Technical Specification

SECTION- TRANSFORMER
(UPTO 400 KV CLASS)

REV 11

FEB’ 2017
 Major changes in the latest Technical Specification
Section – Transformer (Upto 400kV Class) REV 11

Sr. No. Clause Brief description of major changes

i) 2.6 Transportation of Transformer with 2 nos. of electronic impact recorders.

ii) 5.4 Condition of validity of type test on Transformer

iii) 6.11 & 6.12 Remote OTI & WTI has been removed, provision of only 4-20mA signal from
OTI & WTI for SCADA integration

iv) 6.15.4 Provision for earthing of Neutral, HV and IV terminals to grounding mat in
case transformer is not in service

v) 8.3.5 To have better clarity it is mentioned that the Ultra High Vacuum type oil
treatment plant shall be on returnable basis

vi) 9 Spare Transformer Units Connection Arrangement

vii) 10.13 Clause for replacement of bushing within the warrantee period added
&
10.14

viii) 11 & 12 Connection of Neutral bushing to neutral bus through flexible twin conductor.
Tertiary/LV Jumpers wherever provided shall be insulated using suitable
insulation tape or sleeve

ix) 13.2.1 Quantity of standby fan for each bank changed to one number.

x) 14.2 Cable connection of Spare unit and relevant drawing modified

xi) 15.2 ON Load Tap Changing (OLTC) Equipment (Vacuum or Oil type)

xii) 15.4 Digital RTCC Panel specification

xiii) 18.1 Compliance of current transformers as per IEC-61869-1 and 61869-2.

xiv) 22.2 Requirement of type tests on fittings has been modified

xv) Annexure-A Maximum Permissible Losses of Transformers added

Insulation level of 132kV class transformer has been revised
Disclaimer:
Major changes are listed above. However, for details of all major and minor modifications, please
refer the complete technical specification Section - Transformer (Upto 400kV Class) Rev 11.

Technical Specification: Section -Transformer (Upto 400kV Class) Page 2 of 113

C/ENGG/MODEL-SPEC/TRF Rev. 11
 CONTENTS
SECTION- TRANSFORMER (UPTO 400 KV CLASS)

Clause No. Description

1. General
2. Transportation
3. Performance
4. Measurable Defects
5. Design review
6. Construction Details
7. Paint system and procedures
8. Unused inhibited Insulating Oil
9. Spare Transformer Units Connection Arrangement
10. Bushings
11. Neutral Formation and Earthing Arrangement.
12. Delta Formation
13. Cooling Equipment and its Control
14. Cabling
15. Tap Changing Equipment
16. SCADA Integration
Constructional features of Cooler Control Cabinet/ Individual Marshalling Box/ Common
17. Marshalling Box/ Junction Box / Outdoor cubicle and Digital RTCC Panel

18. Current Transformer

19. Hand Tools

20. Test Kit
21. Fittings & accessories
22. Inspection and Testing
Annexure –A Technical Particulars / Parameters of Transformers
Annexure –B Test Plan
Annexure –C Test Procedures
Annexure –D Reference Drawings
Annexure –E Design Review Document
Annexure –F Painting Procedure
Annexure –G Unused inhibited Insulating Oil Parameters
Annexure–H Technical parameters of Current Transformers
Annexure–I Cable specification
Annexure–J BDV Test Set & Portable Dissolved Gas Analysis of Transformer Oil
Annexure–K Online Dissolved Gas (Multi-gas) and Moisture Measuring Equipment
Annexure–L Online Hydrogen and Moisture Measuring Equipment
Annexure–M On-line insulating oil drying system (Cartridge type)

Annexure–N Nitrogen Injection Type Fire Prevention & Extinguishing System

Annexure –O Oil sampling bottles & Oil Syringe
Annexure –P Oil Storage Tank
Annexure–Q Spare Transformer Units Connection Arrangement

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 TECHNICAL SPECIFICATION
SECTION: TRANSFORMER (UPTO 400kV CLASS)

1. General

1.1. This specification covers design, engineering, manufacture, testing, delivery at site
including all materials, accessories, spares, unloading, handling, proper storage at site,
erection, testing and commissioning of the equipment specified.

1.2. The transformers shall in general have constant ohmic impedance between HV and IV
on all taps. However, in case of parallel operation with the existing transformer,

i) The percentage impedance, vector group, OLTC connection and range etc. of
the transformer is to be matched with that of the existing transformer.

ii) Necessary provision is to be kept in the transformer control scheme for parallel
operation with the existing OLTC control scheme having provision of
Master/Follower/Independent /Off operation etc.

iii) External or internal reactors shall not be used to achieve the specified HV/LV
and IV/LV impedances

1.3. Matching of physical orientation, mounting rail gauge etc. shall be done to facilitate
inter-changeability.

2. Transportation

2.1. The Contractor shall be responsible to select and verify the route, mode of
transportation and make all necessary arrangement with the appropriate authorities for
the transportation of the equipment. The dimension of the equipment shall be such that
when packed for transportation, it will comply with the requirements of loading and
clearance restrictions for the selected route. It shall be the responsibility of the
contractor to coordinate the arrangement for transportation of the transformer for all the
stages from the manufacturer’s work to site.

2.2. The contractor shall carry out the route survey along with the transporter and finalise
the detail methodology for transportation of transformer and based on route survey; any
modification/ extension/ improvement to existing road, bridges, culverts etc. if
required, shall be in the scope of the contractor.

2.3. The inland transportation of the Transformer shall be on trailers equipped with GPS
system for tracking the location of transformer at all times during transportation from
manufacturer works to designated site. The contractor shall intimate to Employer about
the details of transporter engaged for transportation of the Transformer for tracking the
Transformer during transit. Requirement of Hydraulic trailer is envisaged for 400kV
class Transformers.

2.4. All metal blanking plates and covers which are specifically required to transport and
storage of the transformer shall be considered part of the transformer and handed over
to the Purchaser after completion of the erection. Bill of quantity of these items shall be
included in the relevant drawing/document.

2.5. The Contractor shall despatch the transformer filled with dry air at positive pressure.
The necessary arrangement shall be ensured by the contractor to take care of pressure
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 drop of dry air during transit and storage till completion of oil filling during erection. A
dry air pressure testing valve with necessary pressure gauge and adaptor valve shall be
provided. Generally, the duration of the storage of transformer at site with dry air, shall
preferably be limited to three months, after which the Transformer shall be processed
as per the recommendation of manufacturer if not filled with oil. The dry air cylinder(s)
provided to maintain positive pressure can be taken back by the contractor after oil
filling.

In case turret, having insulation assembly, is transported separately then positive dry air
pressure shall be ensured.

2.6. Transformer shall also be fitted with Electronic impact recorders (on returnable basis)
at least 2 numbers for 400kV Class Transformer and 1 number for below 400kV class
Transformers during transportation to measure the magnitude and duration of the
impact in all three directions. The mounting location of impact recorder shall be
finalised during detailed engineering. The acceptance criteria and limits of impact,
which can be withstood by the equipment during transportation and handling in all
three directions, shall not exceed“3g” for 50mSec (20Hz) or as per contractor standard,
whichever is lower.

3. Performance

3.1. The transformers shall be used for bi-directional flow of rated power. The major
technical parameters of single phase and three phase transformer units are defined at
Annexure – A.

3.2. Transformers shall be capable of operating under natural cooled condition up to the
specified load. The forced cooling equipment shall come into operation by pre-set
contacts of winding temperature indicator and the transformer shall operate as a forced
cooling unit initially as ONAF up to specified load and then as OFAF. Cooling shall be
so designed that during total failure of power supply to cooling fans and oil pumps, the
transformer shall be able to operate at full load for at least ten (10) minutes without the
calculated winding hot spot temperature exceeding 140 deg C. Transformers fitted with
two coolers, each capable of dissipating 50 per cent of the loss at continuous maximum
rating, shall be capable of operating for 20 minutes in the event of failure of the oil
circulating pump or blowers associated with one cooler without the calculated winding
hot spot temperature exceeding 140deg C at continuous max rating. The contractor
shall submit supporting calculations for the above and the same shall be reviewed
during design review.

3.3. The transformer shall be free from any electrostatic charging tendency (ECT) under all
operating conditions when all oil circulation systems are in operation. In general, oil
flow speed shall not exceed 1.0 m/sec within winding in the oil flow system of the
transformers. The manufacturer shall ensure that there is no electrostatic charging
tendency in the design.

3.4. The transformers shall be capable of being continuously operated at the rated MVA
without danger, at any tapping with voltage variation of ±10% corresponding to the
voltage of that tapping.

3.5. The transformers shall be capable of being over loaded in accordance with IEC-60076-
7. There shall be no limitation imposed by bushings, tap changers etc. or any other
associated equipment.

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3.5.1. Tank hotspot shall not exceed 130 Deg. Celsius. Maximum ambient temperature shall
be considered as 50 Deg. C.

3.6. The transformer and all its accessories including bushing/ built in CTs etc. shall be
designed to withstand without damage, the thermal and mechanical effects of any
external short circuit to earth and of short circuits at the terminals of any winding for a
period of 2 secs. The short circuit level of the HV & IV System to which the
transformers will be connected is as follows:

400kV system - 63kA for 1 sec (sym, rms, 3 phase fault)

220kV system - 40 kA for 1 sec (sym, rms, 3 phase fault)
132kV system - 31.5 kA for 1 sec (sym, rms, 3 phase fault)
66kV system - 31.5 kA for 1 sec (sym, rms, 3 phase fault)
33kV system - 25 kA for 1 sec (sym, rms, 3 phase fault)

However, for transformer design purpose, the through fault current shall be considered
limited by the transformer self-impedance only (i.e. Zs = 0).

3.7. Transformer shall be capable of withstanding thermal and mechanical stresses caused
by symmetrical or asymmetrical faults on any terminals. Mechanical strength of the
transformer shall be such that it can withstand 3-phase and 1- phase through fault for
transformer rated voltage applied to HV and / or IV terminals of transformer. The short
circuit shall alternatively be considered to be applied to each of the HV, IV and tertiary
(LV) transformer terminals as applicable. The tertiary terminals shall be considered not
connected to system source. For short circuit on the tertiary terminals, the in-feed from
both HV & IV system shall be limited by the transformer self-impedance only and the
rated voltage of HV and IV terminals shall be considered. The maximum short circuit
output current at the tertiary terminals shall be limited to a safe value to make the
transformer short circuit proof.

The transformer shall be designed to withstand for short circuit duration of 2 seconds
for Thermal stress and the same shall be verified during design review.

3.8. The maximum flux density in any part of the core and yoke at the rated MVA, voltage
and frequency shall be such that under 10 % continuous over-voltage condition it does
not exceed 1.9 Tesla at all tap positions.

3.9. Transformers shall withstand without damage, heating due to the combined voltage and
frequency fluctuations which produce the following over fluxing conditions:

110 % for continuous

125 % for 1 minute
140 % for 5 seconds

3.10. The air core reactance of HV winding of transformer shall not be less than 20% for
400kV class Transformer.

3.11. Tertiary Windings (if applicable as per Annexure - A)

The tertiary windings shall be suitable for connection of reactors or capacitors which
would be subjected to frequent switching and shall be suitable for connection to LT

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 Transformer for auxiliary supply. All the windings shall be capable of withstanding the
stresses which may be caused by such switching.

The Tertiary winding shall be designed to withstand mechanical and thermal stresses
due to dead short circuit on its terminals.

3.12. Radio Interference and Noise Level

The transformers shall be designed with particular attention to the suppression of

harmonic voltage, especially the third and fifth so as to minimise interference with
communication circuit.

The noise level of transformer, when energised at normal voltage and frequency with
fans and pumps running shall not exceed the values specified at Annexure - A, when
measured under standard conditions.

3.13. Dynamic Short Circuit Test requirement

3.13.1. For 400 kV Class Auto transformer

Bidder / Manufacturer should have successfully carried out Dynamic Short Circuit test
on 315MVA, 400/220/33kV Auto transformer as on the originally scheduled date of bid
opening and shall enclose the relevant Test Report/certificate along with bid. In case
bidder has not successfully tested 315MVA, 400/220/33kV Auto transformer for
Dynamic Short Circuit test, their bid shall be considered technically non responsive.
Further, design review of offered 400 kV Class Auto transformer shall be carried out
based on the design of short circuit tested 315MVA Auto transformer.

3.13.2. For 220 kV Class Transformer:

Bidder / Manufacturer should have successfully carried out Dynamic Short Circuit Test
on any rating of 220 kV or above voltage class transformer as on the originally
scheduled date of bid opening and shall enclose the relevant Test Report / Certificate
along with bid. In case bidder has not successfully tested 220 kV or above voltage class
transformer for Dynamic Short Circuit Test, their bid shall be considered technically
non-responsive. Further design review of offered 220 kV class transformers shall be
carried out based on design of short circuit tested 220 kV or above voltage class
transformer.

3.13.3. For 132 kV Class Transformer:

Bidder / Manufacturer should have successfully carried out Dynamic Short Circuit Test
on any rating of 132 kV or above voltage class transformer as on the originally
scheduled date of bid opening and shall enclose the relevant Test Report / Certificate
along with bid. In case bidder has not successfully tested 132 kV or above voltage class
transformer for Dynamic Short Circuit Test, their bid shall be considered technically
non-responsive. Further design review of offered 132 kV class transformers shall be
carried out based on design of short circuit tested 132 kV or above voltage class
transformer.

4. Measurable Defects
The following shall constitute as Measureable Defects for the purpose of Defect
Liabilities as per relevant clauses of GCC / SCC of the bidding document:

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C/ENGG/MODEL-SPEC/TRF Rev. 11
 a) Repair, inside the Transformer and OLTC (including oil migration) either at
site or at factory is carried out after commissioning.

b) The concentration of any fault gas is more than values of condition-1

indicated in clause no 6.5 of IEEE-C57.104-2008, which are as detailed
below.

H2 CH4 C2H2 C2H4 C2H6 CO CO2 TDCG

100 120 1 50 65 350 2500 720

c) The winding tan delta goes beyond 0.005 or increase more than 0.001 within a
year w.r.t. pre-commissioning values. No temperature correction factor shall
be applicable for tan delta.

d) The moisture content goes above 12 ppm at any temperature during operation
including full load.

5. Design review

5.1. The transformer shall be designed, manufactured and tested in accordance with the best
international engineering practices under strict quality control to meet the requirement
stipulated in the technical specification. The manufacturer will be required to
demonstrate the adequate safety margin w.r.t thermal, mechanical, dielectric and
electrical stress etc. shall be maintained during design, selection of raw material,
manufacturing process etc. in order to achieve long life of transformer with least
maintenance and to take into account the uncertainties of his design and manufacturing
processes. The scope of such design review shall include but not limited to the
requirement as mentioned at Annexure – E.

5.2. Design reviews shall be conducted by Purchaser or an appointed consultant during the
procurement process for transformers; however the entire responsibility of design shall
be with the manufacturer. Purchaser may also visit the manufacturer’s works to inspect
design, manufacturing and test facilities at any time.

The design review will commence after placement of award and shall be finalised
before commencement of manufacturing activity. These design reviews shall be carried
out in detail to the specific design with reference of the transformer under the scope. It
shall be conducted generally following the “Guidelines for conducting design reviews
for transformers - Guidelines for conducting design reviews for power transformers
working group A2.36 Task Force 2 (Replaces TB 204).

5.3. The manufacturer shall provide all necessary information and calculations to
demonstrate that the transformer meets the requirements for short circuit strength and
durability. The latest recommendations of IEC and Cigre SC 12 shall be applied for
short circuit withstand evaluation.

5.4. The validity of Type tests (except dynamic short circuit test) of Transformer shall
be 5 years as on the date of NOA, provided that offered transformer is of same design
as that of type tested transformer and active materials like – CRGO, copper conductor
and insulation material are of same or better grade with respect to type tested unit.
Failing which, type testing of transformer shall be carried out by the contractor at his

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 own cost. Further, type test report of Transformer from the same manufacturing plant
shall only be acceptable. With regard to Validity of Dynamic short circuit test, refer
clause 3.13 above.

6. Construction Details

The construction details and features of transformer shall be in accordance with the
requirement stated hereunder. .

6.1. Tank

6.1.1. Tank shall be fabricated from tested quality low carbon steel of adequate thickness.
Unless otherwise approved, metal plate, bar and sections for fabrication shall comply
with BS-4360 / IS 2062.

6.1.2. All seams and joints which are not required to be opened at site, shall be factory
welded, and wherever possible they shall be double welded. Welding shall conform to
BS-5135/IS 9595. After fabrication 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 of tank/stress relieving shall be
based on recommendation of BS-5500 table 4.4.3.1/IS 10801.

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

6.1.4. The tank shall be of proven design either bell type with bolted /welded joint or
conventional type with welded / bolted top cover. Bell type tank shall be provided with
joint at about 500 mm above the bottom of the tank. The welded joint shall be provided
with flanges 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 at the joint.

6.1.5. Tank shall be provided with:

a. Lifting lugs: Four symmetrically placed lifting lugs shall be provided so that it will
be possible to lift the complete transformer when filled with oil without structural
damage to any part of the transformer. The factor of safety at any one point shall
not be less than 2.

b. A minimum of four jacking pads in accessible position to enable the transformer

complete with oil to be raised or lowered using hydraulic jacks. Each jacking pad
shall be designed to support with an adequate factor of safety at least half of the
total mass of the transformer filled with oil allowing in addition to maximum
possible misalignment of the jacking force to the centre of the working surface.

c. Suitable haulage holes shall be provided.

d. 04 nos. of Gate valves for UHF sensors for PD Measurements (applicable for
400kV Transformer only) at various locations. Location of valves shall be finalized
during design review.

e. Suitable provisions of pockets for OTI, WTI & RTDs including two spare pockets.

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6.1.6. The tank shall be designed in such a way that it can be mounted either on the plinth
directly or on rollers, as per manufacturer's standard practice.

6.1.7. The base of each tank shall be so designed that it shall be possible to move the
complete transformer unit by skidding in any direction without damage when using
plates or rails.

6.2. Tank Cover

6.2.1. 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.

6.2.2. 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 25 kg. Handles shall be provided on the inspection cover to
facilitate lifting.

6.2.3. The tank cover shall be provided with pockets for oil and winding temperature
indicators. The location of pockets (for OTI, WTI & RTDs including two spare
pockets) shall be in the position where oil reaches maximum temperature. Further, it
shall be possible to remove bulbs of OTI/WTI/RTD without lowering the oil in the
tank. The thermometer shall be fitted with a captive screw to prevent the ingress of
water.

6.2.4. 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.

6.2.5. To allow for the effect of possible induced and capacitive surge current flow, the tank
cover and bushing turret shall be fixed to the transformer in such a way that good
electrical contact is maintained around the perimeter of the tank and turrets.

6.2.6. The transformer shall be provided with a suitable diameter pipe flange, butterfly valve,
bolted blanking plate and gasket shall be fitted at the highest point of the transformer
for maintaining vacuum in the tank.

6.2.7. Gas venting - The transformer cover and generally the internal spaces of the
transformer and all pipe connections shall be designed so as to provide efficient venting
of any gas in any part of the transformer to the Buchholz relay. The space created under
inspection /manhole covers shall be filled with suitable material to avoid inadvertent
gas pockets. The Covers shall be vented at least at both longitudinal ends. The design
for gas venting shall take into accounts the slopes of the plinth (if any) on which the
transformer is being mounted.

6.3. Gasket for tank & cover

All gasketed joints shall be designed, manufactured and assembled to ensure long-term
leak and maintenance free operation. All gasketed joints shall preferably of O-ring and
groove type. The Gaskets / O-Ring in contact with oil shall be Nitrile rubber or any
other better approved quality.

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 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.

The properties of all the above gaskets / O-Rings shall comply with the requirements of
IS-11149. Gaskets and O-rings shall be replaced every time whenever the joints are
opened.

6.4. Roller Assembly and Anti Earthquake Clamping Device

The roller mounted transformers are to be provided with flanged bi-directional wheels
and axles. This set of wheels and axles shall be suitable for fixing to the under carriage
of transformer to facilitate its movement on rail track. Suitable locking arrangement
along with foundation bolts shall be provided for the wheels to prevent accidental
movement of transformer. The rail track gauge shall be 1676 mm. In case rail is not
required for smaller rating Transformers, arrangement of unidirectional roller mounted
on channel shall be provided and channel shall be locked with the plinth suitably.

To prevent transformer movement during earthquake, suitable clamping devices shall

be provided for fixing the transformer to the foundation.

6.5. Conservator

6.5.1. Main tank conservator shall have air cell type constant oil pressure system to prevent
oxidation and contamination of oil due to contact with moisture. Conservator shall be
fitted with magnetic oil level gauge with potential free high and low oil level alarm
contacts and prismatic oil level gauge.

6.5.2. Conservator tank shall have adequate capacity with highest and lowest visible-levels to
meet the requirements of expansion of total cold oil volume in the transformer and
cooling equipment from minimum ambient temperature to top oil temperature of 110
deg C. The capacity of the conservator tank shall be such that the transformer shall be
able to carry the specified overload without overflowing of oil.

6.5.3. The conservator shall be fitted with 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 as applicable.

6.5.4. Conservator shall be positioned so as not to obstruct any electrical connection to

transformer.

6.5.5. The connection of air cell to the top of the conservator is by air proof seal preventing
entrance of air into the conservator. The main conservator tank shall be stencilled on its
underside with the words “Caution: Air cell fitted”. Lettering of at least 150 mm size
shall be used in such a way to ensure clear legibility from ground level when the
transformer is fully installed. To prevent oil filling into the air cell, the oil filling
aperture shall be clearly marked. The transformer rating and diagram plate shall bear a
warning statement that the “Main conservator is fitted with an air cell”.

6.5.6. Contact of the oil with atmosphere is prohibited by using a flexible air cell of nitrile
rubber reinforced with nylon cloth. The temperature of oil in the conservator is likely to
raise up to 110OC during operation. As such air cell used shall be suitable for operating
continuously at this temperature.

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6.5.7. The transformer manual shall give full and clear instructions on the operation,
maintenance, testing and replacement of the air cell. It shall also indicate shelf life, life
expectancy in operation, and the recommended replacement intervals.

6.5.8. The conservator tank and piping shall be designed for complete vacuum / filling of the
main tank and conservator tank. Provision must be made for equalising the pressure in
the conservator tank and the air cell during vacuum / filling operations to prevent
rupturing of the air cell.

6.5.9. The contractor shall furnish the leakage rates of the rubber bag/ air cell for oxygen and
moisture. It is preferred that the leakage rate for oxygen from the air cell into the oil
will be low enough so that the oil will not generally become saturated with oxygen. Air
cells with well proven long life characteristics shall be preferred.

6.5.10. OLTC shall have conventional type conservator (without aircell) with magnetic oil
level gauge with potential free oil level alarm contact and prismatic oil level gauge.

6.6. Piping works for conservator

6.6.1. Pipe work connections shall be of adequate size preferably short and direct. Only
radiused elbows shall be used.

6.6.2. The feed pipe to the transformer tank shall enter the transformer cover plate at its
highest point and shall be straight for a distance not less than five times its internal
diameter on the transformer side of the Buchholz relay, and straight for not less than
three times that diameter on the conservator side of the relay. This pipe shall rise
towards the oil conservator, through the Buchholz relay, at an angle of not less than 5
degrees. The. feed pipe diameter for the main conservator shall be not less than 80mm.
The Gas-venting pipes shall be connected to the final rising pipe between the
transformer and Buchholz relay as near as possible in an axial direction and preferably
not less than five times pipe diameters from the Buchholz relay.

6.6.3. A double flange valve of preferably 50 mm and 25 mm size shall be provided to fully
drain the oil from the main tank conservator and OLTC conservator tank respectively.

6.6.4. Pipe work shall neither obstruct the removal of tap changers for maintenance or the
opening of inspection or manhole covers.

6.7. Dehydrating Silicagel Filter Breather

Conservator of Main Tank and OLTC shall be fitted with a dehydrating silicagel filter
breather. Connection shall be made to a point in the oil conservator not less than 50
mm above the maximum working oil level by means of a pipe with a minimum
diameter of 25 mm. Breathers and connecting pipes shall be securely clamped and
supported to the transformer, or other structure supplied by the contractor, in such a
manner so as to eliminate undesirable vibration and noise. The design shall be such
that:

a) Passage of air is through silicagel.

b) Silicagel is isolated from atmosphere by an oil seal.
c) Moisture absorption indicated by a change in colour of the crystals.
d) Breather is mounted approximately 1200 mm above rail top level.

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 e) To minimise the ingress of moisture three breathers (of identical size) shall be
connected in series for main tank conservator. Contractor shall provide flexible
connection pipes to be used during replacement of any silicagel breather.
f) To minimise the ingress of moisture, two in series of identical size shall be
connected to OLTC Conservator. Contractor shall provide flexible connection
pipes to be used during replacement of any silicagel breather.

6.8. Pressure Relief Device

Adequate number of pressure relief devices (at least 2 numbers) shall be provided at
suitable locations preferably close to bushing turret/ cover. These shall have opening
diameter of at least 100 mm for rapid release of any pressure that may be generated in
the tank and which may result in damage to equipment. The device shall maintain its
oil tightness under static oil pressure equal to the static operating head of oil plus 20
kPa. The device shall operate and attain its full opening in not more than 2.5 ms when
subject to an internal pressure impulse equal to static operating head of oil plus 50 kPa.
It shall be capable of withstanding full internal vacuum at mean sea level. It shall be
mounted directly on the tank. Suitable canopy shall be provided to prevent ingress of
rain water. One set of potential free contacts (with plug & socket type arrangement)
per device shall be provided for tripping. Following routine tests shall be conducted on
PRD:

a) Air pressure test

b) Liquid pressure test
c) Leakage test
d) Contact operation test
e) Dielectric test on contact terminals

6.9. Sudden Pressure Relay

One number of Sudden Pressure relay with alarm/trip contacts (Terminal connection
plug & socket type arrangement) shall be provided on tank of transformer. Operating
features and size shall be reviewed during design review. Suitable canopy shall be
provided to prevent ingress of rain water. Pressurised water ingress test for Terminal
Box (routine tests) shall be conducted on Sudden Pressure Relay

6.10. Buchholz Relay

Two numbers double float, reed type Buchholz relay shall be provided in series of the
connecting pipe between the oil conservator and the Transformer tank with minimum
distance of five times pipe diameters between them. Any gas evolved in the
Transformer shall be collected 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 tube shall be connected from the gas collector to a valve located about 1200
mm above ground level to facilitate sampling while the Transformer in service.
Suitable canopy shall be provided to prevent ingress of rain water. Each device shall be
provided with two potential free contacts (Plug & socket type arrangement), one for
alarm / trip on gas accumulation and the other for tripping on sudden rise of pressure.

The Buchholz relay shall not operate during starting/ stopping of the transformer oil
circulation under any oil temperature conditions. The pipe or relay aperture baffles
shall not be used to decrease the sensitivity of the relay. The relay shall not mal-operate
for through fault conditions or be influenced by the magnetic fields around the

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 transformer during the external fault conditions. Pressurised water ingress test for
Terminal Box (routine tests) shall be conducted on Buchholz relay.

6.11. Oil Temperature Indicator (OTI)

All transformers shall be provided with a dial type thermometer of around 150 mm
diameter for top oil temperature indication. It shall have adjustable, potential free alarm
and trip contacts besides that required for control of cooling equipment if any. A
temperature sensing element suitably located in a pocket on top oil shall be provided.
This shall be connected to the OTI by means of capillary tubing. Temperature indicator
dials shall have linear gradations to clearly read at least every 2 deg C. Accuracy of
OTI shall be ± 3.0 deg C or better or better for a temperature of 100 deg C. The setting
of alarm and tripping contacts shall be adjustable at site.

In addition to the above, the following accessories shall be provided for remote
indication of oil temperature:

Temperature transducer with Pt100 sensor

RTD shall be provided with PT100 temperature sensor having nominal resistance of
100 ohms at zero degree centigrade. The PT100 temperature sensor shall have three
wire ungrounded system. The calibration shall be as per IEC 60751-2 or equivalent.
The PT100 sensor may be placed in the pocket containing temperature sensing element.
RTD shall include image coil for OTI system and shall provide dual output 4-20mA for
SCADA system. The transducer shall be installed in the Individual Marshalling Box.
Any special cable required for shielding purpose, for connection between PT100
temperature sensor and transducer, shall be in the scope of Contractor. 4-20mA signal
shall be wired to Digital RTCC panel / BCU for further transfer data to SCADA
through IEC 61850 compliant communications.

6.12. Winding Temperature Indicator (WTI)

All Transformers shall be provided with a device for measuring the hot spot
temperature of each winding (HV, IV and LV) with dial type thermometer of 150 mm
diameter for winding temperature indication and shall have adjustable potential free
alarm and trip contacts besides that required for control of cooling equipment if any.
WTI shall have Temperature sensing element, Image coil and Auxiliary CTs, if
required to match the image coil, shall be mounted in the cooler control cabinet.
Temperature indicator dials shall have linear gradations to clearly read at least every 2
deg C. Accuracy of WTI shall be ± 3.0 deg C or better for a temperature of 100 deg C.

The setting of alarm and tripping contacts shall be adjustable at site.

In addition to the above, the following accessories shall be provided for remote
indication of oil temperature:

Temperature transducer with Pt100 sensor for each winding

RTD shall be provided with Pt100 temperature sensor having nominal resistance of 100
ohms at zero degree centigrade. The Pt100 temperature sensor shall have three wire
ungrounded system. The calibration shall be as per IEC 60751-2 or equivalent. The
Pt100 sensor may be placed in the pocket containing temperature sensing element.
RTD shall include image coil, Auxiliary CTs, if required to match the image coil, for

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 WTI system and shall provide dual output 4-20mA for remote WTI and SCADA
system individually. The transducer, Auxiliary CT shall be installed in the Individual
Marshalling Box. Any special cable required for shielding purpose, for connection
between Pt100 temperature sensor and transducer, shall be in the scope of Contractor.
4-20mA signal shall be wired to Digital RTCC / BCU panel for further transfer data to
SCADA through IEC 61850 compliant communications.

6.13. The temperature indicators (OTI & WTI) shall be so mounted that the dials are about
1200 mm from ground level. Glazed door of suitable size shall be provided for
convenience of reading.

6.14. Optical sensors & temperature measuring unit (for 400kV Class Transformer)

Optical temperature sensors shall be fitted on each Transformer unit. 16 number probes
for 3-ph unit and 8 number probes for 1-ph unit shall be provided. The optical sensors
measuring system shall be of direct measurement non-calibrating type. All the sensors
shall be brought out to separate optical sensor box or in Individual Marshalling Box
mounted on transformer tank to facilitate measurement of temperature during service
life on each unit.

In order to facilitate measurement of temperature from the optical sensors,

temperature-measuring unit/system having at least 16 channels shall be mounted inside
the separate optical sensor box or Transformer Marshalling Box for each transformer
unit. The measuring unit shall be capable to retain temperature data for at least 30 days
with facility to download these data.

Temperature measuring unit/system shall be suitable for satisfactory operation with

ambient conditions and IEC 61850 compliant to interface with Employer’s SCADA
system through FO port.

Location of optical temperature sensors inside the transformer shall be decided during
design review.

The installation and commissioning at site shall be done under the supervision of OEM
representative or OEM certified representative.

6.15. Earthing Terminals

6.15.1. Two (2) earthing pads (each complete with two (2) nos. holes, M16 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.

6.15.2. Two earthing terminals suitable for connection to 75 x 12 mm galvanised steel flat shall
also be provided on each cooler, individual/common marshalling box and any other
equipment mounted separately. For the tank-mounted equipment like online drying/
Online DGA/ Optical Sensor Box etc. double earthing shall be provided through the
tank for which provision shall be made through tank and connected through two
flexible insulated copper link.

6.15.3. Equipotential flexible copper link of suitable size at least 4 Nos. for Tank mounted
turret with tank and tank with cover and or Bell shall be provided. For other

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 components like - pipes, conservator support etc. connected to tank shall also be
provided with equipotential flexible copper link.

6.15.4. Each transformer unit should have provision for earthing and connected to grounding
mat when not in service. For this purpose, neutral shall have provision for connection
to ground by a brass/tinned copper grounding bar supported from the tank by using
porcelain insulator. The end of the tinned/brass copper bar shall be brought to the
bottom of the tank at a convenient point for making bolted connection to 75 X 12 mm
GS flat connected to station grounding mat. The other end of the tinned/brass copper
bar shall be connected to the neutral bushing through flexible conductor/jumper.

HV & IV Terminals shall also be earthed through neutral by flexible copper

connection. Contractor shall provide suitable arrangement for the above.

6.16. Core

6.16.1. The core shall be constructed from non-ageing, cold rolled high permeability grade (as
per BIS / IEC) or better grain oriented silicon steel laminations. Indian transformer
manufacturers shall use core material as per above specification with BIS certification.

6.16.2. 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.

6.16.3. The temperature of any part of the core or its support structure in contact with oil shall
not exceed 120 deg C under normal operating condition and 130 deg C under 10% over
voltage and maximum ambient air temperature conditions of 50 deg C. Adequate
temperature margin shall be provided to maintain the long life expectancy for this
material.

6.16.4. Core and winding shall be capable of withstanding the shock during transport,
installation and service. Adequate provision shall be made to prevent movement of core
and winding relative to tank during these conditions.

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

6.16.6. Each core lamination shall be insulated with a material that will not deteriorate due to
pressure and hot oil.

6.16.7. The supporting frame work of the core shall be so designed as to avoid presence of
pockets which would prevent complete emptying of tank through drain valve or cause
trapping of air during oil filling.

6.16.8. Adequate lifting lugs will be provided to enable the core and windings to be lifted.

6.16.9. The core shall be earthed to the core clamping structure at one point only, through a
removable external link of minimum size of 80 sq. mm copper suitably located and
protected to facilitate testing after installation of the transformer. The removable links
shall have adequate section to carry ground fault current. Separate identification name
plate/labels shall be provided for the ‘Core’ and ‘Core clamp’ on the outside of tank
cover.

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6.16.10. In case core laminations are divided into sections by insulating barriers or cooling ducts
parallel to the plane of the lamination, tinned copper bridging strips shall be inserted to
maintain electrical continuity between sections.

6.17. Windings

6.17.1. The Contractor shall ensure that windings of all transformers are made in dust proof
and conditioned atmosphere.

6.17.2. The conductors shall be of electrolytic grade copper free from scales and burrs.

6.17.3. The insulation of transformer windings and connections shall be free from insulating
compounds which are liable to soften, ooze out, shrink or collapse and shall be non-
catalytic and chemically inactive in transformer oil during service.

6.17.4. Coil assembly and insulating spacers shall be so arranged as to ensure free circulation
of oil and to reduce the hot spot of the winding.

6.17.5. The coils would be made up, shaped and braced to provide for expansion and
contraction due to temperature changes.

6.17.6. The conductor shall be transposed at sufficient intervals in order to minimize eddy
currents and to equalise the distribution of currents and temperature along the winding.

6.17.7. The windings shall be designed to withstand the dielectric tests specified. The type of
winding used shall be of time tested. An analysis shall be made of the transient voltage
distribution in the windings, and the clearances used to withstand the various voltages.
Margins shall be used in recognition of manufacturing tolerances and considering the
fact that the system will not always be in the new factory condition.

6.17.8. The barrier insulation including spacers shall be made from high- density pre-
compressed pressboard (1.1 gm/cc minimum for load bearing and 1 gm/cc minimum
for non-load bearing) to minimize dimensional changes.

6.17.9. The conductor insulation shall be made from high-density (at least 0.75 gm/cc) paper
having high mechanical strength. The characteristics for the paper will be reviewed at
the time of design review.

6.17.10. Wherever required, electrostatic shield, made from material that will withstand the
mechanical forces, will be used to shield the high voltage windings from the magnetic
circuit.

6.17.11. All winding insulation shall be processed to ensure that there will be no detrimental
shrinkage after assembly. All windings shall be pre-sized before being clamped.

6.17.12. Windings shall be provided with clamping arrangements which will distribute the
clamping forces evenly over the ends of the winding.

6.17.13. The bracing of the windings and connections shall be such that these parts shall safely
withstand the cumulative effects of stresses which may occur during handling,
transportation, installation and service including line-to–line and line-to–ground faults.

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6.18. Current carrying connections

The mating faces of bolted connections shall be appropriately finished and prepared for
achieving good long lasting, electrically stable and effective contacts. All lugs for
crimping shall be of the correct size for the conductors. Connections shall be carefully
designed to limit hot spots due to circulating eddy currents.

6.19. Winding terminations into bushings

6.19.1. Winding termination interfaces with bushings shall be designed to allow for repeatable
and safe connection under site conditions to ensure the integrity of the transformer in
service.

6.19.2. The winding end termination, insulation system and transport fixings shall be so
designed that the integrity of the insulation system generally remains intact during
repeated work in this area.

6.19.3. Allowances shall be made on the winding ends for accommodating tolerances on the
axial dimensions of the set of bushings and also for the fact that bushings may have to
be rotated to get oil level inspection gauges to face in a direction for ease of inspection
from ground level.

6.19.4. In particular, rotation or straining of insulated connections shall be avoided during the
fastening of conductor pads (or other methods) on the winding ends onto the
termination surfaces of the bushing.

6.19.5. Suitable inspection and access facilities into the tank in the bushing oil-end area shall
be provided to minimize the possibility of creating faults during the installation of
bushings.

7. Paint system and procedures

The typical painting details for transformer main tank, pipes, conservator tank, radiator,
control cabinet/ marshalling box / oil storage tank etc. shall be as given in Annexure –
F. The proposed paint system shall generally be similar or better than this. The quality
of paint should be such that its colour does not fade during drying process and shall be
able to withstand temperature up to 120 deg C. The detailed painting procedure shall be
finalized during award of the contract.

8. Unused inhibited Insulating Oil

The insulating oil shall be virgin high grade inhibited, conforming to IEC-60296 & all
parameters specified at Annexure – G, while tested at oil supplier's premises. The
contractor shall furnish test certificates from the supplier against the acceptance norms
as mentioned at Annexure – G, prior to despatch of oil from refinery to site. Under no
circumstances, poor quality oil shall be filled into the transformer and thereafter be
brought up to the specified parameter by circulation within the transformer. The
Unused inhibited Insulating Oil parameters including parameters of oil used at
manufacturer’s works, processed oil, oil after filtration and settling are attached at
Annexure – G. The oil test results shall form part of equipment test report.

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 Sufficient quantity of oil necessary for maintaining required oil level in case of leakage
in tank, radiators, conservator etc. till the completion of warranty period shall be
supplied.

Inhibited oil used for first filling, testing and impregnation of active parts at
manufacturer's works shall be of same type of oil (in line with IEC 60076-3) which
shall be supplied at site and shall meet parameters as per specification.

8.1. Particles in the oil

The particle analysis shall be carried out in an oil sample taken after completion of the
oil filtration at site. The procedure and interpretation shall be in accordance with the
recommendation of CIGRE report WG-12.17 - “Effect of particles on transformer
dielectric strength”.

8.2. Moisture content in the solid insulation

Dummy insulation test block (2 Nos.) shall be inserted in the active part of Transformer
at factory and same shall be used to detect the volume of moisture content.
Manufacturer to ensure that moisture content in the dummy insulation test block is less
than 0.5% after drying process of solid insulation. Out of two dummy blocks, one block
shall be used during manufacturing stage and another one shall be sent with
Transformer at site. Before application of vacuum and oil filling, the 2nd dummy block
shall be used for DP Test (Degree of polymerisation).

To review the moisture content in the active part insulation at site during erection, Dew
Point method shall be applied.

8.3. Oil filling

8.3.1. Procedures for site drying, oil purification, oil filling etc. shall be done as per
EMPLOYER Field Quality Plan (FQP).

8.3.2. The duration of the vacuum treatment shall be demonstrated as adequate by means of
water / dew point measurement with a cold trap or other suitable method. The vacuum
shall be measured on the top of the transformer tank and should be less than 1mbar.

8.3.3. Oil filling under vacuum at site shall be done with transformer oil at a temperature not
exceeding 65°C. Vacuum shall not be broken until the Transformer is oil filled up to
the Buchholz relay.

8.3.4. The minimum safe level of oil filling (if different from the Buchholz level) to which
the Transformer shall be oil filled under vacuum, shall be indicated in the manual.

8.3.5. The Ultra High Vacuum type oil treatment plant (on returnable basis) of adequate
capacity (generally 6000 litres per hour and above) suitable for treatment of oil in EHV
class Transformer shall be used. The plant shall be capable of treatment of new oil (as
per IEC 60296 and reconditioning of used oil (as per IS: 1866/IEC: 60422 for oil in
service) at rated capacity on single pass basis as follow:

i) Removal of moisture from 100 ppm to 3 ppm (max.)

ii) Removal of dissolved gas content from 10% by Vol. to 0.1% by vol.
iii) Improvement of dielectric strength break down voltage from 20 to 70 KV

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 iv) Vacuum level of degassing chamber not more than 0.15 torr/0.2 mbar at rated
flow and at final stage. Machine shall have minimum of two degassing chambers
and these should have sufficient surface areas to achieve the final parameters.
v) Filter shall be capable of removing particle size more than 0.5 micron in the
filtered oil.
vi) Processing temperature shall be automatically controlled and have an adjustable
range from 40°C to 80°C.

The above oil treatment plant (Filtration unit) shall be arranged by the bidder at his
own cost.

8.3.6. Transportation of Oil

The insulating oil for the Transformer shall be delivered at site generally not before 90
days from the date of commissioning, with prior information to the Employer, in view
of risk involved in balk storage, pilferage and fire hazard. In case this oil is not filled in
Transformer due to delay in commissioning, same oil shall be used only after testing
and ensuring that oil parameters are well within the specified limits.

Insulating oil shall be delivered to the site in returnable oil drums / flexi bag / tanker.
The oil drums / flexi bag / tanker shall be taken back without any extra cost to
Employer within generally 45 days after utilisation of oil but in any case before
contract closing. However, the spare oil shall be delivered in non-returnable drums.

9. Spare Transformer Units Connection Arrangement

Detail procedure for storage of spare transformer unit with and without isolator
switching arrangement is enclosed at Annexure-Q.

10. Bushings

10.1. Bushings shall be robust and designed for adequate cantilever strength to meet the
requirement of seismic condition, substation layout and movement along with the spare
Transformer with bushing erected and provided with proper support from one
foundation to another foundation within the substation area. The electrical and
mechanical characteristics of bushings shall be in accordance with IEC: 60137/DIN
42530. All details of the bushing shall be submitted for approval and design review.

10.2. Bushing for voltage of 52 kV and above shall be RIP bushing with composite polymer
insulator. 36 kV and below voltage class bushing shall be solid porcelain or oil
communicating type.

10.3. RIP type bushing shall be provided with tap for capacitance and tan delta test. Test taps
relying on pressure contacts against the outer earth layer of the bushing is not
acceptable.

10.4. Where current transformers are specified, the bushings shall be removable without
disturbing the current transformers.

10.5. Bushings of identical rating shall be interchangeable to optimise the requirement of

spares. Mounting dimensions of bushing shall be as per drawing mentioned at
Annexure – D.

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10.6. Porcelain used in bushing manufacture shall be homogenous, free from lamination,
cavities and other flaws or imperfections that might affect the mechanical or dielectric
quality and shall be thoroughly vitrified, tough and impervious to moisture.

10.7. Polymer / composite insulator shall be seamless sheath of a silicone rubber compound.
The housing & weather sheds should have silicon content of minimum 30% by weight.
It should protect the bushing against environmental influences, external pollution and
humidity. The interface between the housing and the core must be uniform and without
voids. The strength of the bond shall be greater than the tearing strength of the polymer.
The manufacturer shall follow non-destructive technique (N.D.T.) to check the quality
of jointing of the housing interface with the core. The technique being followed with
detailed procedure and sampling shall be finalized during finalization of MQP.

The weather sheds of the insulators shall be of alternate shed profile as per IEC 60815-
3. The weather sheds shall be vulcanized to the sheath (extrusion process) or moulded
as part of the sheath (injection moulding process) and free from imperfections. The
vulcanization for extrusion process shall be at high temperature and for injection
moulding shall be at high temperature & high pressure. Any seams / burrs protruding
axially along the insulator, resulting from the injection moulding process shall be
removed completely without causing any damage to the housing. The track resistance
of housing and shed material shall be class 1A4.5 according to IEC60587. The strength
of the weather shed to sheath interface shall be greater than the tearing strength of the
polymer. The composite insulator shall be capable of high pressure washing.

End fittings shall be free from cracks, seams, shrinks, air holes and rough edges. End
fittings should be effectively, sealed to prevent moisture ingress, effectiveness of
sealing system must be supported by test documents. All surfaces of the metal parts
shall be perfectly smooth with the projecting points or irregularities which may cause
corona. All load bearing surfaces shall be smooth and uniform so as to distribute the
loading stresses uniformly.

The hollow silicone composite insulators shall comply with the requirements of the IEC
publications IEC 61462 and the relevant parts of IEC 62217. The design of the
composite insulators shall be tested and verified according to IEC 61462 (Type &
Routine test)

10.8. Clamps and fittings shall be of hot dip galvanised/stainless steel.

10.9. Bushing turrets shall be provided with vent pipes, to route any gas collection through
the Buchholz relay.

10.10. No arcing horns shall be provided on the bushings.

10.11. RIP Bushing shall be specially packed to avoid any damage during transit and suitable
for long storage, with non-returnable packing wooden boxes with hinged type cover.
Without any gap between wooden planks. Packing Box opening cover with
nails/screws type packing arrangement shall not be acceptable. Bushing oil end portion
shall be fitted with metal housing with positive dry air pressure and a suitable pressure
monitoring device shall be fitted on the metal housing during storage to avoid direct
contact with moisture with epoxy. Alternatively, oil filled metal housing with suitable
arrangement for taking care oil expansion due to temperature variations shall also be
acceptable. Manufacturer shall submit drawing/ documents of packing for approval

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 during detail engineering. Detail method for storage of bushing including accessories
shall be brought out in the instruction manual.

10.12. The terminal marking and their physical position shall be as per IEC: 60076.

10.13. Tan delta measurement at variable frequency (in the range of 20 Hz to 350 Hz) shall be
carried out on each condenser type bushing (OIP & RIP) at Transformer manufacturing
works as routine test before despatch and the result shall be compared at site during
commissioning to verify the healthiness of the bushing.

10.14. If the bushing Tan delta goes beyond 0.005 or increase is more than 0.001 within the
warrantee period w.r.t. pre-commissioning values, the contractor shall arrange to
replace the defective bushing by new one. No temperature correction factor shall be
applicable for tan delta.

11. Neutral Formation and Earthing Arrangement

11.1. For 3-Phase Unit

The neutral of the transformer shall be brought out through bushing. The neutral
terminal of 3-phase transformer 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 grounding mat.

11.2. For 1-Phase Unit ( if specified in BPS)

The neutral of the transformer shall be brought out through bushing. The contractor
shall connect the neutrals of 1-phase transformers by overhead connection using an
overhead common brass/tinned copper/Aluminum pipe /ACSR conductor grounding
bus, supported from the tank and fire walls by using porcelain insulators and wherever
flexible jumper needs to be provided, same shall be through twin conductor. All
material like Bus post insulator, Aluminium tube, conductor, clamps & connectors,
earthing materials, support structure, hardware etc required for neutral formation and
connection with neutral CT and earthing of neutral shall be provided by contractor. The
neutral formation shall be such that neutral winding of single-phase spare transformer
can be disconnected or connected to either of the three phase banks.

12. Delta Formation (applicable for 1-Phase Transformer) :( if specified in BPS)

The tertiary/LV winding terminals of the transformer shall be brought out through
bushing. The contractor shall connect Tertiary/LV of 1-phase transformers in DELTA
configuration by overhead connection to operate in 3-Phase Bank. The Delta shall be
formed by approximate size of 3" IPS Al tube, which shall be insulated with heat
shrinkage insulating sleeve or cable of suitable voltage class and adequate thickness
and shall be supported by structure mounted bus post insulators at suitable intervals.
Jumpers (twin) wherever provided shall also be insulated at site using suitable
insulation tape or sleeve atleast 52kV class for 33kV Bus and atleast 36kV class for
below 33kV voltage class Bus. The minimum phase to phase horizontal spacing for
delta formation shall be 1.5 meter. Suitable cable shall be used for delta formation for
below 33kV winding All associated materials like bus post insulators, Aluminium tube,

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 clamps & connectors, support structures; hardware etc. required for tertiary delta
formation shall be provided by the contractor.

13. Cooling Equipment and its Control

13.1. Cooling Equipment for Radiator Bank

13.1.1. The cooler shall be designed using radiator banks or tank mounted radiators. Design of
cooling system shall satisfy the performance requirements.

13.1.2. In case of separately mounted radiator bank arrangement, the main tank shall have
provision such that cooler banks can be placed on either side of the main tank without
the need of any extra member/pipe maintaining the electrical clearances.

13.1.3. The radiator shall be of sheet steel in accordance with IS 513 and minimum thickness 1
mm. Each radiator bank shall be provided with the following accessories:

(a) Cooling Fans, Oil Pumps, Oil Flow Indicator (as applicable)
(b) Top and bottom shut off valve
(c) Drain Valve and sampling valve
(d) Top and bottom oil filling valves
(e) Air release plug
(f) Two grounding terminals for termination of two (2) Nos. 75x12 mm galvanised
steel flats.
(g) Thermometer pockets with captive screw caps at cooler inlet and outlet.
(h) Lifting lugs

13.1.4. Each radiator bank shall be detachable and shall be provided with flanged inlet and
outlet branches. Expansion joint shall be provided on top and bottom cooler pipe
connection.

13.2. If radiators are directly mounted on tank, sufficient number of thermometer pockets
fitted with captive screw cap on the inlet and outlet of tank side pipe of radiators shall
be provided to record temperature during temperature rise test.

13.2.1. One number standby fan shall be provided with each radiator bank.

13.2.2. Cooling fans shall not be directly mounted on radiator. It may cause undue vibration.
These shall be located so as to prevent ingress of rain water. Each fan shall be suitably
protected by galvanised wire guard. The exhaust air flow from cooling fan shall not be
directed towards the main tank in any case.

13.2.3. Two (2), 100% centrifugal or axial in line oil pumps, if applicable, (out of which one
pump shall be standby) shall be provided with each radiator bank. Measures shall be
taken to prevent mal-operation of Buchholz relay when all oil pumps are
simultaneously put into service. The pump shall be so designed that upon failure of
power supply to the pump motor, the pump impeller will not limit the natural
circulation of oil.

13.2.4. An oil flow indicator shall be provided for the confirmation of the oil pump operating
in a normal state. An indication in the flow indicator and potential free contacts for
remote alarm shall be provided.

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13.2.5. Valves shall be provided across the pump and oil flow indicator to avoid oil drain and
long outage during maintenance / replacement of pump and oil flow indicator.

13.2.6. Cooling fans and oil pump motors shall be suitable for operation from 415 volts, three
phase 50 Hz power supply and shall conform to IS: 325 / IEC 60034. Each cooling fan
and oil pump motors shall be provided with starter thermal overload and short circuit
protection. The motor winding insulation shall be conventional class 'B' type. Motors
shall have hose proof enclosure equivalent to IP: 55 as per IS: 4691/ IEC 60034-5.

13.2.7. The cooler pipes, support structure including radiators and its accessories shall be hot
dip galvanised or corrosion resistant paint should be applied to external surface of it.

13.2.8. Air release device and oil plug shall be provided on oil pipe connections. Drain valves
shall be provided in order that each section of pipe work can be drained independently.

13.3. Cooling Equipment Control for Radiator banks

13.3.1. Automatic operation control of fans/pumps shall be provided (with temperature

change) from contacts of winding temperature indicator. The Contractor shall
recommend the setting of WTI for automatic changeover of cooler control over entire
cooling option. The setting shall be such that hunting i.e. frequent start-up operations
for small temperature differential do not occur.

13.3.2. Suitable manual control facility for cooler fans and oil pumps shall be provided.
Selector switches and push buttons shall also be provided in the cooler control cabinet
to disconnect the automatic control and start/stop the fans and pump manually.

13.3.3. The changeover to standby oil pump in case of failure of service oil pump shall be
automatic.

13.3.4. In addition to the traditional starting of fan and pump by winding & oil temperature, the
starting of forced cooling shall be done if the load exceeds a current setting of 0.6 p.u.
for 5 seconds. Furthermore, a one-week timer is required to check the healthiness of the
cooling system on a routine basis for one hour at a time.

13.3.5. Following lamp indications shall be provided in cooler control cabinet:

a) Cooler Supply failure (main)

b) Cooler supply changeover
c) Cooler Supply failure (standby)
d) Control Supply failure
e) Cooling fan failure for each bank
f) Cooling pump failure for each pump
g) Common thermal overload trip

One potential free initiating contact for all the above conditions shall be wired
independently to the terminal blocks of cooler control cabinet and for single ph. unit
connection shall be extended further to CMB.

13.3.6. The cooler control cabinet / Individual Marshalling box shall have all necessary devices
meant for cooler control and local temperature indicators. All the contacts of various
protective devices mounted on the transformer and all the secondary terminals of the
bushing CTs shall also be wired upto the terminal board in the cooler control

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 cabinet/Individual Marshalling box. All the CT secondary terminals in the cooler
control cabinet shall have provision for shorting to avoid CT open circuit while it is not
in use.

13.3.7. All the necessary terminations for remote connection to Purchaser's panel shall be
wired upto the Common Marshalling box (in case of 1-Ph unit) or Marshalling Box (3-
Ph unit).

13.3.8. The Contractor shall derive AC power for Cooler Control Circuitry from the AC
feeder. In case auxiliary power supply requirement for Cooler Control Mechanism is
different than station auxiliary AC supply, then all necessary converters shall be
provided by the Contractor. Details of station auxiliary power supply are mentioned in
GTR.

13.4. Unit cooler arrangement for transformer (if applicable)

13.4.1. The cooler shall be designed using Unit Cooler arrangement with capacity as specified
in Annexure-A. Design of cooling system shall satisfy the performance requirements.

13.4.2. Each Unit Cooler shall have its own cooling fans, oil pumps, oil flow indicator, shut off
valves at the top and bottom of at least 80 mm size, lifting lugs, top and bottom oil
filling valves, air release plug at the top, a drain and sampling valve and thermometer
pocket fitted with captive screw cap on the inlet and outlet.

13.4.3. An oil flow indicator shall be provided for the confirmation of the oil pump operating
in a normal state. An indication shall be provided in the flow indicator to indicate
reverse flow of oil/loss of oil flow.

13.4.4. Valves shall be provided across the pump and oil flow indicator to avoid oil drain and
long outage during maintenance / replacement of pump and oil flow indicator.

13.4.5. Cooling fans and oil pump motors shall be suitable for operation from 415 volts, three
phase 50 Hz power supply and shall conform to IS: 325/IEC34. Each cooling fan and
oil pump motors shall be provided with starter thermal overload and short circuit
protection. The motor winding insulation shall be conventional class 'B' type. Motors
shall have hose proof enclosure equivalent to IP:55 as per IS:4691/IEC:34-5

13.4.6. The cooler, pipes, support structure and its accessories shall be hot dip galvanised or
corrosion resistant paint should be applied to external surface of it.

13.4.7. Expansion joint shall be provided on top and bottom cooler pipe connections as per
requirement.

13.4.8. Air release device and oil plug shall be provided on oil pipe connections. Drain valves
shall be provided in order that each section of pipe work can be drained independently.

13.5. Cooling Equipment Control (OFAF or ODAF) for Unit Coolers (if applicable)

i) Suitable manual control facility for unit cooler shall be provided.

ii) The changeover to standby unit cooler bank oil pump in case of failure of any
service unit cooler shall be automatic.

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C/ENGG/MODEL-SPEC/TRF Rev. 11