Section-11

250 KVA and 100KVA,33kV/400V Station Transformers

1 SCOPE: Refer Clause-I of Section-I; General

This Specification covers design, manufacture, assembly, shop

testing, forwarding and delivery F.O.R. destination of
250 KVA, 33 kV/400 Volts Station Transformers. The prices quoted
shall be FIRM.

2 STANDARDS:

Except otherwise specified or implied herein the station transformers shall comply in all respects
with the latest applicable IS-2026 and CBIP manual on transformers.

3 TYPE AND RATING:

The transformers shall be of core type, three phase, oil immersed and shall be suitable for outdoor
service under the service conditions indicated in clause 1.8 of this specification. The transformers
are normally used as step down transformers.

The required rating electrical characteristics of station Transformers are furnished below:

a) Type : Core type 3 phase oil immersed outdoor

type.

b) Rated KVA : 250 KVA 100KVA

c) Service : Outdoor as step down

d) No.of phases in the system : Three

e) Frequency : 50 Hz.

f) i) Double wound or Auto Transformers : Double wound

ii)Winding conductor material : Copper

iii) Winding connections : a) HV Delta

b) LV Star

g) Type of cooling medium : Mineral oil

h) Rated Voltage:

i) Higher voltage winding : 33 kV

ii) Lower voltage winding : 400 Volts

i) Highest System Voltage :

i) Highest System Voltage : 36KV

ii) Lower Voltage System : As per IS:2026

j) Method of System Earthing : Solidly Earthed Neutral

k) Insulation level of winding :

a) 33 kV windings : 170 kV

b) Lower Voltage winding : As per IS:2026

l) Power Frequency voltage

a) 33 kV Windings : 70 kV

b) Lower Voltage winding : As per IS:2026

m) Vector relation ship

required between windings
and Vector symbol : Dy 11

n) Tap changing : off circuit

o) Tapping shall be provided in

Higher voltage winding for : 0.0 to-10% in variation of lv voltage 2.5% steps

p) Type of Cooling : ONAN

q) Impedance Voltage at 75 deg C

with (+10% Tolerance as per/
ISS:2026 : 5%
r) Stabilising Winding : Not required

s) Whether Neutral Terminals

are to be brought out:

i) Higher Voltage winding : No

ii) Lower Voltage winding : Yes

4. Technical Requirements

4.1 The following no load loss and copper loss in watts at rated voltage, frequency and output shall be
guaranteed under penalty.
250kV 100kVA
No load loss (Watts) : 675 + IS tol 325+ IS tol
250kV 100kVA
Copper loss (Watts) : 3600 + IS tol 1650+ IS tol

For the purpose of penalty computations, the test figures of the losses will be compared with the
corresponding guaranteed figures. No tolerance is permitted over the test figures of the losses.
The penalties shall be calculated at the following rates.

i) Penalty for no load loss : Rs.2,08,848 }{

}{ per
ii) Penalty for copper loss : Rs.83,540 }{ KW

For fraction of kilowatt, penalties shall be applied prorata. For the purpose of comparison of
tenders, the quoted prices shall be capitalised for the transformer losses at the following rates per
KW.

No load loss .. Rs.1,04,424

Copper loss .. Rs.41,770
 If the guaranteed losses are subject to plus tolerance, the maximum tolerance shall be added to the
losses in computing the capitalised costs. The maximum plus tolerance applicable may please be
stated clearly in the tender.

4.2 The temperature rise of the windings, core and oil of the transformer shall not exceed the specified
limits in latest IS:2026 and the guaranteed values shall be furnished in the Tender submitted.

4.3 CORE:

The core shall be built up with high grade non-ageing, low loss and high permeability CRGO
Silicon, steel laminations specially suitable for transformer cores. The laminations shall be treated
to remove all burrs and shall be reannealed to remove all residual stresses. Each lamination shall
be coated with a durable,black enamel insulation coating which shall be inert to the action
of hot transformer oil. Paper and varnish insulation will not be accepted. The nature of
nsulation should specified in the Tender.

The core shall be tightly clamped and bolted to ensure adequate mechanical strength and to
prevent vibration during operation. The bolts used in the assembly of the core shall be suitably
insulated and clamping structure shall be so constructed that eddy current will be minimum.

The core shall be provided with lifting lugs suitable for lifting the complete core and coil
assembly of the Transformer.

The core and the coil shall be so fixed in the tank that shifting will not occur when the transformer
is moved or during a short circuit.

The transformers shall be suitable for over fluxing (due to combined effect of the voltage and
frequency) upto 12.5% on any tappings without core heating. The maximum flux density in any
part of the core under such conditions shall not exceed 1.9 tesla.

4.4 WINDING:

The windings shall be so designed that all the coil assemblies of identical voltage ratings shall be
interchangeable and field repairs to the windings can be made readily without special equipment.
The coils shall be supported between adjacent sections by insulating spacers and barriers, bracings
and other insulation used in the assembly of the windings shall be treated with suitable insulating
varnish or equivalent compound to develop the full electrical strength of the windings. All
materials used in the insulation and assembly of the windings shall be insoluble non-catalytic and
chemically inactive in the hot transformer oil and shall not soften other-wise be adversely affected
under the operating conditions.

All threaded connections shall be provided with locking facilities. All leads from the winding to
the terminal board and bushings shall be rigidly supported to prevent injury from vibration.

The windings shall be clamped securely in place so that they will not be displaced or disturbed
during short circuits. The assembled core and windings shall be vacuum dried and suitably
impregnated before removal from the treating tank.The conductors used in the coil structure shall
be best suited to the requirements and all permanent current carrying joints in the windings and
the loads shall be welded or brazed.

4.5 INSULATING OIL:

The oil for first filling shall be supplied with each transformer. The oil shall comply in all
respects with the provisions of latest IS:335.

4.6 TANK:

The transformer tank and cover shall be fabricated from good commercial grade low carbon steel
suitable for welding and of adequate thickness. The tank and the cover shall be welded
 construction. The main tank body shall have sufficient strength to withstand without permanent
distortion (1) filling by vacuum at 750 mm mercury without oil and (2) continuous internal gas
pressure of 0.35 atmospheres upto operating level of oil. The tank cover shall be bolted to the
tank and the transformer design shall be such that the tank will not be split between the lower and
upper cooler connection for untanking.

All bolted connections to the tank shall be fitted with suitable oil tight gaskets which shall give
satisfactory services under the operating conditions. Special attention shall be given to the
method of making the hot oil tight joints between the tank and the cover, also between the cover
and the bushings and all other outlets to ensure that the joints can be remade satisfactorily with
the help of semiskilled labour. Where compressable gaskets are used, steps shall be provided to
prevent over compression.

Suitable guides shall be provided for positioning the various parts during assembly or dismantling.
Adequate space shall be provided between the cores and the windings and the bottom of the tank
for collection of any sediment.

Lifting eyes or lugs shall be provided on all parts of the transformer requiring independent
handling during assembly or dismounting. In addition, the transformer tank shall be provided
with lifting lugs properly secured to the sides of the tank, for lifting the transformer either by
crane or by jacks.

The design of the tank, the lifting lugs and boxes shall be such that the complete transformer
assembly filled with oil can be lifted with the use of four lugs without any damage or distortions.

The tank shall be provided with two suitable copper alloy lugs for the purpose of grounding.

The tank shall have two filter valves, one at the bottom at one end and one at the top at the
opposite end.

The transformer tank shall be supported on a structural steel frame with forged steel or cast steel
single flanged wheels suitable for moving the transformer completely filled with oil.

4.7 TAPS:

Tappings shall be provided in high voltage 0.0 to - 10% winding to obtain a voltage variation
insteps of 2.5% on low voltage side. The transformer shall give full load on all taps.

Tap changing shall be carried out by means of an externally operated self positioning switch and
when the transformer is in de-energised condition. Switch position No.1 shall correspond to the
maximum plus tappings. Provision shall be made for locking the tapping switch handle in
position.

4.8 OIL PRESERVING EQUIPMENT:

The conservator shall have a shut off valve and sump with a small drain valve and stop cock.

A Silicagel breather shall be provided for each conservator vessel. The external atmosphere shall
not be in continuous contact with the Silicagel.

4.9 BUSHINGS;

The bushings shall have high factors of safety against leakage to ground and shall be so located as
to provide adequate electrical clearances between bushings and grounded parts. Bushings of
identical voltage and current rating shall be inter changeable. All bushings shall be equipped
with suitable bushes of approved type and size and all external current carrying contact surfaces
shall be silver plated adequately.

All the main winding leads shall be brought out through outdoor type bushings which shall be
located such that the full flash over strength will be utilised and the adequate phase clearance shall
be realised.
 Each bushing shall be so co-ordinated with the transformer insulation, that all flash-overs will
occur outside the tank.

All porcelain used in bushings shall be of the wet process, homogenous and free from cavities or
other flaws. The glazing shall be uniform in colour and free from blisters, burrs and other defects.

All bushings shall have puncture strength greater than the dry flash over value. The spacing
between the bushing shall be adequate to prevent flash over between phases under all conditions
of operation.

The bushings used shall comply with IS:2099 and the dimensions for the following voltage
classes shall conform to latest ISS mentioned against them.

Indian standard For metal

Voltage classes Specification parts
for porcelain parts.

upto 11 kV IS:3347 part-I IS:3347 Part-I

Section .. 1965 Section .. 1967

36 kV IS:3347 part-V IS:3347 Part-V

Section .. 1973 Section .. 1967

4.10 CENTRE OF GRAVITY:

The centre of gravity of the assembled transformer shall be low and as near the vertical centre
line as possible. The transformer must be stable with or without oil.

4.11 ACCESSORIES:

The supply shall include the following with each transformer.

a) First filling of oil conforming to ISS:335.

b) FITTINGS AND ACCESSORIES:

i) Rating and terminal making plates.

ii) Earth terminals .. 2 Nos.

iii) Lifting lugs.

iv) Main oil guage.

v) Drain valve with plug or cover plate .. 20 mm dia.

vi) Thermometer pocket.

vii) Air release plug.

viii) Oil conservator with drain plug and oil filling hole with blanking flange.

ix) Pressure relief vent.

 x) Silicagel breather.

xi) Top filling valve with plug or cover plate (32mm dia.)

xii) Mounting channel and plain rollers.

xiii) Lock with keys in duplicate for externally

operated tap switch.

xiv) H.V.Outdoor bushings.

xv) L.V.Outdoor bushings.

xvi) Oil level indicator.

The transformer shall be supplied with all the accessories and fittings for normal operation
whether they are mentioned above or not and the transformer shall be complete in itself.

4.12 PAINTING:

Before despatch all steel works not under oil shall be painted with a primary coat of anti-corrosive
paint of durable nature and two coats of dark admiral grey paint. The interior surfaces shall be
painted according to the manufacturers standard practice.

PACKING:

The packing may be in accordance with tenderers standard practice to withstand the
transportation.

4.13 TERMINALS:

H.V.Transformer terminal shall be suitable for connecting Zebra/Deer conductor and L.V.
terminals for connecting PVC Aluminium power cable.

4.14 CLEARANCE:

The minimum clearance in air shall be as follows ( as per CBIP Manual)

------------------------------------------------------------------------------------------------------------------
Clearance phase
Voltage Medium to phase in mm
--------------
Open Enclosed
---------------------------------------------------------------------------------------------------------------
400 volts AIR 40 25

33 kV AIR 350 -
--------------------------------------------------------------------------------------------------------------

4.14 GUARANTEED TECHNICAL AND OTHER PARTICULARS:

The Guaranteed technical and other particulars of the transformers shall be furnished in the
proforma given in annexure.

In case bidders can not furnish Guaranteed Technical Particulars along with the bid, they should
submit an undertaking that they would furnish Guaranteed Technical Particulars shortly.
 5. Transformers of similar ratio shall operate satisfactily in parallel with each other,if connected between
high voltage and loe voltage bus bars.

6.0 TESTS :

a) All the offered equipment shall be fully type tested by the bidder as per the relevant standard. The
type tests must have been conducted on the similar or higher capacity of HV voltage class of
transformers not earlier than 1995. The bidder shall furnish two sets of the following type test
reports as per relevant standards for each type of equipment offered along with the bid.

i) Impulse Test on one phase HV & LV limbs

ii)Temperature rise test

iii)Tank pressure and vacuum test.

In case bidders can not furnish type test reports along with the bid, they should mention
the make of the equipment/material in the Technical bid and they should submit an
undertaking that they would furnish type test reports shortly and adhere to supply the
make of equipment indicated in the bid.

b) Special tests other than type and routine tests, as agreed between Purchaser and Bidder shall
also be carried out as per IS: 2026. with latest amendments.

c) The pre-shipment checks to be carried out by the Bidder are given under clause 7.0, "Inspection".

6.1 Routine tests

All standard routine test in accordance with IS:2026, with dielectric tests corresponding to
Method 2 as per amendment No.1 issued in September,1980 to IS:2026 and latest amendments
shall be carried out on each transformer.

Operation and dielectric testing of OLTC shall be carried out as per IS: 2026 and latest
amendements.

Following additional routine tests shall also be carried out on each transformer :

a) Magnetic Circuit Test

After assembly, each core shall be tested for 1 minute at

2000 Volts between all bolts, side plates, structural
steel work.

b) Oil leakage test on transformer tank

c) Measurement of capacitance and tan delta to determine capacitance between winding & earth.
This measurement shall be carried out before and after series of dielectric tests.

6.2 High voltage withstand test shall be performed on auxiliary equipment and wiring after
complete assembly.

6.3 Tests on terminal connectors

Terminals connectors shall be tested as per IS: 5561. In addition, the Bidder shall carry out an
additional test to demonstrate withstand capacity of wind load. The test procedure and
acceptance norms shall be furnished for Purchaser's approval.
6.4 Test reports

a) Four (4) sets of certified test reports and oscillograms shall be submitted for approval prior to
despatch of the equipment. The equipment shall be dispatched only when all the required type and
routine tests have been carried out and test reports have been approved by the Purchaser.

b) Four (4) copies of the test reports for the tests carried out on the ancillary apparatus shall be
furnished to the Purchaser for approval prior to despatch.

c) All auxiliary equipment shall be tested as per the relevant standard. Test certificate shall be
submitted for bought out items.

7.0 INSPECTION

7.1 General

i) The owner shall have access at all times to the works and all other places of manufacture
where the transformers are being manufactured and the Bidder shall provide all facilities for
unrestricted inspection of the Bidder's works, raw materials, manufacture of all the accessories
and for conducting necessary tests as detailed herein.

ii) The successful Bidder shall keep the Purchaser informed in

advance of the time of starting and of the progress of
manufacture of equipment in its various stages so that
arrangements could be made for inspection.

iii) No material shall be dispatched from its point of manufacture unless the material has been
satisfactorily inspected and tested.

iv) The acceptance of any quantity of equipment shall in no way relieve the successful Bidder of his
responsibility for meeting all the requirement of this specification and shall not prevent
subsequent rejection if such equipment are later found to be defective.

7.2 Inspection programme

a) The Bidder shall chalk out a detailed inspection and testing programme for manufacturing
activities for the various components. An indicative programme of inspection as envisaged by
the Purchaser is given in Annexure-III. This is not however intended to form a comprehensive
programme as it is Bidder's responsibility to draw up and carry out such a programme duly
approved by the Purchaser. The owner reserves the right to carryout any tests by a third
party.

b) Cost of inspection/tests and third party inspection if any shall be borne by the Bidder.

c) Additional tests, if required, are deemed to be included in the scope of work.

d) Stages of inspection and Purchaser's participation would be defined and tied up at

the time of award of contract.

8.0 QUALITY ASSURANCE PLAN :

8.1 The bidder shall invariably furnish the following information along with his
offer failing which the offer shall be liable for rejection. Information shall
be separately given for individual type of equipment offered.

a) The Structure of organization

b) The duties and responsibilities assigned to staff ensuring quality of work

c) The system of purchasing, taking delivery and verification of materials

d) The system for ensuring quality of workmanship

e) The quality assurance arrangements shall confirm to the relevant requirement of ISO-9001 on ISO 9002 as
applicable.

vi) Statement giving list of important raw materials, names of sub-supplies for the raw materials, list of
standards according to which the raw material are tested, list of tests normally carried out on raw
material in the presence of suppliers representative, copies of test certificates.

vii) Information and copies of test certificates as on (i) above in respect of bought out items.

viii) List of manufacturing facilities available

ix) Level of automation achieved and list of areas where manual processing exists.

x) List of areas in manufacturing process, where stage inspections are normally carried out for
quality control and details of such tests and inspections.

xi) List of testing equipment available with the bidder for final testing of equipment specified and test plant
limitation, if any vis-a-vis the type. Special acceptance and routine tests specified in the relevant
standards. These limitations shall be very clearly brought out in "Schedule of Deviations" from
the specified test requirements.

8.2 The Contractor shall within 30 days of placement of order, submit the following information to the
purchaser.

i) List of the raw material as well as bought out accessories and the names of sub-suppliers selected
from those furnished along with the offer.

ii) Type test certificates of the raw material and bought out accessories if required by the purchaser.

iii) Quality Assurance Plan (QAP) with hold points for purchasers inspection. QAP and purchasers hold
points shall be discussed between the purchaser and contractor before the QAP is finalised.

The contractor shall submit the routine test certificates of bought out accessories and central excise asses
for raw material at the time of routine testing if required by the purchaser and ensure that the quality
assurance requirements of specification are followed by the sub-contractor.

8.3 The Quality Assurance Programme shall give a description of the Quality System and Quality Plans with
the following details.
a) Quality System:

* The Structure of the Organisation

* The duties and responsibilities assigned to staff ensuring quality of work.
* The system of purchasing, taking delivery of verification of materials.
* The system of ensuring of quality workmanship.
* The system of control of documentation.
* The system of retention of records.
* The arrangement of contractor internal auditing.
* A list of Administrator and work procedures required to achieve contractors quality
requirements. These procedures shall be made readily available to the purchaser for
inspection on request.

b) Quality Plans:

a. An outline of the proposed work and program sequence.

b. The structure of contractors organizations for the contract.
c. The duties and responsibilities ensuring quality of work
d. Hold and notification points.
 e. Submission of engineering documents required by this specification.
f. The Inspection of the materials and components on request.
g. Reference to contractors work procedures appropriate to each activity.
h. Inspection during fabrication/construction.
i. Final inspection and test.

9.0 DOCUMENTATION:

9.1 i) The Bidder shall furnish along with the bid the dimensional drawings of transformer, GA
and all other accessories.

ii) These drawings shall include the following information.

a) Detailed internal drawings of transformer clearly indicating insulation, core

assembly and windings duly incorporating all important dimensions.

b) Tolerances on dimensions.

c) Material designation used for different components with reference to standards.

d) Fabrication details such as welds, finishes and coatings.

e) Catalogue or part numbers for each component and the total assembly with bill of materials.

f) Identification marking.

g) Weight of individual components and total assembled weight.

iii) The assembly drawings shall include the following:

a) Brief installation instructions.

b) Design installation torque for the bolt or cap screw.

c) Withstand torque that can be applied to the bolt or cap screw without failure of
components or parts thereof.

d) Compression die number with recommended compression pressure.

e) Relevant technical details of significance.

9.2 Test Reports

i) Four copies of type test reports shall be furnished to the Purchaser within one month of
conducting the tests. one copy will be returned duly certified by Purchaser to the Bidder
within three weeks thereafter and on receipt of the same Bidder shall commence with
the commercial production of the concerned material.

ii) Four copies of acceptance test reports shall be furnished to the Purchaser. One copy
will be returned duly certified by the Purchaser and only thereafter shall the materials be
dispatched.

iii) All records of routine test reports shall be maintained by the Bidder at his works for
periodic inspection by the Purchaser.

iv) All test reports for tests conducted during manufacture shall be maintained by the Bidder.
These shall be produced for verification as and when requested for by the Purchaser.
9.3 All drawings shall conform to International Standards Organization (ISO) 'A' series of
drawing sheet/Indian Standards Specification. All drawings shall be in ink and suitable for
micro filming. All dimensions and data shall be in S.I. Units only.

The Bidder shall within 2 weeks of placement of order, submit four sets of final versions of
all the above drawings for Purchaser's approval. The Purchaser shall communicate his
comments/approval on the drawings to the Bidder within reasonable time. The Bidder shall,
if necessary, modify the drawings and resubmit four copies of the modified drawings for
Purchaser's approval within two weeks from the date of Purchaser's comments.

After receipt of Purchaser's approval, the Bidder shall within three

weeks, submit 6 prints and two good quality reproducible of the
approved drawings for Purchaser's use.

9.4 Adequate copies of contract drawings, acceptance and routine test certificates, duly approved by
the Purchaser shall accompany each of the dispatched consignment.

9.5 The manufacturing of the equipment shall be strictly in accordance with the approved
drawings and no deviation shall be permitted without the written approval of the Purchaser.
All manufacturing and fabrication work in connection with the equipment prior to the approval
of the drawing shall be at the Bidder's risk only.

9.6 Six copies of nicely printed and bound volumes of operation, maintenance and erection
manuals in English language shall be supplied by the Bidder along with each Transformer
to destination. The manual shall contain all the drawings and information required for erection,
operation and maintenance of the transformers. The manual shall also contain a set of all the
approved drawings, type, routine & acceptance Test reports etc.

9.7 Approval of drawings by the Purchaser shall not relieve the Bidder of his responsibility and
liability for ensuring correctness and correct interpretation of the latest revision of applicable
standards, rules and codes of practices. The equipment shall conform in all respects to high
standards of engineering, design, workmanship and latest revisions of relevant standards at
the time of ordering and the Purchaser shall have the power to reject any material which in
his judgement is not in full accordance therewith.

10.0 PACKING AND FORWARDING: Refer Clause-4 of Section-I, General

11.0 QUANTITY AND DELIVERY REQUIREMENTS : Refer Clause-3 of Section-I, General l

The scope of supply shall include a supply of 2.5% extra quantity of bolts, nuts, washers, split pins, cotter pins
and such other small loose items free of cost.

12.0 Supervision Services: Refer Clause-6 of Section-I, General

TO BE FILLED BY THE BIDDER

ANNEXURE - 1
GUARANTEED TECHNICAL PARTICULARS-250 kVA 33kV/400V STATION TRANSFORMERS
----------------------------------------------------------------------
SL. Particulars
NO.
----------------------------------------------------------------------
1. Make :

2. Normal full load output :

 (KVA)

3. i)Type of Transformer :

ii) Winding type (HV & LV) :

iii) Material :

4. Type of cooling :

5. Indoor or Outdoor :

6. Rated high voltage (V) :

7. Rated low voltage (V) :

8. Connection and vector group :

9. Maximum temperature rise of :

i) Winding by resistance :
.. (oC)

ii) Oil by thermometer :

.. (oC)

iii) Maximum ambient air :

temperature .. (oC)

10. Core loss at normal

voltage and frequency :
(KW)

11. Copper loss at normal :

voltage and current (KW)

12. Impedance (Percentage) :

13. Tap changer
i) Make :
ii) Type :
iii) Indicator arrangement :
iv) Packing arrangement :
v) Other details :
14. Tapping on HV side for LV :
variation.

15. Impulse strength of HV

winding :

16. Impulse strength of LV

winding :

17. Overall dimensions of

transformer in mm :

18. Approximate weight of :

i) Core cum windings (Kg) :

ii) Oil (Kg) :
iii) Complete transformer :
with all fittings and
including oil (Kg)
19. Type of tank :

20. Make and type of breather :

fitted to the transformer

21. Particulars of bushings :

i) Country of origin :
ii) Rating :
iii) Types :

HV bushings :
LV bushings :

iv) Impulse and flashover

voltages :

22. Efficiency at u.p.f. and :

0.8.p.f.

23. Regulation at full load :

u.p.f. and 0.8.p.f.

24. Terminal arrangements of :

bushings (HV and LV)

25. Mounting arrangement for :

the transformer

26. List of fittings and :

accessories provided.
SIGNATURE OF THE BIDDER
WITH DATE & SEAL