TENDER SPECIFICATION FOR 40 MVA RECTIFIER TRANSFORMER AT HOT STRIP MILL & TANDEM MILL NO.

1 IN BOKARO STEEL PLANT

STEEL AUTHORITY OF INDIA BOKARO STEEL PLANT DESIGN BUREAU (ELECTRICAL) JUNE06 1.0 1.1 INTRODUCTION General

LIMITED

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1.2

In HSM & Tandem Mill complex of Bokaro steel plant 11 nos. of Soviet make transformer type T PYX - 40000/10T have been employed to provide 6 (Six) phase, 800V A.C power supply to the existing group of thyristor converters. The rectifier transformer type T PYX40000/10T have two cores on common base. The diagram of primary winding connection of one core is Star and of the other core is Delta. The secondary winding of each core - two inverse Stars with built-in equalizing reactor providing continuous 40% reduction of the rectified voltage with the help of grids with the tap changer at the highest step. With voltage reduced by taps the range of phase angle control by grids is increased. Transformer T PYX-40000/10T has the separate changer for remote changing of the primary windings taps to vary secondary winding voltage. The taps 17 to 15 are used for + 5% compensation and the rest 14 taps are designed for 40% reduction of the rectified voltage. Intent of the Specification: The intent of this specification is to procure an identical transformer or of improved design with similar technical / dimensional / fitment features so that in the event of any failure of existing transformer an immediate replacement is readily available.

Tenderers are advised to examine Special Instructions to the Tenderer under para 6 of the specification carefully and make sure that they generally fulfil all the requisite criteria (as elaborated under various paras of the said instructions) before making the offer. 2.0 SCOPE OF WORK 2.1 Scope in Brief 2.1.1 The scope of work of the tenderer shall include design, manufacture, testing at manufacturers works, supply FOR BSL Plant Site, Bokaro Steel City, unloading at Site, supervision during erection, testing before commissioning and supervision of commissioning of 1 No. Indoor, 11 KV, Rectifier Transformer for replacement of existing Soviet make & type T PYX- 40000 / 10 T Rectifier transformer. The rated output of the existing transformer is 2 X 7912KVA. The technical particulars, design data, constructional features, broad dimensional details of the existing Soviet transformers have been described in the subsequent paras as well in the Annexure -I to the TS for guidance of the tenderers. These details are to be considered as indicative only and shall be suitably taken into account for design of the offered transformer by the tenderers. The broad / overall dimensions of the existing transformer and schematic diagram are indicated in the enclosed drg No. M-109-EL-DNW-336-19 & M-109-ELRO-20 forming part of the tender specification. The tenderers shall examine the relevant details carefully so that the design of the offered transformer facilitates replacement of the existing Soviet transformer most conveniently and without requiring any modification in the existing Bus bar connections. 2.1.2 Equipment supplied and installed shall be strictly in accordance with the technical specifications given in the clause 3.0 of this TS. 2.2 Drawings & Technical Literature
The contractor shall submit 6 (Six) copies of the following drawings and documents within four weeks of LOI to the purchaser for their approval. The purchaser shall send back one copy of the drawing with his comments/approval. The list of drawings to be submitted for approval.

a Dimensional & labeled General Assembly Drawing of the Rectifier Transformer with list of all fittings and accessories, foundation plan, details of weight, etc. b) Drawing of rating & diagram plate. c) Wiring & connection diagram for protective & indicating devices with marshalling box. Terminal strip plan with terminal numbers. 2.2.2 Six (6) copies of all final approved drawings, installation, operation & maintenance manuals together with one (1) set of Micro-films of Archives quality of all drawings shall be furnished immediately after despatch of the equipment. All drawings and operating instructions shall be in English language. Dimensions, technical data and weights furnished shall be in metric
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2.2.3

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3.00

OPERATING AND SITE CONDITIONS The rectifier transformer shall satisfactorily operate upto its rated output and with its guaranteed performance figures under the following operating and site conditions: SYSTEM VOLTAGE : 11 KV + 10% SYSTEM FREQUENCY : 50 C/S, 6% GROUNDED/UNGROUNDED : UNGROUNDED SYSTEM SYSTEM SHORT CIRCUIT LEVEL : 500 MVA 3-Phase Symmetrical on 11 KV 28.0 MVA 3 Phase Symmetrical on 807V AMBIENT AIR TEMP. a) Maximum : 500C b) Minimum : 40C ALTITUDE RELATIVE HUMIDITY (Max.) LIGHTNING DUST STORMS ATMOSPHERE : Below 1000M : 100% However, max. temperature and maximum humidity may not occur simultaneously, : Heavy during Monsoon : Severe during summer : Highly polluted

3.01 3.02 3.03 3.04 3.05

3.06 3.07 3.08 3.09 3.10 4.00

RATING, DESIGN DATA AND CONSTRUCTIONAL FEATURES The rectifier transformer shall conform to the following rating and design data

4.01 4.02 4.03 4.04 4.05 4.06 4.07

Quantity Required : Standard specification to be : followed Type of Transformer Rated output of HV winding Type of cooling Rated Frequency Winding Connections Primary Secondary : : : : :

One (1) Generally as per IS:2026 and/or relevant GOST/ accepted International Standard. Indoor, Step-down, three phase double wound (Primary & Secondary both), oil immersed, core type. 2X7912 KVA ON AF (Fan cooling) 50 cycles per second. 2X3 Phase, 11000V, (All terminals brought out through bushings 2x6 phases, for half wave rectification with I.P.T.
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4.08 4.09 4.10

% Impedance Rated voltage (for each winding) Vector group and diagram of connection: Active Part No. 1 Active Part No. 2

: :

9.05 11000V - Primary (line to line) 807V - Secondary (line to line) Y/Ymm-Y o 6 /Y-m-mY 5 11 drawing) 400C 500C Not less than class A Buchholz (gas) relay & explosion vent/ PRV (Pressure reducing valve) Motorized on load type tap changer with voltage variation in 16 Steps Full quantity + 5% extra, Insulating Oil (Transformer oil) for rectifier transformer shall be as per IS: 355-1953 with its latest amendments. The tank shall be absolutely oil tight and made of preferably with boiler plate. The tank shall with stand full vacuum in standard atmospheric condition. No valve shall drip and no weld shall sweat. The magnetic core shall be built of cold rolled grain oriented silicon steel laminations conforming to the standard specification of manufacturer. This rectifier transformer will not go under parallel operation at any stage.

: :

(Details may be seen in the Annexed 4.11 Maxm. allowable temp. rise over ambient :a) Oil : b) Winding : 4.12 Winding Insulation : 4.13 Type of protection : 4.14 4.15 Details of Tap changing Insulating Oil : :

4.16

Transformer Tank

4.17

Transformer Core

4.19

Parallel operation

5.3 Inspection and Testing 5.3.1 The inspection of equipments, components, fittings and mounting shall be carried out at the manufacturers premises. The contractor shall provide all necessary facilities to carry out stage inspection / final inspection and testing of the assembled equipments at the manufacturers premises.

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5.3.2 The inspection by the purchaser or his authorised representative / agency shall not relieve the contractor of his liability for rectifying any defects which may subsequently appear or be detected. 5.3.3 The inspection shall be carried out by the purchaser and/or his authorised representative after receiving 30 days clear advance notice. All routine test shall be witnessed by the purchaser at suppliers premises. 5.3.4 The routine and special tests on these transformer include but not limited to the following: Standard to be followed: As per IS 2026: 1977, IS 10028:1981 (with its latest amendments) and/or accepted International Standard. Certificates for all type tests shall be furnished by the manufacturer. Along with all routine tests under the routine dielectric test the following shall be conducted during inspection: 1) 2) 3) a) A separate source power frequency voltage withstand test. An induced over voltage with stand test. Other tests to be conducted during inspection include: Magnetic balance test

b) Measurement of zero sequence impedance. c) Measurement of harmonics on no load current. d) Measurement of power taken by fans and pumps. 5.4 Pre -commissioning tests 5.4.1 Pre-commissioning Tests shall be carried out by the representative of the Contractor. 5.4.2 The tests to be carried out on the equipment at pre- commissioning stage shall include but not limited to the following: 1) Voltage ratio and polarity for all taps. 2) Winding resistance for all taps. 3) Impedance voltage 4) Measurement of loss tangent. 5) No load losses.
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6) Checking of wiring at marshalling box. 7) Checking of Buchhoitz relay, magnetic oil level gauge, temp. indicators ( WTI & OTI ), silica gel breather etc. 8) Functional checking differential protection scheme and other transformer protection. 9) Checking of oil sample and all site tests on oil sample. 10) Magnetic balance test. 11) Vector group test. 12) Insulation resistance between windings & windings to earth. 13) Tests on load tap changers. 14) Physical inspection. 15) Earthing connections. 16) Polarity and matching with the existing system. 17) Differential protection operation. 5.5 All labour, tools, tackles and consumables required during erection, pre-commissioning test and commissioning will be provided by the Purchaser. The Contractor shall provide only supervision for these activities.

6.7

Details to be furnished by the Tenderer The tenderer shall submit/furnish the alongwith the Technical Bid of the Tender: following informations

i) Product manuals of various equipments with list of Users (In India/ Abroad), Performance certificates, etc.. All the technical parameters, dimensions, make and other details of various components and subassemblies of equipment under the scope of this tender shall be shown in these manual. ii) Relevant IS Standard/International standard for the entire equipment
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and sub-assemblies under the scope of this Tender. iii) All other documentary evidence and details as elaborated under Special Instruction to the Tenderer. 6.8 The tenderer shall submit alongwith his Tender a statement under his signature and official seal a list of similar equipment supplied to various parties in the past ten (10) years indicating the name of purchaser, value, order reference, the time period of delivery /execution. Spares for two years operation and maintenance for the proposed equipments and facility shall be indicated at one place alongwith the technical bid. Spare parts for two years of operation shall be quoted by the bidder and a detailed list of recommended spares shall be furnished. The offer of 2 yrs operational spares shall be valid for 2 years. Any vague stipulation such as Any other item not specifically mentioned in our scope of work will make the tender liable for rejection. The tenderer will state clearly and specifically all items of exclusions. Deviation from Tender specification, if any, shall be clearly stated under heading DEVIATIONS quoting the respective index and serial reference of the tender document and shall be furnished. The reasons for such deviations may also be explained in brief. The price offer for the transformer will be considered after capitalisation of losses. Loss capitalisation shall be done while assessing the techno commercial suitability of various offers. formula to be adopted for loss capitalisation shall be as follows: e = 8y considering discount rate per annum =12% life of transformer =30 years y = [IL(KW) X 8000+ CUL(KW) X 8000 X(X)2] X SCP X = load factor = 0.60 SCP = Specific cost of electricity

6.9

6.10

6.11

6.12

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IL = Iron loss CUL = Copper loss ANNEXURE-I TECHNICAL DETAILS & OTHER DATA OF RECTIFIER TRANSFORMER - TYPE T HPYX-40000/10T (EXISTING) Sl. No. 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2.0 2.1 2.2 Main Characteristics Rated Rated Rated Rated Rated Rated output of HV winding, KVA voltage of converter, V current of converter, A voltage of HV windings, V current of HV windings, A voltage of LV winding, V Data 2 x 7912 825 2 x 8000 11000 + 5% 2 x 415 Y - 807.3 - 804.8 2309 P H (Tap Changer in 16 Steps) Total 17 taps 415V 415V 50 3 Phase/2 x 6 phases for half wave rectification with I.P.T. of Y/Ymm-Yo 6 /Y-m-mY5 11 Fan cooling 380 95850 33450 42400 20000 Remarks

Rated current of LV winding, A Mode of voltage control Voltage of P H mechanism drive Voltage of cooling system drive Rated frequency, Hz Number of phases Primary Secondary Vector group connection: Active Part No. 1 and diagram

2.3

2.4 2.5 2.6

Active Part No. 2 Mode of cooling Permissible residual pressure in tank, mm Hg. Weight, Kg Total Oil Two Active Parts Removable Tank Portion (bell portion)

NOTE : Rectifier Transformer ratings are true for 16 steps of tap changer. 3.3 TRANSFORMER WINDING CAPACITANCE
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3.3.1 ACTIVE PART NO. 1 Measurements HV Winding - LV Winding and tankgrounded LV Windings - HV Winding and tankgrounded HV and LV Winding - tank grounded 3.3.2 ACTIVE PART NO. 2 Measurements HV winding - LV Winding and tank grounded LV Winding - HV Winding and tank grounded HV and LV Winding - tank grounded Temp. 0C 16 16 16 Capacitance, PF 15200 8450 11800 Temp. 0C 16 16 16 Capacitance, PF 15700 8830 11500

3.4

TEST DATA ON LOSSES, % IMPEDANCE ETC.

3.4.1 ACTIVE PART NO. 1 Short circuit losses at 750C Impedance voltage at 750C No Load Losses No Load Current Iron Losses of IPT at 150 HZ and 545V Copper Losses of IPT at 150 HZ & 4000A 3.4.2 ACTIVE PART NO. 2 Short Circuit Losses at 750 C Impedance Voltage at 750C No load losses No Load Current Iron Losses of IPT at 150 Hz & 545V Copper losses of IPT at 150 Hz & 4000 A 57050W 8.95% 18000W 0.826% 3000W 11900W 57250 W 9.0% 18000W 0.848% 2830W 11900 W

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3.5

No Load Losses at transformer excitation by voltage of 380V at HV Winding

3.5.1 ACTIVE PART NO. 1 Supplied phases BC Short Circuit phase A Supplied phases AC Short Circuited phase B Supplied phases AB Short Circuited phase C 5.2 ACTIVE PART NO. 2 Supplied phases BC Short Circuit phase A Supplied phases AC Short Circuited phase B Supplied phases AB Short Circuited phase C 3.6 22 W 22 W 29.5 W 17.8W 23.3W 17.8W

Insulation Test by overrating voltage at 50 Hz (duration 1 minute)

3.6.1 ACTIVE PART NO. 1 HV winding ------ LV winding and tank grounded. LV winding -- HV winding & tank grounded LV winding (each) - windings and tank grounded. Between interphase transformer branches 3.6.2 ACTIVE PART NO. 2 HV winding -- LV winding and tank grounded. LV winding -- HV winding & tank grounded LV winding (each) - windings and tank grounded. Between interphase transformer branches 45 KV 8 KV 8 KV 8 KV ANNEXURE-II 45 KV 8 KV 8 KV 8 KV

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Standard Accessories and Fittings to be attached are as shown below and the fittings shall be as per IS 3639 : 1966. 1) 2) 3) 4) 5) Oil conservator with plain oil gauge, drain valve and oil gauge, drain valve and oil filling hole with cover. Pressure releasing device with detector. Oil sealed dehydrating silica gel breather. Thermometers; 1 No. stem type with slot (pocket) Dial type indicator (size 150 mm) with capillary tubing for oil temperature with maximum temperature indicator and Alarm/Trip contacts. One on local marshalling box and the other on remote tap changer panel. Dial type indicator (size 150 mm) with capillary tubing for winding temperature with maximum temperature indicator and Alarm/Trip contacts. One on local marshalling box and the other on remote tap changer panel. ON load tap changer with motor control from remote. Earthing terminals (2 Nos.) One No. double float Buch holtz relay with shut off valve on conservator side and other provisions for instruments and controls. Additional single float buchholtz relay shall be provided. Explosion vent. (Double diaphragm type) Filter valves (top and bottom). Sampling valves both at top and bottom. Shut off valves for radiators and conservator. Drain valve with cover plate Lifting lugs & jacking lugs. Rating & diagram plate with terminal markings. Flanged rollers suitable for rail gauge with appropriate arrangement for 900 lateral shift. Radiators/cooling tubes : Detachable with valves. Inspection cover for Tap switch and the transformer.
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6)

7) 8) 9)

10) 11) 12) 13) 14) 15) 16) 17) 18) 19)

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20) 21)

Oil level gauge (magnetic operated) with low oil level alarm and markings of max., min. and filling levels and oil level indicators. Cat ladder for approaching the top. ANNEXURE-IV SCHEDULE OF EQUIPMENT / WORK

Sl. No. 1.

Item Description Design, Manufacturing, Supply & Testing before commissioning of 11 kV / 807 Volt/807 Volt ; 40 MVA ON AF (Fan Cooling) Indoor Rectifier Transformer as per TS.

Unit No.

Qty. 1

SCHEDULE - I

LIST OF COMMISSIONIG SPARES 1) 2) 3) 4) 5) 6) 7) 8) HT Bushing - 03 nos. LT Bushing - 06 nos. Neutral Bushing - 02 nos. IPT Terminal Bushing - 02 nos. Electric Motor for Tap changer - 01 no. Filter Valve - 01 no. Shut off Valve for Radiator - 03 nos. Drain Valve 01 no.

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