JINDAL STEEL & POWER LIMITED

ANGUL (ORISSA)
ORDERING SPECIFICATION FOR 40 MVA LADDLE
FURNACE TRANSFORMER

1. INTENT OF SPECIFICATION

1.1 This specification is intended to cover the design, engineering, manufacture, assembly,
testing at manufacturer's works, packing, forwarding, supply & delivery, transportation
and transit insurance, complete with all auxiliaries and accessories for efficient and
trouble-free operation in a manner acceptable to Owner.

1.2 The scope of work shall also include supervision for unloading at site, erection,
testing, commissioning and putting into successful commissioning and operation of all
equipment furnished under this specification.

2. SCOPE
This specification covers the requirements for the design, engineering, fabrication, testing
and delivery of 40 MVA furnace transformer for 250t Ladle furnace at Jindal steel &
Power Ltd Limited (JSPL), Angul, Orissa as per the following Specification. The
transformer will be located indoors close to the furnace itself in steel plant atmosphere in
JSPL, Angul, Orissa.

2.1 SCOPE OF SERVICES

2.1.1 Furnishing of all labour (skilled and unskilled), supervisory and administrative personnel,
erection, tools and tackles, testing equipment, implements, supplies, consumables &
hardware for timely efficient execution of complete work.

2.1.2 Transport vehicles required for intra-site transportation of equipment.

2.1.3 Complete assembly, erection and connection, grounding, testing and commissioning,
putting into successful and satisfactory commissioning and operation of the Power
Transformers.

2.1.4 The items of work to be carried out on all equipment and materials shall include but not
limited to the following:

a) Receiving, loading and unloading, transportation at site to owner’s and/or

contractor’s stores and from there up to actual place of erection and excess
materials back to owner’s stores. Storage / security of the material at site shall be
in the scope of Bidder.

b) Opening of packing in the presence of owner (if necessary) and inspection of the
equipment and materials at site and reporting damages, shortages etc. if any,
immediately after opening to the owner.

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 JINDAL STEEL & POWER LIMITED
ANGUL (ORISSA)
ORDERING SPECIFICATION FOR 40 MVA LADDLE
FURNACE TRANSFORMER

c) Proper storing arrangement at plant site with suitable enclosure for protection from
weather and pilferage of items under their scope of supply and materials,
consumable, testing equipment etc. brought to site by the contractor.

d) Maintaining and managing of contractor’s own store and reconciliation of free

issue items, if any, whenever desired by owner.

e) Returning to owner’s stores unused materials after final reconciliation or

completion of job.

f) Arranging to repair and/or re-order all damaged and short supply items.

g) Assemblies, erection and complete installation.

h) Necessary co-ordination between works done by other contractors.

i) Pre-commissioning check-up to ensure correctness of erection as per actual

manufacturer’s instruction.

j) Final checking, testing and commissioning of all equipment in presence of owners

representatives including checking of interlocks and correctness of wiring as per
scheme.

k) Modification jobs in schemes, wiring etc., if required by Consultants/ Owner till

the date of handing over the equipment.

l) Preparing the protocols in the mutually agreed format for the satisfactory erection,
testing and commissioning of the equipment.

m) Submission of various test reports, protocols etc. to purchaser along with the
commissioning of the equipment.

n) Satisfactory routine and emergency maintenance of the equipment/ systems

erected and commissioned by the contractor till the completion of the contract.

o) Obtaining engineer’s approval and owner’s written acceptance of satisfactory

performance.

p) Handing over of installation for commercial operations.

q) Field modification carried out shall be marked-up in red in one (1) set of erection
drawing and submitted to the owner for approval. Preparation of ‘As Built’
drawings based on approved field modification drawing.

r) Abiding to all rules and regulations in vogue at owner’s premises in reference

particularly to the administration, security, safety etc.

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 JINDAL STEEL & POWER LIMITED
ANGUL (ORISSA)
ORDERING SPECIFICATION FOR 40 MVA LADDLE
FURNACE TRANSFORMER

s) Attending meetings with Owner so as to give priority of work to match with

overall project. Arranging for adequate resources both man and material for the
targets decided in the meetings.

2.2 EXCLUSION FROM SCOPE OF WORK

2.2.1 All concrete foundation works.

2.2.2 Bus duct, cables and ACSR conductor for connection between transformer and equipment
supplied by other. But all terminal connectors are to be included under the scope of
Bidder.

2.2.3 Fire protection system, oil drain pit and drain piping, lighting and surge arrestors.

2.3 DELIVERY AND COMMISSIONING SCHEDULE

The supply of the equipments for the project shall be completed within as agreed with
JSPL from the date of placement of Purchase Order.

Time schedule for submission of drawings and documents (as per list enclosed) in 6 sets
along with soft copy (2 set) of each listed drawings/ documents shall be as per enclosed
list.

3.0 DRAWINGS FOR EQUIPMENT INSPECTION AT WORKS.

Complete 3 sets of approved dimensioned drawing with specification, un-priced

purchased order, and manufacturer’s test certificates for inspecting the equipment for
issuing inspection certificate except proprietary items and bought outs (ordering
specification of proprietary items shall be furnished).

4.0 COMPLETENESS OF SUPPLY.

A It is not the intent to specify completely herein all details of the equipment. Nevertheless,
the equipment shall be complete and operative in all aspects and shall conform to highest
standard of engineering, design and workmanship.

B Any material or accessory which may not have been specifically mentioned but which is
necessary or usual for satisfactory and trouble-free operation and maintenance of the
equipment shall be furnished by the Bidder without any extra charge.

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 JINDAL STEEL & POWER LIMITED
ANGUL (ORISSA)
ORDERING SPECIFICATION FOR 40 MVA LADDLE
FURNACE TRANSFORMER

C The Contractor shall supply all brand new equipment and accessories as specified herein
with such modification and alteration as agreed upon in writing after mutual discussion.

4.1 Guaranteed Performance and Liquidated Damages

The performance figures quoted in Technical Particular sheets shall be guaranteed within
the tolerance permitted by relevant standards except without any (+)ve tolerance on loss
figures quoted by the Bidder. In case of failure of the equipment to meet the guarantee,
the equipment may be liable for rejection.

The loss figures quoted by the bidders for transformers shall be guaranteed without any
(+) ve tolerance and shall be liable for liquidated damages (L.D.) on tested losses in
excess of the guaranteed figures, at the rates indicated below.

a) Rs. 2, 28,000 /- per KW of No-load losses.

b) Rs. 1, 71,000 /- per KW of load losses.

c) Rs. 91,500/- per KW of Auxiliary losses.

For fraction of a Kilowatt, the L.D. shall be levied pro-rata.

Transformer losses will be taken into account during bid evaluation. The loss figures quoted by the
bidders for transformers shall be guaranteed without any (+) ve tolerance and shall be taken into
account for evaluation at the rates indicated below:

a) Rs. 1, 52,000 /- per KW of No-load losses.

b) Rs. 1, 14,000 /- per KW of load losses.

c) Rs. 61,000/- per KW of Auxiliary losses.

d) For fraction of a Kilowatt, the rate shall be pro-rata basis.

4.2 Deviation

Should the Bidder wish to deviate from this specification in any way, he shall draw
specific attention to such deviation.

All such deviations shall be clearly mentioned on the Deviation sheet enclosed with
reference to the respective clause of the specification. The deviation listed elsewhere in
the text of the tender will not be considered.

Unless such deviations are recorded in the Deviation sheets and submitted with the offer,
it will be taken for granted that the offer is made in conformity with this specification in
all respects.
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 JINDAL STEEL & POWER LIMITED
ANGUL (ORISSA)
ORDERING SPECIFICATION FOR 40 MVA LADDLE
FURNACE TRANSFORMER

Unless such deviations are recorded in the deviation sheets and submitted with the offer, it
will be taken for granted that the offer is made in conformity with this condition of
contract in all respects.

4.3 Drawing Approval

Before starting manufacture of any equipment, the contractor shall have to take approval
of relevant drawings and data from Engineer in writing.

Any manufacture done prior to the approval of drawings/data shall be rectified in

accordance with the approved drawings/data by the Contractor at his own cost and the
equipment shall be supplied within the stipulated period.

4.4 Recommended Spares

List of recommended spares with their ordering specifications, catalogue nos. etc shall be
furnished.

In addition to above ordering specifications for operating consumables shall be furnished.

4.5 Operation and Maintenance Manuals

Integrated operation/safety and maintenance manuals for equipments including assembly/

dismantling instruction, performance data, characteristic curves, safety aspects etc. shall
be furnished in 6 sets in bound volumes

5. AS-BUILT DRAWINGS AND DOCUMENTS

As-built drawings and documents to be delivered within 45 days after successful

commissioning as per the list hereunder:

5.1 Test certificates and inspection certificates sets in 6 sets

Classified manner in bound volumes (in addition
to those submitted along with invoice)

5.2 All design calculations with respective design criteria 6 sets

in bound volumes

5.3 Updated and approved classified list of drawings 6 sets

(as per drawing list) in A4/A3 size

5.4 General arrangement assembly and sub-assembly 6 sets

drawings

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 JINDAL STEEL & POWER LIMITED
ANGUL (ORISSA)
ORDERING SPECIFICATION FOR 40 MVA LADDLE
FURNACE TRANSFORMER

5.5 Soft copy in electronic media (CD) of all 2 set

drawings and documents as per drawing list

6. STATUTORY APPROVAL/ CLEARANCE

Submission of drawings, documents and data to statutory authorities for approval and
clearance shall be submitted as per the requirement.

7. PAC INSPECTION

Complete 3 sets of approved/ as-built drawings shall be submitted for inspecting the
completion of work for the purpose of Preliminary Acceptance Certificate except
proprietary items and bought outs.

Detailed master PERT/CPM Network/ Network monitoring software of the package as a

whole shall be submitted by the contractor within 2 weeks from the date of placement of
purchase order. PERT network shall be prepared based on the milestones, which shall be
the basis for the performance of this contract.

8. PAINTING

Painting and surface preparation of the equipments/ panels shall be as per relevant IEC
Standard and Paint shade shall be RAL 7032 as per IS-5 or equivalent as per IEC
standard.

9. DESIGN BASIS

The electrical equipment for the Ladle furnace shall be designed taking into account
following design data:

Ambient condition

- Temperature LF bay maximum 55 deg. C

All rooms maximum 45 deg. C

- Relative Humidity maximum 100%, non-condensing

Note: All electrical equipment shall be designed to work reliably at ambient

Temperature of 50 deg C.

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 JINDAL STEEL & POWER LIMITED
ANGUL (ORISSA)
ORDERING SPECIFICATION FOR 40 MVA LADDLE
FURNACE TRANSFORMER

10. POWER SUPPLY

Voltage Fault Voltage Frequency Earthing

Level Variation variation

33 kV 1800 MVA + 10% + 5% Solidly earthed

415V 36 MVA + 10% + 5% Solidly earthed

Control voltages

MCC 220 VAC

HT switchgear 220 V DC and 240 VAC

Signal lamps, 24 V DC
Solenoid valves and
interrogation for PLC

11. DEGREE OF PROTECTION

- Control desks/panels IP 54
- LT AC motors IP 55

12. The transformer and accessories shall be complete in all respect and any device not
included in the specification but essential for proper operation of the equipment shall be
deemed to be within the scope of the specification, whether specifically mentioned in this
specification or not.

12.1 JSPL/ SMS Demag reserves the right of selecting particular manufacturer for transformer
accessories, if so required apart from as listed.

12.2 The transformer is used for stepping down the primary voltage to the voltage level
required for operation of the plant. Characteristic features of the transformer are low
secondary voltages and high secondary currents. The pronounced dynamic stresses
generated by these high currents place maximum demands on windings, cores and
mountings.
The windings of the furnace transformer are cooled by the transformer oil. Oil circulating
pumps feed the oil through heat exchangers. The transformer is equipped with protections
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 JINDAL STEEL & POWER LIMITED
ANGUL (ORISSA)
ORDERING SPECIFICATION FOR 40 MVA LADDLE
FURNACE TRANSFORMER

like Buchholz relay, oil level gauge with alarm contacts for the transformer main tank and
water flow indicator with alarm contacts. The protection facilities feature audible and
visual signals. In the event of a fault, the transformer is immediately isolated from the
mains.
The operating voltage is set on the regulating winding using a motor operated ON-load
tap changer. The tap changer is installed inside the transformer tank in a separate oil
compartment but not isolated. The secondary delta closure is arranged inside the
transformer tank. The secondary terminals are brought from the sidewall.

13. STANDARDS

The transformer shall generally conform to IEC 214: 1994, IEC 76 - 1 through 76
- 5 / DIN VDE 0532 and latest IEC standards in the same order of preference and the
associated Standards wherever available, in order that specific aspects under Steel Plant
conditions are taken care of.

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 JINDAL STEEL & POWER LIMITED
ANGUL (ORISSA)
ORDERING SPECIFICATION FOR 40 MVA LADDLE
FURNACE TRANSFORMER

14. MAIN FEATURES AND REQUIREMENTS

Voltages, rated power and other Technical specification

Primary voltage 33 kV, + 10%

50 Hz., + 5%
Secondary voltages:
1. Constant MVA 470 V - 415 V

2. Constant current 415 V - 310 V

Secondary Current (max.) 55.65 kA

Rated power 40 MVA

Impulse test voltage 250 kV peak

Power frequency test voltage primary 95 kV rms.

Power frequency test voltage secondary 10 kV rms.

Transformer winding Electrolytic grade copper

Vector Group Dd0

Flux density (maximum & firm) 1.60T max.

Current density (maximum & firm) 3.0 A/mm2 max. For HV winding
3.0 A/mm2 max. For LV winding

No-load losses at 40 MVA base (firm) Less than 0.1% at principal tap

Load losses at 40 MVA base (firm) Less than 0.7% at principal tap

Auxiliary losses (firm) To be specified by supplier

No load current at rated voltage Less than 0.2 % of rated current

Temperature rise at 37C inlet water & 45C max. of oil

50C ambient 50C max. of winding

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ANGUL (ORISSA)
ORDERING SPECIFICATION FOR 40 MVA LADDLE
FURNACE TRANSFORMER

Type of cooling OFWF

Type of heat exchanger Double wall type (GEA make)

Heat exchanger capacity 2 x 150%

Number of heat exchangers 2 (kW of each to be indicated by supplier)

OLTC On load, reversing type, MR make (Oil

Immersed or alternately Vacutap type)

Core (sheet) M5 grade (thickness to be specified by

Supplier).

Cooling water inlet temperature 37 °C

Cooling water outlet temperature 47 °C at rated load

Type of tap changer ON-LOAD, diverter type by MR

No. of transformer taps 17 (shall be finalised during detail engg.)

Delta connection inside

Hot Spot temperature Approx. 95 deg.C max at 50 deg.C ambient

and 37 deg.C cooling water temp.

Transformer inrush current 6 – 7 times without reactor.

with & without reactor

Fault level at 33 kV bus Transformer shall be suitable to withstand

31.5 kA fault current for 3 seconds at HV
bushings.

Voltage and frequency occurrence Transformer shall be suitable for

combined
over voltage and frequency variation of
+ 10 %.

Mounting brackets for surge arresters to be provided on the transformer.

SUPPLIER to furnished sketch of winding configuration and voltage variation table. Transformer
is of booster type.
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 JINDAL STEEL & POWER LIMITED
ANGUL (ORISSA)
ORDERING SPECIFICATION FOR 40 MVA LADDLE
FURNACE TRANSFORMER

14.1 The secondary sidewall of tank plate shall be of SS 304 grade (non-magnetic) and thickness
of the same shall be minimum 12 mm (supplier to confirm).

14.2 SUPPLIER to confirm the make of insulating oil and 10% extra oil shall be supplied in
sealed non-returnable drums.

14.3 SUPPLIER to confirm that ON-LINE filter of MR for the tap changers (for booster
design).

14.4 Bracket for mounting the surge arrestors on transformer tank to be provided by SUPPLIER.

14.5 SUPPLIER to confirm their transformer core has no bolts.

14.6 SUPPLIER to confirm that the transformer tank and insulating plates shall be designed to
withstand full vacuum.

14.7 In event of order, SUPPLIER shall furnish transformer capacitance value at HV

terminals. SUPPLIER shall carry out capacitance test on transformer.

14.8 SUPPLIER to inform the transformer tank thickness as follows:

a. Bottom – min. _ _ _ mm
b. Side wall – min. _ _ _ mm Supplier to specify.
c. Top Cover – min. _ _ _ mm
However, during preliminary design SUPPLIER shall furnish the exact thickness.

14.9 JSPL will furnish the water quality report to SUPPLIER. SUPPLIER shall design the cooler
bank accordingly.

14.10 SUPPLIER to confirm that the cooler bank shall be of GEA, Germany makes.

14.11 SUPPLIER to confirm that the noise level shall be 75 dB at a distance of two meters
from the transformer.

14.12 SUPPLIER to confirm that the voltage class of OLTC shall be 72 kV / 140 kVrms /
350 kVpeak.

14.13 SUPPLIER to confirm that the color shade of external surfaces and cooler bank shall be
RAL 7032.

14.14 SUPPLIER to confirm that impulse test shall be carried on all three HV terminals (full wave
as well as chopped wave).

14.15 SUPPLIER to confirm that Heat Run Test (at rated Full load losses) shall be carried on
the furnace transformer.
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 JINDAL STEEL & POWER LIMITED
ANGUL (ORISSA)
ORDERING SPECIFICATION FOR 40 MVA LADDLE
FURNACE TRANSFORMER

15. PRIMARY AND SECONDARY CONNECTION

Vector group Dd0

Impedance at 470 V tap position 40 MVA base = 6.0 %
Impedance at 415 V tap position 40 MVA base = 9-10 %
Impedance at 310 V tap position 24 MVA base = To be informed by supplier

16. PRIMARY AND SECONDARY TERMINATION

Primary/ phase Shall be terminated in the form of bushings. Primary

connection by Copper bus bar of adequate rating. Primary
bushings shall be 52 KV grade, 4500 amps.

Secondary/ phase Terminals in the form of Copper Bus tubes to be brought

out from the side of transformer tank. Three phases should
come out to form an equilateral triangle. Secondary
connection by water-cooled bus tubes in triangulated
fashion on side of transformer tank. The centre to center
distance between adjacent bus tubes shall be minimum 210
mm to facilitate connection of flexible between transformer
bus tubes and bus tubes on transformer house wall. 3 x 6/8
double pipe tubes (35/65 dia. approx.) (to be decided
during detail engineering and fulfilling SMS Demag’s
requirement).

17. POWER FREQUENCY WITHSTAND VOLTAGES

Short duration voltage:

Primary (50 Hz.1 min) 95 kV rms

Secondary (50 Hz. 1 min) 10 kV rms

Impulse withstand voltage

Primary (1.2/50 250 kV peak
Micro seconds)

Induced over voltage 2 times rated voltage.

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 JINDAL STEEL & POWER LIMITED
ANGUL (ORISSA)
ORDERING SPECIFICATION FOR 40 MVA LADDLE
FURNACE TRANSFORMER

18. INSULATION MINERAL OIL

The insulating value of mineral oil shall be 60 kV / mm or better established in

accordance with IS 335: 1983 /IEC 296. Operation of the transformer shall be possible if
the insulating value of the oil has decreased to 35 kV /mm.

Transformer shall be supplied complete with first fill of oil. Additional 10% oil in
non - returnable sealed drums shall be supplied. Oil type shall be according to IEC
296. (SUPPLIER to specify the class)

19. SHORT CIRCUIT DESIGN

The transformer design shall be suitable for a 3 seconds duration short circuit of the
secondary side after a prolonged use at rated power. This shall be possible at any tapping
switch position without any damage to the transformer. The transformer shall be designed
for arc furnace operation.

Suitable for frequent short circuits on electrodes, when secondary current could briefly
rise to 2 times rated currents for duration less than 1 second.

Suitable for rare short circuits on electrodes when secondary current could be 2 times
rated current for maximum 30 seconds duration, before the furnace breaker cuts off the
supply. The thermal effect of surge currents shall be such as not to overload the furnace
transformer.

Suitable for no load energization 70-100 times a day, when inrush currents could be
typically 8 to 10 times rated current.

20 TRANSFORMER CONSTRUCTION REQUIREMENT

20.1 General Construction

The transformer will be core type construction.

In case of direct voltage regulation, the high voltage winding which is wound around the
core limb, has its tapping brought out for connection to tap changer. The low voltage
winding is wound around the high voltage winding.

In case of buck/boost regulation design, the transformer consists of two active parts i.e.
main transformer and a booster transformer. The main transformer contains the high
voltage winding, a part of the low voltage winding and the regulating winding. The
booster transformer contains the second part of the low voltage winding (connected in
series with first part) and a high voltage winding, fed by the regulating winding of the

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 JINDAL STEEL & POWER LIMITED
ANGUL (ORISSA)
ORDERING SPECIFICATION FOR 40 MVA LADDLE
FURNACE TRANSFORMER

main transformer. The voltage of regulating winding will be selected on the basis of the
on load tap changer capacity.

Shorting of parallel section of secondary winding in each secondary phases shall be done
inside the transformer tank.

20.2 On Load Tap Changer

A suitable on load remote motor operated tap changing equipment to be provided to the
tappings on the regulating windings. The OLTC shall be designed and tested as per IEC
214. The tap changer shall be suitable for frequent switching. Special care shall be taken
to ensure a long life and facilitate repair / replacement of a defective tap changer within a
short period of time. A manual handle shall also be provided to operate the tap changer in
case of emergencies.

OLTC shall be 72 KV grade, Oil immersed type, reversing, diverter type, make MR.
OLTC shall be suitable for following test voltages (insulation level):

Power frequency withstand voltage (50 Hz.1 min) 140 kV rms

Impulse withstand voltage

Primary (1.2/50 350 kV peak
Micro seconds)

Induced over voltage 2 times rated voltage.

4 sets of dial type step switch duly wired shall be provided for remote tap position
indication, Desired tap position operation & 2 spares as per our requirement and shall be
connected to tap changer terminal. Special attention must be paid to the fact that the
OLTC design shall be suitable for “desired position" i.e. the tap changer shall stop only
the selected tap position & not at the intermediate steps.

Selection of desired position of OLTC is possible only from remote & necessary circuitry
will be placed in the OLTC control panel.

Control manually by crank, motor operated through push buttons on Tap Changer Panel,
motor operated through Raise/Lower command from remote.

OLTC shall be assembled inside the transformer tank, suspended from cover with separate
diverter switch in oil-tight cylinder. Selector switch oil shall be in separate tank so that
inspection can be carried out without draining the main oil tank.
Expected contact life (in operations) – more than 400,000
1 set. On-line oil filter of MR make shall be provided in the OLTC to increase the
periodic maintenance time from 40,000 operations to minimum 200,000 operations.
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 JINDAL STEEL & POWER LIMITED
ANGUL (ORISSA)
ORDERING SPECIFICATION FOR 40 MVA LADDLE
FURNACE TRANSFORMER

20.3 Tank and Cover.

- The bottom of the tank shall be flat, skid or wheel type, heavy under base and the tank
with insulating plates shall be designed to withstand full vacuum.

- Transformer tank plate thickness shall be as follows:

Bottom – _ _ _ _ mm
Side wall – _ _ _ _ mm to be specified by supplier
Top cover – _ _ _ _ mm

The exact thickness shall be furnished by SUPPLIER during engineering. The

secondary side wall of transformer tank plate shall be SS 304 grade (non-magnetic
material) and its thickness shall be minimum 12 mm.

- Under carriage with flanged bi-directional wheels with locking and bolting devices.

- Lifting lugs, jacking pads, jacking lugs, haulage lugs etc.

- Lifting lugs shall be positioned at least 30 cm above the bottom.

- Connection clamps for earthing rail copper of 50 mm x 5 mm.

- Two valves with blind flanges (minimum size 50 mm diameter) shall be positioned at
diagonally opposite locations on the transformer for filtration of the mineral oil.

- Special arrangement shall be made so as to facilitate the draining of the OLTC tank oil
so that it can be filtered by an external pump.

- One drain and two sampling valve connection with blind flanges shall be made at the
bottom of the tank in accordance with relevant IS / IEC /DIN standards.

- Two numbers bulb type thermometers with pocket shall be provided on the tank.

- One gas sampling arrangement up to flange shall be provided.

- One pressure relief valve with trip contact. Oil collector should be provided with a
pipe to direct the oil towards the ground.

- Inspection cover shall be provided on the side wall plate.

- Air release plug shall be given on tank top.

- Atmoseal type (COPS) Main conservator with the prismatic type oil level glass.
- Prismatic type oil level glass for OLTC conservator.
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ANGUL (ORISSA)
ORDERING SPECIFICATION FOR 40 MVA LADDLE
FURNACE TRANSFORMER

- Make of rubber cell shall be indicated by supplier.

20.4 Cooling

The transformer shall be OFWF cooled. The two (2) external heat exchanger with their
respective pumps shall be designed for 150% capacity each. Cooling system shall be
designed to restrict the temperature rise of winding at full load to 50 °C (measured by
resistance method) and that of oil (measured at top by thermometer method) to 45°C, for a
cooling water inlet temperature of 38 °C & 50°C ambient. Cooling water temperature rise
shall not be more than 10 °C at rated load.

Cooling water to be used for transformer cooling shall have following analysis:
(JSPL will confirm these datas after order placement)
pH 8.5 - 9.5

Carbonate hardness, less than 5 dH

Total hardness (Ca-Mg), less than 480

Nitrates (NO3), less than 5.0 mg/l

Chlorides (Cl), less than 50 mg/l

Sulphates (SO4), less than 150 mg/l

Free carbonic acid (CO2), less than 5 mg/l

Free chlorine (CL2), less than 3 mg/l

Ammonia (NH3+NH4), less than 0.5 mg/l

Hydr. Sulphide (H2S), less than 0.1 mg/l

Iron (Fe), less than 0.1 mg/l

Manganese (Mn), less than 0.1 mg/l

Copper (Cu), less than 0.1 mg/l

Oxygen (O2), less than 7.0-9.0 mg/l

Un-dissolved matters, less than 5 mg/l

Particle size, less than 0.2 mm

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ANGUL (ORISSA)
ORDERING SPECIFICATION FOR 40 MVA LADDLE
FURNACE TRANSFORMER

Organic content(KMnO4), less than 10 mg/l

Conductivity, less than 1000 my S/cm

*Conversion factor Ca: 10dH = 100 mg/CaCO/l

= 71 mg Ca/l
Mg: 10dH = 42 mg/Mg/l

Note : Corrosion inhibitors as well as biocides need to be admixed.

Pressure at furnace:
Platform / transformer wall 5-6 bar
Pressure loss on furnace 3 bar max.
Average outlet temperature 50C

20.5 Oil Conservator Tank

The transformer shall be equipped with an COPS type oil conservator tank, which shall be
mounted on the transformer. The conservator tank shall have two compartments, one for
the transformer (COPS Type) and one for the on load tap changer (normal type) with
detachable endplate, oil air release valve and drain valve. Each compartment shall be
equipped with valve oil filling pipe, air release valve, a drain valve and a silica gel
breather. All the valves will have blank plate. Lifting lugs for the conservator tank shall
also be provided.

20.6 Bushings

- As per IEC standards.

- The bushings for the primary side will be suitable for at least 3150 amps/ 52 KV (BIL 250
kV peak and 95 kV rms for one minute).

- The bushings shall be replaceable without removing the tank cover.

- The bushing shall be solid porcelain with brown enamel surface.

- Bushing shall be dispatched separately and it should be possible to install them without
draining the oil beyond winding top level.

- All windings and wiring shall be made of electrolytic grade Copper.

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 JINDAL STEEL & POWER LIMITED
ANGUL (ORISSA)
ORDERING SPECIFICATION FOR 40 MVA LADDLE
FURNACE TRANSFORMER

20.7 Transformer protection and alarming.

The contacts shall be suitable for voltage and current as indicated in the table below and
shall have contacts and rating as per table. The following safeguarding equipment shall be
installed.
i) One No. double float gas relay (Buchhloz) mounted between two shut off
valves with two separate output contacts: one for alarm and one for trip for main
tank and having provision for collecting gas at about 1250mm from transformer
room floor level.
ii) One no. single float surge relay for OLTC tank with trip contacts.
iii) One magnetic type oil level gauge for the transformer main tank, readable from
the floor with clear markings for minimum, maximum and recommended level at
30°C. The gauge shall be equipped with switch contacts for alarm and trip for the
minimum level.
iv) One magnetic type oil level gauge for the tap changer tank with an alarm and
trip contact for the minimum level.
v) One temperature gauge with two adjustable temperature switch contacts and
dial type indicator for winding. Additionally, 4 – 20 mA signal for connection to
furnace automation system shall be provided.
vi) One analog type temperature gauge with two adjustable temperature switch
contacts and dial type indicator for transformer oil. . Additionally, 4 – 20 mA
signal for connection to furnace automation system shall be provided.
vii) Two bulb type thermometer with pockets on tank cover according to DIN 42554.
viii) Oil flow indicator with alarm and trip contacts for each heat exchanger.
Additionally, 4 – 20 mA signal for connection to furnace automation system shall
be provided.
ix) Water flow indicator with alarm and trip contacts for each water circuit for each
heat exchanger. Additionally, 4 – 20 mA signal for connection to furnace
automation system shall be provided.
x) Water leakage detector with electrical contacts for both coolers.
xi) Pressure gauge in the oil and water inlet and outlet of each cooler.
xii) Thermometer at inlet and outlet of oil and water circuit of each heat exchanger.
xiii) Atmoseal type (COPS) main conservator.
xiv) 1 no. per phase Current transformer (2 core secondary) for Protection and
Metering shall be provided.

Table 1. Voltage, current & Number of contacts details of protection equipment.

Sr. No. Item No. of Current Rating Make

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 JINDAL STEEL & POWER LIMITED
ANGUL (ORISSA)
ORDERING SPECIFICATION FOR 40 MVA LADDLE
FURNACE TRANSFORMER

contacts
1 Winding Temp. 4 NO 220V, 5A
Indicator AC/DC
2 Oil Temp Indicator 2 NO 220V, 5A
AC/DC
3 Pressure Relief Device 2 NO 240V AC, 5A
220V DC, 1.0 A
4 Buchholz Relay 2 NO 240V AC, 2A
220V DC, 1.0 A
5 Magnetic Oil Gauge 2 NO 240V AC, 5A
220V DC, 1.0 A
6 Oil Flow Indicator 1 NO+1 NC 240V AC, 5A
220V DC, 1.0 A
7 Oil Surge Relay 2 NO 240V AC, 2A
220V DC, 1.0 A
8 Water Flow Indicator 1 NO+1 NC 240V AC, 5A
220V DC, 1.5 A
9 Water leakage detector 2 NC+2 NO 240V AC, 5A

20.8 Rating And Diagram Plate

(Details as per relevant clause of IEC to be covered)

The transformer shall be equipped with an adequate rating plate in accordance

with IEC. The text shall be in English and clearly readable from the floor. In
addition to the requirements of IEC, the following data shall be given.

- Number and size of the tapings along with connection of diverter switch,
tap selection switch, tap position, winding connection at different taps.

- Schematic diagram of the coils with vector group.

- Maximum temperature increase of mineral oil.

- Weight of the transformer unit that may be lifted from the

transformer tank.

- Oil volume to be drained for inspection of tapings.

- Cooler circuit diagram shall also be fixed on transformer.

- Voltage and current at different taps in both primary and

secondary along with Vector diagram.
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 JINDAL STEEL & POWER LIMITED
ANGUL (ORISSA)
ORDERING SPECIFICATION FOR 40 MVA LADDLE
FURNACE TRANSFORMER

- Volume of oil, Weight of oil.

- Weight of core assembly (core + winding).

- Heat exchanger type
- Instruction for vacuumization and oil filteration
- Instruction for COPS
- Hot spot temperature

20.9 Miscellaneous Auxiliaries

Transformer shall be supplied complete with accessories as per IEC, including in

particular (but not restricted to).

- One set piping and fitting for oil cooling circuits.

- One set interconnection pipe for oil & water circuit (i.e facility for any pump can
run with either HE).

- One number control panel accommodating controls for pumps for heat exchanger
(rating of all motors to be specified).

- One set transport rollers (wheels suitable for rotating 90 degree)

- One (1) No auxiliary CTs for measurement of winding temperature.

- One set jacking lugs.

- One set inspection covers.

Following items shall be loose supplied by the supplier for mounting on panels / desks in
furnace control room.

- 1 No digital tap position indicator

- OLTC selector switch to be installed in separate tank so that inspection can be carried out
without draining the main oil tank.

21. GENERAL REQUIREMENT FOR INSPECTION AND TESTING

General

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 JINDAL STEEL & POWER LIMITED
ANGUL (ORISSA)
ORDERING SPECIFICATION FOR 40 MVA LADDLE
FURNACE TRANSFORMER

If in this specification or in referred documents for a specific feature of the transformer no

test requirements are specified, then Supplier shall prove the acceptability of the
transformer with respect to this feature by means of calculations or other design
documents.

Execution of the tests

All tests including routine tests shall be carried out in the factory where the transformer is
produced or assembled using facilities made available by Supplier.

JSPL/ SMS Demag may require copies or the calibration certificates of the test equipment
and may require the use of test equipment provided by JSPL/ SMS Demag

Supplier shall advise JSPL/ SMS Demag in time about the planned execution of specified
tests in order to enable JSPL/ SMS Demag or consultant to send a witness to the tests.
Consultant may require that specific tests will be carried out by the manufacturer without
JSPL/ SMS Demag attendance and that the resulting test certificates will be forwarded to
JSPL/ SMS Demag

Rejection of the transformer

JSPL/ SMS Demag/ its consultant have the right to reject the transformer if any
specification item is not fulfilled. In that case Supplier shall try to correct the fault within
the time possibly available in the project schedule. All modifications and re-tests will be
on Supplier's account.
If Supplier fails in correcting the transformer within the available time, the transformer
will be installed and used for the Ladle furnace during the time that a new transformer
will be manufactured. All costs associated with this procedure will be on Supplier's
account.

Access to facilities
At any time during fabrication and assembly of the transformer, JSPL/ SMS Demag shall
be entitled access to the production facilities in order to be able to inspect the material,
activities and the progress of work.

Progress Reports
A monthly progress report (as per sample to be given later) shall be given by Supplier to
JSPL/ SMS Demag.

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 JINDAL STEEL & POWER LIMITED
ANGUL (ORISSA)
ORDERING SPECIFICATION FOR 40 MVA LADDLE
FURNACE TRANSFORMER

22. SPECIFIC TEST REQUIREMENTS

Transformer

Since the Ladle furnace transformer will be a very specific item, following extensive test
requirements according to IS 2026 / IEC 76 - 1 through 76 -5 shall be carried out:

1. Measurement of winding resistance

2. Measurement of voltage ratio and check of voltage vector relationship
3. Measurement of impedance voltage
4. Measurement of short circuit impedance and load loss

5. Measurement of no load loss and current

6. Induced over voltage test

7. Separate source voltage withstand test

8. Measurement of insulating resistance

9. Check of accessories

10. Temperature rise test/ Heat Run Test (method to be agreed upon preferably by
supplying rated load losses) (all accessories required to perform this test shall be
arranged by supplier).

11. Impulse voltage withstand test (Chopped Impulse and full wave Impulse voltage
withstand test on all three phases).

12. Test for core losses after core assembly as per mutually agreed schedule.

13. Pressure test (with N2)

14. Full Vacuum Test after assembly of complete transformer without oil.

15. Capacitance test on transformer to determine natural frequency shall be carried

out. This will include test from each winding with remaining winding shorted and
grounded.

16. The supplier shall furnish analysis of hot spots in the winding and on the tank by
Finite Element Method (FEM) analysis during engineering. The design will be
verified during Temperature rise test/ Heat run test.

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 JINDAL STEEL & POWER LIMITED
ANGUL (ORISSA)
ORDERING SPECIFICATION FOR 40 MVA LADDLE
FURNACE TRANSFORMER

Tap Changer

Before purchasing, Supplier shall hand over to JSPL/ SMS Demag the type test certificate
according to IEC 214: 1994.

All the routine tests certificates shall be submitted as described in IEC 214: 1994. Routine
test shall be carried out as per relevant clause of IEC.

23. DATA TO BE SUBMITTED

Supplier shall provide sufficient information in addition to the information already

mentioned in this specification, this implies at least the following:

Immediately after the award of order (weeks to be agreed by JSPL)

(All the information/ data required to be furnished as per IS 2026)
1) A) GENERAL ARRANGEMENT DRAWING SHOWING
OVERALL DIMENSION.
B) UNTAKING HEIGHT
C) WEIGHT OF CORE AND WINDING
D) WEIGHT OF COPPER
E) WEIGHT OF THE TANK WITH FITTING
F) WEIGHT OF THE OIL
G) TOTAL WEIGHT

2) A) QUANTITY OF OIL FOR MAIN TANK

B) QUANTITY OF OIL FOR OLTC TANK

3) HEAT EXCHANGER

A) QUANTITY OF WATER REQUIRED FOR EACH HEAT

EXCHANGER IN M³ / HR.
B) CAPACITY OF COOLER IN KW AND ITS BACKUP CALCULATION.
C) COOLING WATER OUTLET TEMPERATURE
CONSIDERING INLET TEMPERATURE 38 ° C
D) WATER INLET PRESSURE
E) DROP IN THE PRESSURE BETWEEN WATER INLET AND OUT
LET.
F) OIL PRESSURE
G) RATING OF OIL PUMP MOTORS AND MAKE.

4. LOSS AT LOWEST CONSTANT MVA TAP AND LOWEST VOLTAGE TAP.

5. PERCENTAGE REACTANCE AT THE TAPS CORRESPONDING TO
VOLTAGES 470V, 415V & 310V.

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 JINDAL STEEL & POWER LIMITED
ANGUL (ORISSA)
ORDERING SPECIFICATION FOR 40 MVA LADDLE
FURNACE TRANSFORMER

6. CORE LOSS AND COPPER LOSS AT FULL LOAD

7. MAKE OF THE TAP CHANGER.

Subsequently:

- Key design data, main dimension and relevant drawings and documents.

- Detailed description of the transformer; particularly with respect to :

The coils

The magnetic circuit

The oil circuit

The bushings (including make and type)

The tank construction (with wall thickness)

Capacity of the tank

The secondary tapings and switching mechanism (on load tap changer).

The volume of the mineral oil.

Type and material of seals.

Make and type of valves.

Spare part list.

Inspection manual.

Trouble shooting instructions.

- Electrical wiring and schematic drawing for tap changer and pump control.

- Schematic diagram of oil cooling circuit indicating water requirement, flange type
of incoming and outgoing side of heat exchanger for water circuit.

- Piping drawing for water base, shipping weight and shipping dimension of
transformer.

- Core Loss
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 JINDAL STEEL & POWER LIMITED
ANGUL (ORISSA)
ORDERING SPECIFICATION FOR 40 MVA LADDLE
FURNACE TRANSFORMER

- Copper loss at full load

- Details of secondary terminals i.e. distance between phases, number of conductor /

phase, size of conductors and distance between conductors in the same phase.

- Percentage reactance at all taps.

- Test certificate in 6 copies

- Final general arrangement drawing

- Final connection diagram of winding showing tap changer connection.

Services
Supplier shall provide services for supervision of erection, testing and commissioning of
the transformer at JSPL, Angul site (to be decided separately). These services required
shall be included and part of the main contract. The services required shall be as follows:

For transformer (SUPPLIER to specify) - --------------- working days

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 JINDAL STEEL & POWER LIMITED
ANGUL (ORISSA)
ORDERING SPECIFICATION FOR 40 MVA LADDLE
FURNACE TRANSFORMER

24. SPECIAL REQUIREMENTS

Technical specifications

1. Shorting of parallel section of secondary winding in each secondary phase shall be done
inside the transformer tank.

2. The oil / water cooling arrangement shall be complete with necessary equipment to make sure
that the oil pressure is always higher than the water pressure.

3. The switching of the transformer will be carried out by means of a VCB. The transformer
design shall be done, taking to into account these considerations. The transformer is operated
with a line side reactance coil. Rating of reactance coil is 14.5 MVAr.

4. The sidewall of the transformer from where the bus tubes go through must be of an
antimagnetic material (SS 304) and so designed that no heat will occur due to magnetic
induction.

5. JSPL/ SMS Demag require witnessing of temperature rise test and impulse test along with all
routine tests and the tests as listed & as per approved QAP of the transformer at
manufacturers works. The manufacturer shall make all necessary arrangements for execution
of these tests at their work & cost.

25. DRAWINGS & DOCUMENTS

The manufacturer shall furnish following information as per the time schedule indicated
below, in 6 copies for timely execution of project.

- Transformer general arrangement drawing.

- Arrangement of bus –tubes (lv side).
- Certified data for cooling water requirement.
- Foundation plan, roller assembly, load data.
- Description of fittings of general arrangement drawing.
- Rating and diagram plate.
- Cooling diagram plate.
- General arrangement and schematic diagram of marshalling panel, tap changer etc.
- Technical literature/ leaflets on OLTC, heat exchanger, indicators and major accessories.
- Technical data sheets for transformer, OLTC, and OLTC motor drive mechanism.
- Any other drawings/ documents required by sms demag/ jspl shall be furnished.

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 JINDAL STEEL & POWER LIMITED
ANGUL (ORISSA)
ORDERING SPECIFICATION FOR 40 MVA LADDLE
FURNACE TRANSFORMER

DOCUMENT SUBMISSION SCHEDULE FOR 40 MVA FURNACE TRANSFORMERS

Sl. No. Description Duration

(From the date of
Contract/Down Payment)
1. Manufacturing Plan To be specified by
Supplier

2. Preliminary Drawing, Outline General - do -

Arrangement Drawing, Load Detail For Civil
And Basic Rating Plate / Data Sheet

3. Final Layout, Outline General Arrangement - do -

Drawings

4. Quality Plan - do -

5. Electric Drawing for Control Panel - do -

6. Tap Changer Drawing - do -

7. Data Sheet - do -

8. Rating Plate - do -

9. Spare Part List with Itemized Price (Price - do -

Break up)

10. Data Sheet for accessories - do -

11. Data Sheet for Oil

- do -
12. P & I Diagram (Cooler Diagram)
- do -
13. Instruction Manual (Preliminary)
- do -
14. As Built Drawing & Instruction Manual - do -
(Final)

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 JINDAL STEEL & POWER LIMITED
ANGUL (ORISSA)
ORDERING SPECIFICATION FOR 40 MVA LADDLE
FURNACE TRANSFORMER

SCHEDULE-I

Sl. Description Unit Qty CIF / CIF / Ex- Excise Custom Counter Any other Freight & For
No. Ex- works Duty Duties Veiling Taxes & Transit Total
works Total Duties Duties / Levies Insurance Price
Unit Price (give detail) (*) (*)
Price
1. Supply of 40 MVA
Furnace
Transformers
complete with Nos 04
fittings accessories
and first filling of oil
& 10% extra oil in
non-returnable
container as
specified in the
specification.

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 JINDAL STEEL & POWER LIMITED
ANGUL (ORISSA)
ORDERING SPECIFICATION FOR 40 MVA LADDLE
FURNACE TRANSFORMER

SCHEDULE-II

SCHEDULE OF TECHNICAL DEVIATIONS

We/I have carefully gone through the Technical specification and we/I have satisfied ourselves/myself
and hereby conform to the requirement of technical specification except for the deviations, which are
given below:-

Sl.No. Descriptions & Stipulation in Deviation Remarks

Clause No. of The specification offered Regarding
specification page No. justification of
the deviation.

Date SIGNATURE OF TENDERER

Place NAME
DESIGNATION
(SEAL)

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© 2009 MECON Limited. All Rights Reserved.’