not more than 1400 mm above ground level. For this purpose the
breathers shall be also fixed onto the tank by solid mounting brackets at their lower ends.

3.1.6 Pressure Relief Device

Adequate number of pressure relief devices shall be provided at suitable locations. These
shall be of sufficient size for rapid release of any pressure that may be generated
in the tank and which may result in damage to the equipment. The device shall
operate at a static pressure less than the hydraulic test pressure of reactor tank. It
shall be mounted directly on the tank. One set of electrically insulated contacts
shall be provided for alarm/tripping. Discharge of pressure relief device shall be
properly taken through pipe and directed away from reactor/other equipment and
this shall be prevented from spraying on the tank. The terminal box/boxes of PRD
should conform to degree of protection as per IP-55 of IS: 13947. Following routine
tests shall be conducted on PRD.

a) Air pressure test

b) Liquid pressure test
c) Leakage test
d) Contact test
e) Dielectric test

3.1.7 Buchholz Relay

A double float type Buchholz relay shall be provided. All gases evolved in the reactor
shall collect in this relay. The relay shall be provided with a test cock suitable for a
flexible pipe connection for checking its operation and taking gas sample. A
copper/stainless steel tube shall be connected from the gas collector to a valve
located about 1200 mm above ground level to facilitate sampling with the reactor in
service. The device shall be provided with two electrically independent contacts, one for
alarm on gas accumulation and the other for tripping on sudden rise of pressure.

3.1.8 Temperature Indicators

a) Oil Temperature Indicator (OTI)
All Shunt reactors shall be provided with a 150 mm dial type thermometer for top
oil temperature indication. The thermometer shall have adjustable, electrically
independent ungrounded alarm and trip contacts.

Page 10 of 38
 The maximum reading pointer and resetting device for the thermometer shall be
mounted in the marshalling box. A temperature sensing element suitably located in
a pocket on top oil shall be furnished. This shall be connected to OTI by means of
capillary tubing. Temperature indicator dials shall have linear gradations to clearly
read at least every 2 C. Accuracy class of OTI shall be ± 1.5% or better.

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

Alarm – 95degC
Trip – 105degC

b) Winding Temperature Indicator (WTI)

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

(i) Temperature sensing element

(ii) Image coil
(iii) Auxiliary Current transformer if required to match the image coil shall be
furnished and mounted in the marshalling box.
(iv) 150 mm dia local indicating instrument with maximum reading pointer
mounted in marshalling box and with two adjustable, electrical independent,
ungrounded contacts, one for high winding temperature alarm and one for trip.
Temperature indicator dial shall have linear gradations to clearly read at least every
2 øC.
(v) Calibration device.
(vi) Accuracy class of WTI shall be ± 1.5% or better.
The setting of alarm and tripping contacts shall be adjustable at site and
typical values are as given below which will be reviewed during detailed
engineering based on manufacturer’s recommendation.
Alarm - 110deg
Trip - 120degC
(vii) In addition to the above, the following shall be provided for remote indication of
winding temperature for each reactor.

(a) Signal Transmitter:

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

The RTD shall be three wire ungrounded system. The calibration shall be as per SAMA
(USA) or equivalent standard. The RTD may be placed in the pocket containing

Page 11 of 38
 temperature sensing element and image coil for WTI system which will be used for
both remote WTI and DAS. Necessary equipment for sending the signal to remote WTI
and DAS shall be provided. In lieu, separate RTD for each of these functions shall be
provided.

(b) Remote winding temperature indicator shall be suitable for flush mounting on
RTCC panel/CRP panel. This shall not be repeater dial of local WTI and will operate
by signal transmitter. Any special cable required for shielding purpose, for
connection between Marshalling box and remote WTI control circuit, shall be in the
scope of Contractor. Drawing showing the mounting details of RWTI shall be
submitted to the Purchaser The difference between local and remote WT indication at
any time shall not exceed 1 deg C.

3.1.9 Earthing Terminals

a) Two (2) earthing pads (each complete with two (2) nos. holes, M 10 bolts, plain
and spring washers) suitable for connection to 75 x 12 mm galvanised steel
grounding flat shall be provided each at position close to earth of the two
(2) diagonally opposite bottom corners of the tank.
b) Two earthing terminals suitable for connection to 75 x 12 mm galvanised
steel flat shall also be provided on cooler, marshalling box and any other
equipment mounted separately.
3.2 Core
In case of gapped core construction the following requirements are stipulated.

a) The core shall be constructed from M4 or better grade, non-ageing, cold

rolled, super grain oriented, silicon steel laminations.

b) The design of the magnetic circuit shall be such as to avoid static

discharges, development of short circuit paths within itself or to the earthed
clamping structure and production of flux component at right angles to the
plane of laminations which may cause local heating.

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

d) Core and winding shall be capable of withstanding the shocks during

transport, installation and service. Adequate provision shall be made to prevent
movement of core and winding relative to tank during these conditions.

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

f) When bell type tank construction is offered, suitable projecting guides shall be
provided on core assembly to facilitate removal of tank.
g) Each core lamination shall be insulated with a material that will not

Page 12 of 38
 deteriorate due to pressure and hot oil.

h) The supporting frame work of the core shall be so designed as to avoid

presence of pockets which would prevent complete emptying of the tank
through drain valve or cause trapping of air during oil filling.

i) Adequate lifting lugs as required shall be provided to enable lifting of the

core and winding. The impedance ratio Xo/X1 specified shall be achieved by
adopting single phase construction locating all three phases in one tank or adopting
5 limb core construction.

j) The core shall be grounded to the tank cover at one point only through removable
links in an appropriate terminal box, place in an accessible position on the tank
cover and which, by disconnection, will enable the insulation between the core
and reactor tank etc., to be tested at voltages up to 9.5KV for the purpose of
checking deterioration during service.

k) In case of coreless construction the magnetic shield shall be provided around the
coreless coils in order to prevent the generation of power frequency and 3rd
harmonic eddy currents in the valves and to prevent the flux from entering the
tank of air core reactor. The shield design and construction shall be such as to
give minimum losses suitable arrangements shall be made for clamping and
bolting shield to the tank of the reactor. The shield shall have adequate
mechanical strength to prevent vibration during operation and to avoid
displacement due to short circuit. Non magnetic material sheets shall form the
central core to minimize vibrator.

3.3 Windings

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

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

c) The insulation of windings and connections shall be free from insulating

components which are liable to soften, ooze out, shrink or collapse shall and
be non-catalytic and chemically inactive in oil during service.

d) Coil assembly and insulating spacer shall be so arranged as to ensure free

circulation of oil and to reduce the hot spots of the winding.

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

f) The conductors shall be transposed at sufficient intervals in order to

minimize eddy currents and to equalize the distribution of currents and
temperature along the winding.

Page 13 of 38
 g) To increase the capability of the reactors of with-standing short-circuits modern
technology in design and construction shall be applied, i.e. by application of a low
current destiny, not exceeding 9.7A/sq.mm in any part of the windings at rated
output, pre-drying and pre-compressing of the windings before mounting onto the
core.

3.4 Paint system and procedures

The painting details for reactor main tank, pipes, conservator tank, radiator, control
cabinet/ marshalling box / oil storage tank etc. shall be as given below. The
detailed painting procedure shall also be submitted along with the bid which shall
be finalized before award of the contract.

a) Equipment and all steel parts of the power reactors shall be painted or treated with
protective coatings to prevent corrosion and provided smart and pleasing
appearance. This work shall comprise the surface treatment, priming and
application of paint or metallic coatings in the work shop and at the site, including
all paint repair works that may be necessary.

b) Wherever possible, equipment shall be designed such that all surfaces can be
finish-coated or re-coated after erection at the site.

c) All steel surfaces, components and elements shall be sandblasted prior to priming
and painting. Scale, rust, grease and dirt shall be removed by abrasive blast
cleaning to the base metal with quartz sand or corundum. The average surface
roughness after sand blasting shall not exceed 40 microns.

d) Parts which cannot be blast-cleaned shall be cleaned free from rust and scale by
power-tool cleaning to the highest possible degree, according to the above
standards.

e) Surface preparation for non-ferrous materials shall be subject to the approval of

the purchaser and will generally be required to conform to the recommendation of
the coating manufacturer.

d) All working of the materials (e.g welding, drilling, grinding ) shall be completed
and surface defects (e.g. weld splatter, burrs, cracks, surface lamination and
pitting) likely to be detrimental to the protective coating shall be eliminated prior
to surface preparation.

g) Welded joints shall be thoroughly steel-brush cleaned prior to the application of

the first primer coat.

h) Before the application of primer, all sand-blasted or otherwise mechanically

treated surfaces shall be subjected to a thorough cleaning process during which all

Page 14 of 38
 dirt, dust, grease, moisture, etc., which may have collected is removed such that
the primer is applied on suitable surfaces. Clean cloths and suitable solvents shall
be used for this process.

i) The reactors shall be painted as follows:

External :
Two (2) primer coats 2 X 40 microns

Binder : epoxy resin hardened with polyamide

Pigment : titanium dioxide, zinc oxide, zinc phosphate,
Tinting additives
or alternatively

one (1) zinc powder coat 80 microns

Binder : epoxy resin hardened with polyamide

Pigment : zinc powder

One (1) intermediate coat 40 microns

Binder : epoxy resin hardened with polyamide

Pigment : titanium dioxide, micaceous iron oxide, tinting
additives

One (1) top coats 40 microns

Binder : Polyurethane hardened with isocyanate

Pigment : titanium dioxide, micaceous iron oxide, tinting
additives
Total coating thickness (dry-film) 160 microns

The final coat of painting shall be of pore-free and homogeneous quality and shall
be of an uniform non-glossy shade No.631 of IS:5 (light grey) (as per latest
amendment) or equivalent.

Internal :

The internal surface (tank, cover, core steel plates, etc.) shall be treated as
follows:

- thorough sand-blasting in accordance with DIN 55928, part-4 (equivalent

to SIS 055900)

One (1) coat (oil resistance dry-film) min. 35 microns

3.5 Insulating Oil

Page 15 of 38
3.5.1 The oil for first filling together with 10% extra shall be supplied with each Reactor. The
oil shall be NEW (unused) UNINHIBITED NAPHTHENIC BASED HIGH GRADE
MINERAL INSULATING OIL and shall comply in all respects with the provisions of
the latest edition of IS : 335 & IEC : 60296-2000 (as amended up to date). Particular
attention shall be paid to deliver the oil free from moisture having uniform quality
throughout. The oil may be supplied either in sealed tanker, or in non-returnable sealed
steel/HDPE drums, which will be opened at site in presence of TSGENCO representative.
The quantity of oil for first filling & 10% extra shall be stated in the tender.
The supplier of reactor shall furnish test certificates of the insulating power oil supplied
against their acceptance norms, prior to dispatch. Subsequently oil samples shall be
drawn
a) at manufacturer’s works before and after heat run test and shall be tested for
following :-
i) BDV in kVrms
ii) Moisture content
iii) Dissolved Gas Analysis – Samples for DGA shall be taken from sampling
device within 24 Hrs prior to commencement of heat run test and
immediately after this test. The acceptance norms shall be as per IS :
10593 (based on IEC-599).

b) Prior to filling in main tank at site and shall be tested for BDV and moisture content
for acceptance norms.

c) Prior to energisation at site and shall be tested for the following :

i) BDV in kV rms
ii) Moisture content
iii) Tan Delta at 90 Deg cen.
iv) Resistivity at 90 Deg cen.
v) Interfacial Tension.

d) The contractor shall dispatch the reactor filled with Nitrogen. The bidder shall take
care of the weight limitation on transport and handling facility at site. Necessary
arrangement shall be ensured by the bidder to take care of pressure drop of nitrogen
during transit and storae till completion of oil filling during erection. A gas pressure
testing valve with necessary pressure gauge and adaptor valve shall be provided.

e) Principle technical Parameters of New Insulating Oil and Test methods.

NEW (unused) UNINHIBITED NAPHTHENIC BASED HIGH GRADE MINERAL

INSULATING OIL CONFORMING TO IEC-60296 for 420kV Class Reactors.

Properties Permissible limiting Method of test

values for measured
characteristics

Page 16 of 38
 PHYSICAL : Revised (Proposed)
1 Appearance The oil shall be clear Visual.
transparent & free from (A representative sample of the
suspended matter of oil shall be examined in a 100
sediments mm thick layer at ambient
temperature.)
2 Kinematic Viscosity, ISO 3104
sqmm/s
i) 40 Deg.C i) Max.12.0
ii) 30 Deg.C ii) Max.1800
3 Flash point (PM) Deg.C Min.140 ISO3104
4 Pour point Deg.C Max.-40 IS : 1448 P10
ISO 3016
5 Density, g/ml at 20 Deg.C Max.0.895 IS : 1448 P16
ISO 3675
ISO 12185
6 Interfacial tension N/m Min.0.04 ISO 62956
against water at 25 Deg.C
7 Water content PPM After final processing at IEC 60814
refinery
i) Max.30 in bulk
delivery
ii) Max.40 in drum
delivery
ELECTRICAL :
1 Dielectric dissipation factor Max.0.002 IEC : 60247
(Tan Delta) at 90 Deg.C&
50 Hz
2 Break down strength Break IEC : 60156
down voltage, kVrms
i) As delivered
ii) After treatment i) Min.30
ii) Min.70
3 Negative impulse strength Above 150kV ASTM method D 3300
CHEMICAL :

1 Carbon type composition (% a) Max Aromatic : IEC 60590 or ASTM D1240

of Aromatic, Paraffinic and between 4% &
Naphthenic compounds) 12%
b) Parafins : <
50% &
c) Naphthenic
compounds : >
42%
2 Total sulphur content (%) Max.0.15 BS 2000 Part 373 or
ISO 14596

Page 17 of 38
 3 Corrosive sulphur (%) No Corrosive IEC 62535
(1500 C for 72 Hrs)
4 Neutralisation value mg Max.0.01 IEC : 62021-1 or 2
KOH/gm oil
5 Anti-oxidant additives Non detectable IEC : 60666
6 PCB Content Absent (Zero) IEC : 61619
7 Oxidation Stability after 164
Hrs. @ 120 Deg.C, (Max)
a) Total acidity in mg
KOH/gm Max. 1.2 IEC 61125 (method C)
b) Total sludge % by 0.8
weight max. 0.5
c) DDF at 90 Deg. C
3.6 Gas-in-oil-incipient Fault Monitor:
Bidder has to supply for each Reactor one intelligent on-line continuous Gas-in-oil
incipient Fault Monitor&water ppm and shall include an intelligent Transmitter with no
moving parts or pumps to detect and continuously monitor the evaluation of the values of
8 gases i.e hydrogen, carbon monoxide, acetylene, ethelene and water ppm etc..through a
gas permeable membrane include a communications controller, to provide remote and
local communications, dual level visual alarm indicators and continuous display and a heat
dissipater shall be mounted between the value and the transmitter. The intelligent on-line
detection and monitoring sensor shall be located on the cooler return pipe or at another by
the sensor manufacturer accepted location at the reactor. It should work for both AC/DC.
It should not fail for high voltage induction(400kv switch yard) or for any voltage
fluctuations communication protocols shall be of open protocols. It shall be provided with
analysis soft ware and latest laptop.Provision for load compensation shall be included.

3.7 Terminal Arrangement

3.7.1 Bushings

(a) The electrical and mechanical characteristics of bushings shall be in

accordance with IS:2099 and IS:3347. Bushing must have been type tested
successfully as per IS:2099 /IEC 60237.

(b) Bushing for voltage of 420kV shall be of oil filled condenser type and draw lead type
to facilitate removal. Bushing for voltage of 145kV shall be oil filled condenser type
and shall be of draw lead type. The characteristics of the oil used in the bushings
shall be the same as that of the oil used in the shunt reactor
(c) Mounting dimensions of 420kV and 145kv bushing shall be as per drawing. The
spacing between the bushings must be adequate to prevent flash over between phases
under all conditions of operation.

(d) Oil filled condenser type bushings shall be provided with atleast the following
fittings:

Page 18 of 38
 (i) Oil level gauge
(ii) Oil filling plug and drain valve if not hermetically sealed.
(iii) Tap for capacitance/tan delta test. Test taps relying on pressure
contacts against the outer earth layer of the bushing is not acceptable

(e) When bushings have an under-oil end of reentrant form the pull through lead shall be
fitted with a gas bubble deflector.

(f) Where Bushing current Transformers are specified, the bushings shall be
removable without disturbing the current Transformers.

(g) Bushings of identical rating shall be interchangeable.

(h) Porcelain used in bushing manufacture shall be homogenous, free from

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

(i) Glazing of porcelain and bushings shall be of uniform brown colour, free from blisters,
burrs and other similar defects. Bushings shall be designed to have ample insulation,
mechanical strength and rigidity for the conditions under which they will be used.

(j) Special precautions shall be taken to exclude moisture from paper insulation during
manufacture, assembly transport and erection. The surface of all paper insulation shall
be finished with non-hygroscopic varnish which cannot be damaged easily.

(k) Clamps and fittings shall be of hot dip galvanised steel.

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

(m) No arcing horns shall be provided on bushings.

(n) All bushings shall be preferably designed for storage in a horizontal position without
any restriction.

3.7.2 Terminal Connectors:

(a) Bushing terminal shall be provided with terminal connectors of approved type and
size for connection to external parts. Terminal connectors must have been type
tested successfully as per IS : 5561.

(b) 420kV terminal connectors shall be suitable for twin moose ACSR conductor
(31.77 mm dia) with sub-conductor spacing 450mm and shall be suitable for
horizontal or vertical take off. However, the contractor shall submit the drawings
of terminal connector he intends to supply and obtain owner’s approval before
Page 19 of 38
 arranging procurement / manufacturing.

(c) (i) All castings shall be free from blow holes, surface blisters, cracks, and
cavities. All sharp edges and corners shall be burred and rounded off.
Aluminium alloy casting if used shall conform to designation A-6. of
IS- 617, or of better quality.
(ii) No part of a clamp shall be less than 10 mm thick.
(iii) All ferrous parts shall be not dip galvanized conforming to IS : 2633.

(iv) For bimetallic clamps, copper alloy liner of minimum 2 mm thickness shall
be cast integral with aluminium body. Alternatively, bidder may offer
bimetallic connector with loose bimetallic sleeve.

(v) Flexible connectors shall be made from tinned copper sheets.

(vi) All current carrying parts shall be designed and manufactured to have
minimum contact resistance.

(vii) 420kV class clamps shall be designed corona controlled to achieve

extinction voltage of 320kV (rms) and shall conform to IS : 5561.

(viii) Short time current rating of the terminal connectors shall be same as that of
corresponding bushings.

(ix) Malleable cast iron for terminal connector and any of its parts and
accessories shall not be acceptable.

(x) Bolts and nuts used shall be of stainless steel.

3.8 Terminal Marking

The terminal marking and their physical position shall be in accordance with
IS:2026/IEC 60076.

3.9 Neutral Earthing Arrangement

(a) The neutral of the shunt reactor shall be brought out through 145kV class
oil filled condenser bushing.
(b) Neutral of Shunt Reactors shall be suitable for grounding directly or through a
NGR of rating 170 KVAR, 145 KV.

(c) The neutral terminals of Reactors (without NGR) shall be brought to the
ground level by a brass/tinned copper grounding bar, supported from the tank
by using porcelain insulators. The end of the brass/tinned copper bar shall
be brought to the bottom of the tank, at a convenient point, for making bolted
connection to two (2) 75 x 12 mm galvanised steel flats connected to Employer's

Page 20 of 38
 grounding mat.

4.0 Cooling Equipment

4.0.1 Oil immersed with natural cooling (ONAN)

(a) The radiator bank of the shunt reactor shall be separately mounted. For
neutral grounding reactor, the radiator, if required, may be tank mounted.

(b) Radiators shall be made from pressed steel.

(c) Each radiator bank shall be provided with the following accessories:

(i) Top and bottom shut off valve

(ii) Drain Valve and sampling valve

(iii) Air release plug

(iv) Two grounding terminals for termination of two (2) Nos. 75x12 mm
galvanized steel flats.

(v) Thermometer pockets with captive screw caps at cooler inlet and outlet.

(vi) Lifting lugs

(d) Each radiator bank shall be detachable and shall be provided with flanged
inlet and outlet branches.

(e) Expansion joint,(SPECIFY THE TYPE I.E.METTLLIC BELLOW OR

BRAIDEDif required, shall be provided on top and bottom cooler pipe connection.

4.0.2 Valves
(a) All valves upto and including 40 NB shall be of gun metal and above 40 NB
shall be cast iron with gun metal fitting. They shall be of full way type with
internal screw and shall open when turned counter clock wise when facing the
hand wheel.

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

(c) Each valve shall be provided with the indicator to show clearly the position of the
valve.

(d) All valve flanges shall have machined faces.

(e) All valves in oil line shall be suitable for continuous operation with shunt
reactor oil at ø 115 C.

Page 21 of 38
 (f) Gland packing/gasket material shall be of teflon rope/nitrile rubber. In case of
gate/globe valves, gland packing preferably of teflon rope shall be used to
prevent oil seepage through the gland.

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

(h) A valve or other suitable means shall be provided to fix the on line
dissolved gas monitoring system to facilitate continuous dissolved gas analysis.
The location& size of the same shall be finalised during detailed engineering
stage.

(i) After testing, inside surface of all cast iron valves coming in contact with
oil shall be applied with one coat of oil resisting paint/varnish. Outside surface
of the valves shall be painted with two coats of red oxide zinc chromate primer
followed by two coats of fully glossy finishing paint conforming to IS:2932.
Outside surface except gasket seating surface of butterfly valves shall be
painted with two coats of red oxide zinc chromate conforming to IS:2074
followed by two coats of fully glossy finishing paint.

(j) All hardware used shall be cadmium plated/electro-galvanised.

(k) For estimation purpose of spares one set of valves mean one valve of each
type used in Reactor.

4.1 Marshalling Box

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

(b) The marshalling box shall be tank mounted type. Suitable anti-vibration pads
shall be provided so that vibration from tank is not transferred to the
marshalling box. The marshalling box shall have sloping roof. It shall have
double hinged doors and shall be provided with locking arrangement. The
exterior and interior painting shall be in accordance with painting.The degree of
protection shall be IP 56 in accordance with IS:2147

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

Page 22 of 38
 (d) The marshalling box shall accommodate the following :
(i) Temperature indicator for winding and oil,
(ii) Terminal blocks and gland plates for incoming and outgoing cables.
(e) The temperature indicator shall be so mounted that the dials are about 1200
mm above ground level. Glass doors of suitable size shall be provided for
convenience of reading. A space heater and cubicle lighting with ON-OFF
switch shall be provided. It shall be so designed that with the space heater
switched on continuously, the temperature inside the marshalling box does not
exceed the safe operating limits at the service conditions.

4.2 TERMINAL BLOCK:

(a) All internal wiring to be connected to the external equipment shall terminate on
blocks, preferably vertically mounted on the side of cabinet, junction box.

(b) The terminal blocks shall be made of moulded, non-inflammable thermosetting

plastic. The material of terminal block moulding shall not deteriorate because of
varied condition of heat, cold humidity, dryness etc., that would be anticipated at
the location the equipment is proposed to be installed.

(c) The terminal shall be such that maximum contact area is achieved when a cable is
terminated. The terminal shall have a locking characteristic to prevent cable from
escaping from the terminal clamp unless it is done intentionally. The terminals
shall be non-disconnecting stud type equipment to Elmex type CAT-M4.
Washers, nuts and lock nuts shall be provided. Fot CT circuits ,they shall be
disconnecting type.

(d) The terminal blocks shall be of extensible design.

(e) The terminal blocks shall have locking arrangement to prevent its escape from the
mounting rails.

(f) The terminal blocks shall be 1100V grade and shall be rated to carry continuously
the maximum current that is expected to be carried by the terminals (atleast 10A
continuous rating).

(g) The terminal blocks shall be fully enclosed with removable covers of transparent,
non-inflammable, non-deteriorating type plastic materials, insulating barriers shall
be provided between the terminal blocks. These barriers shall not hinder the
operator from carrying out the wiring without removing the barriers. The barriers
shall be moulded integrally.

(h) The terminals shall be provided with the marking tags for wiring identification.
The terminal blocks shall have white marking tags for circuit-identification and
washers and binding screws for external circuits wire connection. All terminals

Page 23 of 38
 shall be clearly marked with identification numbers or letters to facilitate
connection to external wiring.

(i) The boxes shall be provided with 20% spare terminals unless otherwise specified
and these spare terminals shall be uniformly distributed on all terminal blocks.

Unless otherwise specified, terminal blocks shall be suitable for connecting the
following conductors of owner's cable on each side:

i) All circuit except Minimum one no. 2.5Sq.mm

CT and PT circuits copper flexible.

ii) All CT circuits Minimum of 4Nos. of 2.5Sq.mm

copper flexible. (disconnecting type
TB’s)

iii) All PT circuits Minimum of 2Nos. of 2.5Sq.mm

copper flexible.

(j) There shall be a minimum clearance of 250mm between the first row terminal
block and the cable gland plate or side of the box. Also the clearance between
two rows of terminal blocks shall be a minimum of 150m.

(l) The arrangements shall be in such a manner so that it is possible to safely connect
or disconnect terminals on live circuits and replace fuse links when the cabinet is
live. Cabinet wiring should be suitable for 60 deg. C. as the space heaters will
keep the temperature 10deg. C. higher than the ambient.

(m) Terminal blocks for current transformer secondary leads shall be provided with
test links and isolating facilities. Also current transformer secondary leads shall
be provided with short circuiting and earthing facilities.

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

(o) The number and sizes of the owner's multi core incoming cable will be furnished
to the contractor after placement of the order.

4.3 CONTROL WIRING AND CABLING:

Page 24 of 38
(a) Supply and erection of all cables and accessories required for proper termination
from the control cabinet/marshalling box to make transformer/reactor functional
shall be supplied by the contractor.
(b) Contractor shall also supply rigid GI conduits/pipes with all accessories required
for routing cable in ground and the concrete. Flexible conduits with accessories
made up of brite cold rolled annealed and electro galvanised mild steel wires shall
be used for running cable between embedded pipe and equipment.
(c) Wire terminations shall be made with solder less crimping type of tinned copper
lugs which firmly grip the conductor and insulation. Insulated sleeves shall be
provided at all the wire terminations.
(d) All wires directly connected to trip circuit breaker shall be distinguished by the
addition of a red coloured unlettered ferrule. Number 6 & 9 shall not be included
for ferrules purpose.
(e) In accordance with the requirement as stipulated under section general control
cabinets, junction boxes, terminal boxes and marshalling boxes shall conform to
type tests and shall be subjected to routine tests in accordance with IS:5039. In
addition to the type tests, verification of the degree of protection, as per IS:2147
for IS-55, shall be conducted. After protection degree tests on control cabinet,
2.0kV rms for 1 minute, for checking insulation resistance shall be applied and
functional test shall also be conducted.
(f) All control wiring from transformer accessories to control cabinet/ marshalling
box shall be 1100 volts grade PVC insulated 2.5 sq. mm stranded copper cable
with armour. All controls, alarms, indicating and relaying devices provided in the
transformer shall be wired upto respective terminal blocks inside the cooler
control cabinet.
(g) Power cable used from transformer accessories to control cabinet/ marshalling
box shall be clearly identified by symbols corresponding to those used on
applicable schematic or wiring diagram. Power cables shall be 1100V grade PVC
insulated armored Copper/ Aluminium conductor. Compression type cable
connectors shall be provided for the termination of power and control cables.

(h) All device and terminal blocks within the control cabinet/marshalling box shall be
clearly identified by symbols corresponding to those used on applicable schematic
or wiring diagram.

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

(j) Engraved core identification plastic ferrules marked to correspond with schematic
diagram shall be fitted at both ends of wires. Ferrules shall fit tightly on wires
and shall not fall off when the wire is disconnected from the terminal block.

Page 25 of 38
 (k) Each terminal shall be suitable for connecting the 2.5Sq.mm stranded copper
conductor from each side. Not more than two wires shall be connected to one
terminal.

4.4 Fittings

The following fittings shall be provided with each shunt reactor covered under this
specification.

1. Conservator for reactor main tank with filling hole and cap, drain valve,
isolating valve, vent pipe and magnetic oil level gauge with low level alarm
contacts.
2. Air release devices.
3. Dehydrating breather complete with first fill of activated silicagel.
4. Inspection openings and covers.
5. Rating & diagram plate for reactors and current shunt reactors. These plates
shall be of material capable of withstanding continuous outdoor service.

6. Terminal marking plate conforming to IEC-60289 / IS:5553

7. Two earthing terminals each on shunt reactor tank, radiators & marshalling
box, SA structures etc.

8. Ladder to climb up to the reactor tank cover with suitable locking

arrangement to prevent climbing during charged condition.

9. Double float/reed type Buchholz relay with alarm and trip contacts.
10. Bottom oil sampling valve and drain valves.
11. Filter valves at top and bottom.
12. Shut off valves on the pipe connection between radiator bank and reactor tank.
13. Shut off valves on both sides of Buchholz relay at accessible height.
14. Sampling gas collectors for Buchholz relay at accessible height.
15. Four jacking pads.
16. Lifting lugs or eyes for the cover.
17. Suitable terminal connectors for ACSR moose conductor on bushings (Shunt
reactor shall be in manufacturer scope.
18. Under carriage with provision for flanged bi-directional wheels, set of
flanged bi-directional wheels, set of flanged bi-directional rollers/trolley for
transportation.
19. Drain valves/plugs shall be provided in order that each section of pipe work

Page 26 of 38
 can be drained independently.
20. Pressure relief devices with alarm/trip contacts.
21. Bushing with metal parts and gaskets to suit the termination arrangement.
22. Winding temperature indicators for local and remote mounting (only for shunt
reactor).
23. Oil temperature indicator
24. Protected type mercury or alcohol in glass thermometer.
25. Marshalling box .
26. Haulage lugs.
27. Bushing CT
28. The fittings listed above are only indicative and any other fittings which
generally are required for satisfactory operation of the reactors are deemed to be
included.

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

30. Suitable galvanized iron tray for cabling on main tank for better aesthetics.
31. Oil filling plate with instruction.

4.5 CENTER OF GRAVITY :

The center of gravity of the reactor shall be low and as near the vertical center line as
possible. The reactor shall be stable with or without oil.

4.6 Transportation

Reactor tank shall be dispatched filled with oil or pure dry inert Nitrogen gas
depending upon the transport weight limitations. A positive pressure of 2 to 2.5
Psi at temperature of 36oC approximate shall be kept. In case the tank is filled
with oil, sufficient space is left above the oil to take care of the expansion of the
oil. The space is filled with pure dry air or inert gas under atmospheric pressure.

The temperature and pressure at the time of gas filling shall be marked on a tag.
A graph showing pressure vs. temperature shall be attached for reading
pressures at different temperatures. Necessary valves, two-stage pressure
regulators, filled up Nitrogen cylinder etc. along with other accessories required
shall be provided with the tank for intermittent replenishment during
transportation.

Page 27 of 38
 4.7 Impact Recorder

Impact recorder/indicator shall be provided to monitor the impact experienced by

the reactor during transport.

5.0 Inspection and Testing:

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

5.1 Inspection

5.1.1 Tank and Conservator

(a) Certification of chemical analysis and material tests of plates.

(b) Checks for flatness

(c) Electrical interconnection of top and bottom tank by braided tin flexible.

(d) Welder's qualification and weld procedure.

(e) Testing of electrodes for quality of base materials.

(f) Inspection of major weld preparation.

(g) Crack detection of major strength weld seams by dye penetration test.

(h) Measurement of film thickness of

(i) Oil insoluble varnish
(ii) Zinc chromate paint
(iii) Light grey paint
(i) Check correct dimensions between wheels, demonstrate turning of wheels through
90ø and further dimensional check.

(j) Check for physical properties of materials for lifting lugs, jacking pads, etc. All
load bearing welds including lifting lug welds shall be subjected to non destructive
test (NDT).

(k) Leakage test of the conservator.

Page 28 of 38
(l) Certification of all test results.

5.1.2 Core

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

(b) Check on the quality of varnish if used on the stampings.

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

(ii) Solvent resistance test to check that varnish does not react in hot oil.

(iii) Check over all quality of varnish on stamping, ensure uniform shining colour,
no bare spots, no over burnt varnish layer and no bubbles on varnished surface.

(c) Check on the amount of burrs.

(d) Bow check on stampings.

(e) Check for the overlapping stampings. Corners of the sheets are to be apart.

(f) Visual and dimensional check during assembly stage.

(g) Check for inter laminar insulation between core sections after pressing.

(h) Visual and dimensional check for straightness and roundness of core.

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

(j) Check of pressure during dimensional stabilisation of winding/core assembly.

(k) Certification of all test results.

5.1.3 Insulation Material

(a) Sample check for physical properties of material.

(b) Check for dielectric strength.

(c) Visual and dimensional checks.

(d) Check for the reaction of hot oil on insulating materials.

(e) Dimensions stability test at high temperature for insulating material.

Page 29 of 38
(f) Tracking resistance test on insulating material.

(g) Certification of all test results.

5.1.4 Winding

(a) Sample check on winding conductor for mechanical properties and electrical
conductivity.

(b) Visual dimensional checks on conductor for scratches, dent marks etc.

5.1.4.3 Sample check on insulating paper for pH value, electric strength.

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

5.1.4.5 Check for the bonding of the insulating paper on conductor.

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

5.1.4.7 Check for absence of short circuit between parallel strands.

5.1.4.8 Check for brazed joints wherever applicable.

5.1.4.9 Measurement of impedance by low voltage to be carried out when

core/yoke is completely restacked and all connections are ready.

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

5.1.4.11 Conductor flexibility test.

5.1.4.12 Heat shrink test for enamelled wire.

5.1.4.13 Certification of all test results.

5.1.5 Checks before drying process

5.1.5.1 Check conditions of insulation on the conductor and between the windings.

5.1.5.2 Check insulation distance between high voltage connection cables and earth
and other live parts.

5.1.5.3 Check insulation distance between low voltage connections and earth and other
parts.

5.1.5.4 Insulation of core shall be tested at 2 kV/minute between core to bolts and core

Page 30 of 38
 to clamp plates.

5.1.5.5 Check for proper cleanliness and absence of dust etc.

5.1.5.6 Certification of all test results.

5.1.6 Checks during drying process

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

5.1.6.2 Check for completeness of drying by measuring IR and tan delta.

5.1.6.3 Certification of all test results.

5.1.7 Assembled Reactor

5.1.7.1 Check completed reactor against approved out line drawing provision for all
fittings, finish level etc.

5.1.7.2 Jacking test on all the assembled reactors.

5.1.7.3 Dye penetration test shall be carried out after Jacking tests.

5.1.8 Accessories:

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

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

(a) Buchholz relay

(b) Axles and wheels/Trolley for transportation.
(c) Winding temperature indicators for local and remote mounting
(d) Oil temperature indicators
(e) Bushings
(f) Bushing current transformers
(g) Marshalling box
(h) Radiators
(i) Pressure relief device

Page 31 of 38
 The above list is not exhaustive and the Contractor shall also include all other
bought out items in his programme.

5.9 Factory Tests

General Requirements for type, routine and special tests are as per given clause no. cl.7.1 of IS :
5553 (PART-II). The requirements given in 16.1 of IS 2026 ( Part 1 ) : 1977 shall apply.

a) One shunt reactor out of similar rating shunt reactor shall be assembled and tested
at the manufacturer's works for all type tests as per clause 5.6. Routine tests shall
be carried out on all the shunt reactors, as per IS 5553(Part-II). The dielectric test
corresponding to method-2 as per IS 2026 (Part-III : 1981) Cl.No. 5.4.

b) Bushings, insulating oil and accessories shall be subjected to type and routine
tests specified in clauses below.

c) The insulation resistance of the windings is to be measured for 15 secs, 60 secs.

and 10 mins. The Polarization Index (PI) is to be calculated with the ratio of IR
value at 10 minutes to IR value at 60 seconds. The Absorption ratio is to be
calculated with the ratio of IR value at 60 seconds to IR value at 15 seconds. The
PI Value shall be maintained as 2.0 for acceptance.

5.9.1 No equipment shall be dispatched until the test reports are duly approved by the
purchaser.

6.0 TYPE TESTS:

6.1. Type tests shall be carried out as per IS:5553 (part-II). Cl.No.7.2Measurement of
auxiliary losses shall be made along with the type test for calculation of temperature rise.

6.2 Temperature rise test as per IS:5553(part-II): Gas chromatographic analysis on oil shall
also be conducted before and after this test and the values shall be recorded in the test
report. The sampling shall be in accordance with IEC 60567. For the evaluation of the
gas analysis in temperature rise test the procedure shall be as per IS:9434 (based on
IEC:60567) and results will be interpreted as per IS:10593 (based on IEC-60599) or
mutually agreement. Temp. rise test shall be performed with all current carrying
accessories (CT,etc.) in place. Measurements of top oil temperatures taken in pockets
shall be corrected by +2K to the obtained value as per applied standard. Measurements
on radiator cooler walls are not acceptable.

6.3 The following dielectric tests shall be carried out:-

a) 420kV winding:
i) Lightning impulse voltage (withstand) test on all the line terminals.
The following test procedure and sequence shall be applied for all shunt reactors
independent on the applied standard:

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 (a) One 50...70% full impulse (lines and neutral)
(b) One 80% full impulse (lines and neutral)
(c) One 100% full impulse (lines and neutral)
(d) One 50...70% chopped impulse (line terminals only)
(e) Two 110% chopped impulses (lines terminals only)
(f) Two 100% full impulses (lines and neutral)
(g) One 80% full impulse (lines and neutrals)
(h) One 50...70% full impulse (lines and neutral)

ii) Switching surge voltage withstand test on all the line terminals.

iii) Induced over-voltage withstand test with partial discharge measurement on all the
line terminals.

iv) Separate source voltage withstand test on neutral terminal.

6.4 Type Tests on Tank:

6.4.1 Following additional type tests shall be conducted on the transformer tank:-

a) Vacuum Test:
One shunt reactor tank of each size shall be subjected to full vacuum and tested at an
internal pressure of 3.33 kN/sq. m (25 Torr) for one hour. The permanent deflection of
flat plates after the vacuum has been released shall not exceed the values specified below
and the performance of the shunt reactor shall not be affected in any way.

Horizontal length of Permanent

flat plate (mm) deflection (mm)

Up to and including 750 5.0

751 to 1250 6.5
1251 to 1750 8.0
1751 to 2000 9.5
2001 to 2250 11.0
2251 to 2500 12.5
2501 to 3000 16.0
Above 3000 19.0

b) Pressure Test:
One shunt reactor tank of each size together with its radiators, conservator vessel and
other fittings shall be subjected to a pressure corresponding to twice the normal head of
oil or to the normal pressure plus 35 kN/sq. m whichever is lower. The applied pressure
shall be measured at the base of the tank and maintained for one hour. The permanent
deflection of flat plates after excess pressure has been released shall not exceed the values
specified in (a).
6.4.2 Pressure Relief Device:

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 The pressure relief device of each size shall be subjected to increasing oil
pressure. It shall operate before reaching the test pressure specified in the test
at clause 6.4.1(b). The operating pressure shall be recorded. The device shall
seal off after the excess pressure has been relieved. The following functional
checks shall be conducted as acceptance tests on each of the pressure relief
devices.

i) Air Pressure test

ii) Liquid Pressure test
iii) Leakage test
iv) Contact test
v) Di-electric test

6.4.3 ROUTINE TESTS:

6.4.3.1 These tests shall be carried out as perIEC-289/ IS:5553shall be carried out as per
IS:5553 part-II Cl.No.7.3 except when specified differently.
6.4.3.2 Measurement of exciting current, excitation losses and harmonics in no-load
current be carried at 85%, 90%, 95%, 100%, 105% and 110% of rated voltage as
per IS:2026 (part-I).
Excitation losses given in the test report shall be those measured after the impulse
tests are completed. Endeavour shall be made to carry out the measurement of
exciting current beyond 150% of rated voltage by the method to be mutually
agreed between the Bidder and the purchaser. The Bidder shall specify in this
bid, the method of such measurement and its limitations.

6.4.4 Additional Routine Tests:

6.4.4.1 In addition to the routine test mentioned in IS:2026 (part-I) the following
additional test shall be carried out.

a) All welds shall be tested by the manufacturer for leak by a standard practice like
dye penetration test etc. and the factory test results shall be furnished. Bidder
shall arrange for witnessing the D.P test on all load bearing points of each tank.
b) Oil leakage test on shunt reactor tank:
All tanks and oil filled compartments shall be tested for oil tightness by
completely filling with air/oil of viscosity not greater than that of insulating oil
conforming to IS:335 at the ambient temperature and applying a pressure equal to
the normal pressure plus 35 kN/sqm measured at the base of the tank. This
pressure shall be maintained for a period of not less than 12 hours for oil and one
hour for air, during which time no leakage shall occur. Bidder shall arrange for
witnessing the leakage test of each tank.

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 c) Magnetic circuit test:

After assembly each core shall be tested for one minute at 2000 volts between all
bolts, side plates and structural steel work. Immediately prior to the dispatch of
the shunt reactor from the manufacturer's works, the magnetic circuit test shall be
pressure tested for one minute at 2000 volts AC between the core and the earth.
d) Power-frequency voltage withstand test.
e) Magnetic balance test and Measurement of Mutual Reactance test.
f) Measurement of winding resistance, insulation resistance, reactance of winding
and losses.

e) Frequency Response Analysis (FRA) test: Supplier shall conduct the test at the
time of final testing of the shunt reactor and record the amplitude and phase shift
results on CDs for subsequent analysis. The test shall also be carried out before
commissioning at site and compare this results with the results obtained
(conducted at factory) before dispatching the shunt reactor and submit the report
along with the above results in CDs for future analysis. Each shunt reactor is
subjected to FRA test and frequency responses recorded as above and analyzed in
any of the following.

i. Shift in the response of the winding.

ii. Differences between the responses of all the phases of the shunt reactor.

f) Dew point measurement test before dispatching: Positive Gas pressure is

generally maintain at 0.175kg / m2 during transportation and during storage. To
ensure the same, dew point measurement shall also be carried out at site. The
procedure and acceptance limits are as per CBIP Manual Pub. No. 295 (2006) or
latest.
6.4.5 SPECIAL TESTS:
Following special tests in addition to type and routine tests shall also be carried out as per
IS:5553 part-II Cl.No.7.4 as applicable on one unit of each type.
a) Measurement of zero seq. reactance clause 16.10 of IS: 2026 part-I.
b) Measurement of mutual reactance on three phase reactors.
c) Measurement of harmonic level in no load current.
d) Measurement of partial discharges at a voltage of 364kV (i.e. 420 x 1.5/ √3) for
30 minutes between the HV line to ground as per IEC:6076-/IS:2026 part-
III/1977.
e) Measurement of magnetization characteristics.

f) Measurement of vibration and stress measurement on tank.

g) Measurement of acoustic noise level:

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 This test shall be carried out in accordance with NEMA audible sound level test
procedure.
h) Capacitance Tan Delta Test:
Capacitance test shall be carried out with the help of ampere turn bridge method
on fully assembled shunt reactor (filled with oil) to determine capacitance and
tan-delta between winding and earth. The tan delta value of bushing / winding
shall not exceed 0.7 at 20 deg. C.
(i) DGA of mineral oil used before and after heat run test as per IS : 10593 : 1983.

6.4.6 TEST ON SHUNT REACTOR BUSHINGS:

Shunt Reactor bushings shall comply in all respects with the type and routine tests laid
down in IS:2099 (as amended up to date). However lightning impulse test at 1425 (kVp)
shall be conducted on 400kV bushings as routine test on all bushings as per the latest
IEC-60137. This shall be conducted before assembled on to the reactor in the presence of
purchaser representative.

6.4.7 TESTS ON INSULATING OIL:

Samples of oil from each bulk consignment shall be tested in accordance with IS:335&
IEC:60296-2000(as amended up to date) and latest CBIP before any oil is dispatched.
Also as specified in Clause 3.5 (a) (i) & (ii), Oil shall be subjected to tests including gas
analysis both at site and works.
The manufacturer shall be fully equipped to perform all the required tests as specified.
Bidder shall confirm the capabilities of the proposed manufacturing plant in this regard
when submitting the bid. Any limitations shall be clearly stated.

6.4.7.2 Loss and current measurements

Measurement of losses on first reactor shall be carried both by calorimetric and
bridge methods for achieving the correction factor. Losses measurement on
subsequent rectors can carried out by bridge method and losses thus obtained shall
be corrected by multiplying with correction factor achieved as above for the
purpose of loss evaluation.
The load losses and load current of every reactor shall be measured as specified in
IEC 60076/ IEC 60289. Measurements shall be also made with maximum flux
conditions in the magnetic circuit. In each case the measurement shall be made at
0.90pu, 1.00pu & 1.10pu.

The following details shall be recorded and submitted with the test certificates
• The voltage readings
• The mode of response and scaling of the voltmeters
• The current reading
• The power reading
• The frequency reading

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

6.4.7.3. Additional tests:

The purchaser reserves the right to have other reasonable tests carried out at his
own expenses either before dispatch or at site to ensure that the shunt reactor
complies with the requirement of the specification.

6.4.7.3 Test on marshalling box / control cabinet :

Besides the type and routine tests as per relevant IS Degree of Protection IP - 55
test as per IS :2147 shall be conducted on marshalling box.

Miscellaneous

All component parts and auxiliary equipment such as oil, bushings, CTs etc..shall
be routine tested as per relevant Indian Standards.

Tests shall be performed in presence of Owner’s representative or his approved third party
inspector, if so desired by Owner. The Bidder/Supplier shall give at least fifteen
(15) days' advance notice of the date when the tests are to be carried out

Similarly Owner’s representative or his approved third party inspector may carry
out stage inspection as per customer hold points finalized.

Bushing – CTs
1.0 Bushing Current transformer

1.1 Current transformer shall comply with IS:2705 /IEC-60185.

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

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

1.4 Bushing Current transformer parameters indicated in this specification are tentative
and liable to change within reasonable limits. The Contractor shall obtain Employer's
approval before proceeding with the design of bushing current shunt reactors. The CT
characteristics shall have to match with the protective relays, meters and instruments.

1.5 Technical Parameters:

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1.5.1 Current transformer Parameter for 420 kV Shunt Reactor (on each phase connection).

Shunt Reactor Core-1 Core-2 Core-3 Core-4

Line Side 200/1A 200/1A 200/1A 200/1A
Neutral Side WTI 200/1A 2000-1000-500/1A 2000-1000-500/1A
burden10 V A Vk>200 V Vk>200 V Vk>200V
Line Side
Class 1.0 Class PS Class PS Class PS
Suitable for Vk>200 V Vk>1000-500-250 Vk>1000-500-250
Neutral Side
WTI Class PS V;Class PS V;Class PS
Line Side
1 ohm 1 ohm 1 ohm 1 ohm
(resistance)
Neutral (resistance) 1 ohm 1 ohm 10-5-2.5 ohm 10-5-2.5 ohm
metering Restricted Back up T-zone differential
Line Side
Earth Fault impedance (21R) Protn./spare
Temperature
Restricted Reactor T-zone differential
Neutral Side indicator
Earth Fault Differential Protn./spare
(Y phase only)

1.5.2 The arrangement of current transformers on shunt reactor.

1.5.3 The secondary excitation current of class PS shall not be more than 4% of
rated secondary current at 25% of knee point voltage.

1.5.4 Accuracy class PS as per IS: 2705.

1.5.5. Class (for the relevant protection and duties) as per IEC 60185.

1.5.6. For estimation of spares, one set of CTs shall mean one CT of each type used in
Reactor. The bushing CTs arrangement will be finalized during detail engineering
and drawing approval as per requirement of field condition after awarding of
contract.

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