5

PARTICULAR TECHNICAL SPECIFICATIONS

POWER TRANSFORMER

Materials and Labeling

All materials used shall be of the best quality and of the class most suitable for working under
the conditions specified and shall withstand the variations of temperature and atmospheric
conditions or the setting up of any undue stress in any part, and also without affecting the
strength and suitability of the various parts for the work which they have to perform. No
welding, filling or plugging of defected parts will be permitted without the permission in writing
of ZESCO's representative.

Cast iron shall not be used for chambers of oil or for any part of the equipment which is subject
to impact and tensile stresses. This clause is not intended to prohibit the use of suitable grades
of cast iron for parts where service experience has shown it to be satisfactory.

All connections and contacts shall be of ample section and surface for carrying continuously the
specified currents without undue heating. Fixed connection shall be secured by bolts or set
screws of ample size, adequately locked. Lock nuts shall be used on stud connection carrying
current.

On outdoor equipment, all bolts nuts and washers in contact with non-ferrous parts which carry
current shall be of phosphor bronze.

DESIGN CRITERIA

Service Conditions

The transformer shall be capable of operating continuously outdoors at any tapping during the
ambient conditions specified in General Specifications.

Note that the average ambient temperature in any one day is 35 oC. The maximum temperature
rise of the top oil shall therefore not exceed 55 oC and 60 oC of the winding above the maximum
ambient temperature of 45 oC.

For temperature correction due to altitude reference is made to IEC Publication 76-2, Clause 2.3
which limits the temperature rise further, when tested at normal altitude, by 2 % for ONAN
cooling and 3 % for ONAF.

Rating

The transformer shall comply with the ratings specified in Scope of Supply under the stated
service conditions without exceeding the temperature rise limits specified in 2.1 above, over the
complete tapping range. If the voltage on the secondary (LV) side is reduced or raised by up to
5% from the rated voltage, the temperature rises of any part shall not rise by more than 5 oC (at
rated power on any primary tapping).
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Tapping

All tappings shall be designed for constant kVA output, the rated voltage of each winding of the
transformer on the principal tapping shall be as specified in Scope of Works and Supply and
unless otherwise specified, shall correspond to the system nominal voltage. The tapping ranges
shall be as specified in Scope of Supply.

Noise

The transformer, tap-changing equipment and supplementary cooling equipment shall operate
without undue noise and every care shall be taken in the design and manufacture to reduce noise
to the level of that obtained in good modern practice. The noise level of the transformer shall
not exceed 78 dB when tested in accordance with IEC Publication 551.

Radio Interference

The design of the transformer shall be such that they will not cause any objectionable
interference with radio reception in the vicinity of the transformer, either by direct radiation or
by transmission through the power-lines and system to which the transformer may be connected,
when energising at full rated voltage and when delivering any load up to the continuous
maximum rating.

Interchangeability and Paralleled Operation

All transformer of any one type shall be identical and interchangeable with one another. No
alteration to control circuits shall be permissible for this purpose except by means of built-in
terminal boards fitted with links for effecting the alteration. All parts are to be made accurately
to dimensions so that any corresponding parts will be interchangeable and any spare parts will fit
into place without need of adjustments. Where similar equipment has previously been supplied,
components shall interchange with those on previous contracts, unless otherwise approved.

The transformer shall be suitable for parallel master-follower operation with each other and with
transformer of a similar rating, previously supplied, both in respect of transformer characteristics
and control circuits on all relevant taps, under which conditions they shall share the load subject
to the tolerances of impedance and voltage laid down in BS 171, IEC Publication 76 or
equivalent standards (See also Section 4.5 of these specifications, i.e. voltage control
equipment).

Insulation Levels

When assembled complete with connections as in service, electrical clearances in air shall be
adequate to withstand the required impulse withstand voltage. The insulation level for bushings
must be corrected for high altitude and particular reference is made to IEC Publication 137,
Clause 16 in this respect. Minimum bushing BIL insulation levels at sea altitude shall be at least
one voltage class (according to IEC) higher than the winding insulation levels which
corresponds to 1425 kV,1300 kV,750 kV and 170 kV for 330kV, 220 kV,132 kV and 33kV
operating voltages respectively. The Bidder shall propose in his Bid details of bushings with
drawings showing air clearances and creapage distances. The creapage distance shall not be less
than 31 mm/kV line voltage. Care shall be taken to ensure that no fittings are located so as to
interfere with the external connections to the bushing terminals.
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The windings at the 330kV level may have graded insulation, the neutral points being solidly
connected to earth. Windings of lower voltages shall have full insulation. The insulation levels at
sea level for the various windings shall be as follows:

_______________________________________________________________________

Operating voltage System highest Impulse test Power frequency

voltage voltage test voltage
kV rms kV rms kV peak kV rms
_______________________________________________________________________

220 300 950 460

330 362 1175 510

_______________________________________________________________________

Short Circuit Performance

The transformers shall be capable of withstanding, without damage, the effects of a symmetrical
three-phase short circuit and a phase to earth short circuit under conditions specified in IEC 76
or in relevant sections of other approved standards.

It can be assumed that during a short circuit, nominal voltage will be maintained on one side of
the transformer with a short on the other, the external impedance being zero. It can also be
assumed that up to four transformers may be connected in parallel between HV and LV busbars.

Frequency

The normal frequency will be 50 cycles per second. The transformer shall, however, be suitable
for continuous operation with frequency variation of plus or minus 2½ per cent from the normal,
without exceeding the temperature rise limit specified in Clause 4.1 in this Section.

Flux Density

The maximum flux density in any magnetic component under any condition of voltage and
frequency specified under all the operating conditions given in this Specification shall not
exceed 1.9 Tesla.

DESIGN

General

Transformer shall be of the oil immersed type suitable for outdoor use, they shall be dried out at
the manufacturers’ works and it should be possible to commission them without further dry out.

Designs shall be such that water does not collect on any of the equipment. Particular attention
shall be paid in the design of all equipment to ensure that there is not damage to working parts
or insulation through the ingress of dust, insects or vermin which are prevalent for long
periods in the year.

Live metal of auxiliary connections in air shall be screened to prevent accidental contact and
shall be enclosed in compartments which are fitted with approved means to provide reasonable
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dry conditions within the compartments; in addition, where there are auxiliary connections at
380 Volts or more, "Danger" notices shall be affixed to the outside of the compartments.

When specified in Scope of Works and Supply and in addition to any range of tappings available
by tap change operations, facilities for selecting a number of different rated voltage ratios shall
be provided preferably by arranging the appropriate untapped windings in sections which may
be connected in series or in parallel readily accessible changeover links shall be provided to
allow selection of series or parallel connections. The cover for the opening providing access to
the links shall be labeled to show the purpose of the opening and shall be fitted with a diagram
plate of incorrodible material which shall be engraved to show the arrangement of links for each
ratio together with link terminal numbers which shall be engraved on link board and shown on
the transformer main diagram.

Cores

The transformer core shall be built up of laminations of the best quality non-ageing cold-rolled
grain oriented silicon sheet steel of high permeability and loss coefficient. All joints between
laminations shall be of the interleaved type and the laminations shall be clamped securely.
Bolting of the core should be avoided to reduce losses. On no account shall butt joints be
offered. The cross-section of the core shall form an approximate circle.

The laminations shall be separated by hot-oil proof insulation, and the clamping of the frame
shall be firm to ensure even pressure over the whole of the core laminations so as to prevent
undue vibrations or noises.

The core sheets shall be insulated with high-grade oil-proof insulation, for example magnesium-
silicate-phosphate. Paper will not be accepted.

The magnetic circuit shall be designed to avoid the production of flux components at right
angles to the plane of laminations, which may cause excessive local heating.

The core clamping arrangement and frame work shall be efficiently insulated from the cores and
withstand applying 2kV, 50 HZ during 1 minute. The core shall be designed and built up in
such a manner as to avoid accidental or slow development of short circuit paths through the iron
and framework.

Each part of the core shall be electrically earthed to the transformer tank. The internal earth
connection shall be of the detachable link type and shall be located in an accessible position.

The core, framework, clamping arrangements and general structure of the transformer shall be of
robust design, capable of withstanding any shock to which they may be subjected during
transport, installation or service.

Suitable axial cooling ducts shall be provided to ensure free circulation of oil and efficient
cooling of the core. The ducts shall be proportioned so that the maximum temperature at any
point will be within the prescribed limits of temperature rise.

Lifting lugs or other similar means shall be provided for conveniently lifting the complete
assembly (with windings).

Provision shall be made for efficient arrangement of guides to prevent movement of the core and
windings during transport, installation or service.
 9

The framework of the core shall be so designed as to prevent the presence of oil pockets, which
would prevent complete emptying of the oil from the tank through the drain valve.

Windings

The bid shall be based on transformers with separate windings.

The windings shall be circular and consist of high quality rectangular section copper, wound
with age resisting paper of high dielectric strength. The current densities in the windings shall
be stated in the Bid.

The amount of insulation between turns shall be determined not merely by normal volts per turn,
but also by due consideration of the line voltages and the service conditions, under heavy
lightning storms.

Adequate insulation and clearances between the windings shall be provided and all insulation
and clearance between live parts must be adequate for operation at 5 per cent over the highest
tap voltages on all the windings.

The insulation of the end turns of each winding adjacent to the transformer terminals shall be
reinforced between turns to protect the windings satisfactorily against surges and transients.
Details of the reinforcements shall be given in the Bid.

The insulation of the transformer windings and connections shall be free from insulating
composition likely to soften, ooze out, shrink or collapse during service. None of the materials
used shall shrink, disintegrate, carbonise or become brittle under the action of hot oil, when the
transformer is operated continuously at the maximum specified over loading.

The windings shall be so placed that they remain electrostatically balanced with their magnetic
centres coincident under all conditions or operation. To prevent excessive static voltage, static
end rings shall be provided, wherever necessary, at the live end of the windings.

The windings, connections and trappings of the transformer shall be clamped in position and
braced so as to withstand shocks or undue stresses during transport, short circuit conditions, and
other transient causes. No mechanical movement of the coils should be possible with dead short
circuit on the transformers.

All windings and all fibrous and hygroscopic materials used in the construction of the
transformer, shall be dried under vacuum and impregnated with hot oil. Full details of the
drying out and vacuum treatment shall be furnished by the Bidder.

Leads from windings to terminal board and bushings shall be rigidly supported to prevent injury
from vibration and short circuit forces.

Adequate provision shall be made for the circulation of oil round and between the winding so
that a low temperature gradient between the conductors and the oil is assured and any danger of
excessive local heating is avoided.

The finished width of any duct and clamping arrangement shall be such as not to impede the free
circulation of oil through the ducts.
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It is essential that the windings shall be subjected to a thorough shrinking and seasoning process,
so that no further shrinkings of windings occur at site. However, clamping arrangement shall be
provided for taking up any possible shrinking of coils when in service.

All similar coils shall be strictly interchangeable.

Full detailed description of the windings shall be submitted with the Bid.

When specified stabilising windings shall be provided. The windings shall be capable of
withstanding the forces to which they are subjected under all conditions, particularly the forces
due to a short circuit between terminals or between any terminal and earth with full voltage
maintained on all other windings intended for connection to external sources of supply. When
stabilising windings are to be used for purposes other than decreasing zero sequence impedance,
this will be declared in the Bid documents and the windings must be designed accordingly.

Unless otherwise specified, each corner of the stabilising winding shall be brought outside the
tank for connection to auxiliary transformers or reactors and suitable bushing shall be provided
for this purpose through the tank cover.

It shall be possible to earth the winding externally to the main tank by means of a flexible bolted
link to be provided by the supplier between the terminal and a suitable pad on the tank cover.

The neutral points of star connected windings shall unless otherwise specified in Scope of
Works and Supply be brought out to bushings located on the tank cover and connected to an
earthing bus attached to the main transformer earth terminal.

Where the star point of a winding is not specified to be brought out through a neutral bushing,
the connection shall, nevertheless, be available under the main tank cover plate to permit the
subsequent fitting of a neutral bushing. The subsequent installation of this bushing shall not
necessitate any alteration to, or repositioning of existing fittings.

Current Transformer

Current transformer for winding temperature measurements shall be mounted inside the
transformer on the bushings, and in the connection between winding and neutral point for auto-
transformers.

Accuracy class 3 shall be used for temperature indication.

Internal Earthing

The transformer and core earthing should be brought to the top of the transformer and be
accessible for test purposes. The top main core clamping structure shall be connected to the tank
body by copper strap.

The bottom clamping structure shall be earthed by one or more of the following methods:

a. by connection through vertical tie rods to the top structure.

b. by connection to the top structure on the same side of the core as the main earth
connection to the tank.
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The magnetic circuit shall be earthed to the clamping structure at one point only through a
removable link placed in an accessible position beneath an inspection opening in the tank cover.
The connection to the link shall be on the same side of the core as the main earth connection and
be taken from the extreme edge of the top yoke.

Magnetic circuits having an insulated sectional construction shall be provided with a separate
link for each individual section and the arrangement of the connections shall be to approval.

Where oil ducts or insulation parallel to the plane of the laminations divide the magnetic circuit
into two or more electrically separate parts, the ducts or barriers shall be bridged in accordance
with Clause 4.2 and the magnetic circuit shall not be regarded as being of sectional construction.

Where coil clamping rings are of metal, each ring shall be connected to the adjacent core
clamping structure on the same side of the transformer as the main earth connection.

All earthing connections, with the exception of those from the individual coil clamping rings,
shall have a cross-sectional area of not less than 90 mm2. Connections inserted between
laminations may have the cross-sectional area reduced to 25 mm2 where in close thermal contact
with the core.

Tanks

Tanks shall be complete with all accessories and shall be designed to allow the complete
transformer in the tank and filled with oil, to be lifted by crane or jacks, transported by road, rail
and water without overstraining any joints and without causing subsequent leakage of oil.
Corrugated tanks are not acceptable.

Each transformer shall be enclosed in a steel tank of welded construction, suitably stiffened by
means of channel or angle sections welded to the tank, for withstanding the stresses imposed
during transit to site and subsequent operation with no signs of oil leakage. Bell type
transformer tanks are not permitted.

The tanks must be so constructed as to be capable of withstanding an internal positive pressure

of not less than 70 kPa without any permanent deflection of any parts. The tank must also be
capable of withstanding a vacuum of 50 mm of mercury absolute when emptied of oil.

Guides shall be provided inside the tank to facilitate the lowering into the tank of the core and
coils and their raising and correct positioning. The guides shall extend from the bottom of the
tank to within 150 mm of the top of the tank.

The tank covers shall be bolted to the tank and of adequate strength and shall not be distorted
when lifted. Inspection openings suitably bolted shall be provided as necessary to give easy
access to bushings, tap changer connections and earth connections. Each inspection opening
shall be of ample size for the purpose for which it is provided. Manhole covers must be
provided with lifting eyes where necessary. The tank cover and all inspection covers shall be
provided with lifting eyes.

Detachable radiators shall have lifting eyes and shall be provided with drain plugs or valves at
their lowest points and vent plugs in the headers. Isolating valves shall be provided immediately
adjacent to the main tank or headers to enable the radiators to be removed without handling the
oil in the transformer tank.
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All oil-pipe connections shall have flanged joints provided with gaskets, preferable set in
grooves or held in position by stops to prevent over-compression of the gaskets.

The base of the tank shall be so designed that it shall be possible to move the complete
transformer unit in any direction without injury when using rollers, plates or rails. A design
which necessitates rails being placed in a particular position shall not be used.

Lifting lugs shall be fitted capable of lifting the transformer complete with windings and filled
with oil.

Four jacking lugs shall be fitted 500 mm above ground level and four holes with a diameter of
not less than 50.8 mm shall be provided on the jacking lugs in order to permit the transformer to
be slewed in any direction.

The tank cover shall be fitted with pockets for a thermometer and for the bulbs of the winding
temperature and oil temperature indicators specified. Protection shall be provided when
necessary for each capillary tube. The thermometer pocket shall be fitted with a captive screwed
cap to prevent ingress of water. The pockets shall be located in the position of maximum oil
temperature and it shall be possible to remove the instrument bulbs without lowering the oil in
the tank.

The tank cooling equipment shall be designed to permit vacuum treatment on site. The
maximum safe permissible vacuum (millimetres of mercury) which may be applied above oil
level, to the tank, cooling equipment and to the conservator, without causing permanent
distortion, shall be stated in the Bid.

Two earthing terminals located at opposite side of the tank, capable of carrying for 30 seconds
the full lower voltage current of the transformer, shall be provided. Provision shall be made at
positions close to each of the four bottom corners of the tank for bolting the earth terminals to
the tank structure to suit local conditions.

A rating plate shall be fixed to the tank at a height of not more than 1,55 mm above ground
level. A diagram plate shall also be fixed to the tank in an easily accessible position.

Gaskets

Oil-resisting synthetic rubber used as a bonding medium for cork or similar material, or
alternatively, where steel stops are provided to prevent over-compression of the gaskets.

The Contractor shall submit details of gasket material for approval.

Spare unused sets of gaskets shall be supplied for use on site for all positions where joints have
to be made after transportation of the transformer.

Bushings

Bushings shall be fitted to the equipment as specified in Scope of Works and Supply.

All terminals shall be marked to correspond with the markings on the diagram plate.

The transformer bushings shall withstand accidental arcing or flashover without seals or other
vital parts becoming damaged. Stresses due to expansion and contraction in any part of the
 13

bushing shall not lead to development of bulges, hair-line cracks or other defects. Suitable
connecting clamps shall be able to absorb shocks due to vibration of the connecting jumpers.
The bushings shall withstand internal vacuum in the transformer tank.

All the bushings of any transformer shall have a rated current of at least 120% of the rated
currents of the windings to which they are connected (in order not to limit over-loads).

Vibration

The transformer shall be erected on anti-vibration pads or mountings when specified to be supplied by the
manufacturer which shall be to the approval of the Employer's representative, the Project Manager.

Painting and Galvanising

Oil-filled transformer shall have their interior surfaces sandblasted and finished with two coats of anti-
corrosive and oil-resistant priming paint. Exterior surfaces shall be sand-blasted and have two rust
inhibiting priming coats and one intermediate coat with paint on zinc chromate or urethane alkyd basis or
equivalent; one final coat of weather and oil resistant paint. Minimum total thickness 0.16 mm.

The radiator external surfaces shall be hot-dip galvanised with a zinc deposit on average not less
than 400g/m2.

Control boards, panel boards, cubicles, cabinets, etc. in dry rooms shall have interior surfaces
painted with at least one priming and one finishing coat of anti-corrosion paint. Exterior
surfaces shall be adequately treated to be substantially corrosion resistant, with one prime coat
and two finishing coats.

Other indoor installations in dry rooms shall be carefully cleaned, if possible sand-blasted and
painted with two coats of oil resistant paint.

Outdoor installations and indoor installations in wet and damp rooms shall have at least one
prime coat and two layers of paint on zinc powder basis to be applied after perfect cleaning.

The particulars of priming and finishing paintings shall be stated in the Bid, with specifications
of paint, together with a listing of colours available, for each of the plant and equipment.

The Employer is not bound to accept the finishing colour proposed by the Bidder.
Determination of colour shall be at the option of the Employer and shall be finalised at the time
of approval of drawings.

The exterior finish of outdoor control cabinets shall be in the same colour as that for the
transformer.

Should any paint work be damaged during transit or erection, this shall be made good on site.

All interior and exterior surfaces, subject to corrosion, that cannot readily be painted shall be
hot-dip galvanised with an average thickness not less than 0.1 mm. Bolts and nuts associated
with galvanised parts shall be hot-dip galvanised, electro-galvanised or sheradised and shall
meet the test prescribed in BS 729, i.e. four dips in Copper Sulphate solution.
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FITTINGS

The transformer shall be supplied with the fittings specified in Scope of Supply. These fittings
shall comply with the following clauses.

Conservator

The conservator shall be mounted on the main tank (should have an air cell).

The conservator shall be fitted with a removable end on which shall be mounted the oil gauge.
The conservator tank shall be mounted to slope lightly downwards towards the drain valve,
which shall be adjacent to the removable end.

The pipe connecting the conservator to the tank shall extend at least 50 mm into the conservator
and shall be brought out from the highest point of the main tank cover. A valve shall be
provided immediately adjacent to the conservator. All pockets and bushing turrets of the main
tank shall be connected into this pipe between the transformer and the Buchholz relay.

The conservator shall be so dimensioned that it will permit all expansion over the working range
of temperatures from no load with the transformer cold and at -10oC ambient air temperature to
full load at 45oC ambient air temperature while the sump pipe remains covered with oil and the
oil level is visible or indicated. In any case, the volume of the conservator shall be at least 10%
of the transformer oil volume.

The oil connections from the transformer tank to the conservator vessel shall be arranged at
rising angle to the horizontal. The Buchholz relay (see Clause 4.6) shall be fitted in this pipe in
such a position that inspection, testing and dismantling is possible with the transformer in
operation. A step valve shall be provided between the conservator and the relay.

The conservator shall be equipped with the following fittings:

a. A sump which may be formed by extending the inlet pipe inside the conservator.
b. A manhole formed by bolting one end-plate of the conservator.
c. A drain valve with flanged plug.
d. A flanged filling plug.
e. An oil level gauge of the type specified in Section 4.4.3 below.
f. A filter valve.

Dial-type Oil Gauges

Dial-type oil gauges, where specified, shall be of the magnetically operated type, in which
breaking of the gauge glass will not release any oil. The gauge shall be fitted with at least two
circuit-closing, ungrounded, low-oil-level alarm contacts.

Silica-Gel Breathers

Each conservator shall be fitted with a silica-gel type dehydrating breather to approval. The
breather shall be provided with an oil cup or other device which prevents contact between the
dehydrating agent and the air outside the transformer. If an oil cup is provided, the oil should be
visible from the outside and the lowest oil level should be marked.
 15

The weight of the dehydrating agent shall be not less than 0,5 kg per 1500 litres of oil in the
transformer and cooler.

Unless the silica-gel container is transparent the breathers shall have a window for inspection of
the colour and condition of the silica-gel and oil cup or other device to prevent continuous
contact of the silica-gel with the air outside the transformer.

Explosion-Vents

Explosion-vent pipes shall have a diaphragm of approved material fitted at the upper end only.
An equalising non-ferrous pipe shall connect the air space of the explosion vent with the air
space of the conservator, but where this pipe would be unduly long or its presence affect
electrical clearances, a small silica-gel breather may be fitted at ground level and connected to
the upper end of the vent pipe by means of a small-bore non-ferrous pipe. If the explosion-vent
pipe is connected to the top of the main tank, it shall either extend 50 mm into the main tank or
be provided at the lower end with a gas deflector.

The explosion-vent shall be provided of sufficient size for the rapid release of any pressure
which may be generated within the tank and which might result in damage to the equipment.
The device if used shall be so placed that any discharge from it will not be deposited on any part
of the transformer or its associated equipment.

The diaphragm shall be of approved design and material and shall be provided with a protective
cover during transport.

The specification of the overpressure relief device shall be approved by the Project Manager.
The device should not mal-function if the oil level in the conservator rises beyond the 75 %
level.

Buchholz Relays

Buchholz relays shall be of the double-float type with separate floats for alarm and shut-down at
low and high speed gas development and shall be of approved manufacture suitable for
operation in transformer oil as specified over the temperature range -10oC to 115oC. The two
contact sets shall not be exposed to oil and shall be wired to the marshalling box.

The relays must be interposed in the connecting pipe between the oil conservator and the
transformer tank in such a manner that all gas from the tank must pass through the relay as it
rises to the oil conservator.

Two copper pipes shall be connected to the two pet cocks on the relay and extended to position
1 m above ground level and fitted with stop cocks for sampling and testing purposes. The stop
cocks are to be labelled and easily accessible and be clear of surrounding steel-work. The sight
window of the relay shall be readily visible from ground level.

Temperature Indicators

The local temperature indicators shall be of the dial-type graded in oC with a manually resettable
pointer to register the highest temperature reached. The local indicators shall be mounted on the
transformer tank in a suitable weatherproof steel cabinet with a lockable door. The cabinet and
gauges shall be so positioned as to allow easy access to and readability of the gauges.
 16

The transformer shall be provided with winding temperature indicators of the "thermal image"
type compensated for changes in ambient temperature (one for each winding type: common,
series, HV, LV and tertiary as appropriate). The indicator shall have a load - temperature
characteristic approximately the same as the hottest part of the windings. The primary current
transformer for operating the indicator shall be built into the main transformer tank on the
bushings. Information shall be included in the maintenance instructions in the form of either a
graph or table showing the relationship between current injected into the heater coil and the
corresponding temperature reading.

The indicators shall be provided with two sets of alarm/trip contacts, adjustable to close at any
temperature between 45o and 150oC such adjustment being possible without dismantling the
instrument. Where supplementary forced cooling is specified, two additional set of contacts
shall be provided on the winding temperature indicators, for automatic start of the cooling fans
in two stages. The differential between "switch on" and "switch off" temperatures must also be
variable in the range 10°C to 15°C.

The instrument and set points shall have an accuracy of ±1% of full scale deflection and the
indicated temperature must reflect the hot spot temperature to within 3±oC under all operating
conditions. Test links are to be provided for calibration purpose.

One temperature indicator of the capillary type for measurement of the top oil temperature shall
be provided for each transformer. The capillary should be protected by steel wire armouring
from the indicator to the point of entry into the thermal pocket. The capillary, shall have extra
protection against heavy objects, at point of entry into the thermal pocket (to prevent gauge
damage during transformer maintenance by personnel stepping on them at this bend).

Alarm and Trip Contacts

All alarm contacts shall have ample inductive making and breaking at the specified alarm and
tripping voltage.

Any auxiliary relays associated with the trip circuits shall be DC operated and suitable for the
specified alarm and tripping voltage.

Alarm and trip contacts shall be provided with independent potential free contact.

Drain, Filter and Sampling Valves

General

All valves shall be attached by bolted-on flanges and shall not be screwed or welded to the tank.
Drain valves or isolating valves larger than 101,6 mm (4"B.S.P.) and of the double-flanged gate-
type construction may have bodies of cast iron or cast steel. All valves shall be opened by
turning counter-clockwise when facing the hand wheel.

Every valve shall be provided with an indicator to show clearly the position of the valve.

Means shall be provided for padlocking the valves in their open and closed position.

All valves shall be suitable for operation in conjunction with transformer oil as specified in IEC
Publication 296 at temperatures up to 115oC.
 17

Drain Valves

Drain valves shall be of suitable dimensions in relation to the volume of oil in the transformer
tank and coolers.

Oil Sampling Valves

Oil sampling valves shall be of the screwed globe type; handle or gate valves located so as to
permit sampling of oil from the extreme bottom of the transformer tank and the bottom of the
tap changer compartment.

Filtration Connections

Filtration connections, which shall have flanges drilled to BS 4504 Table 6, for 50,8 mm (2")
valves, or screwed 50,8 mm (2"B.S.P.) female, shall be as follows:

a. A valve at the top and bottom of the main tank. The drain valve of the main tank may be
used for this purpose if of the size described above.

b. The oil conservator drain valve located within easy reach of the ground, by means of a
pipe extension if necessary shall be suitable for a filter connection.

Valve Entries

All valve entries shall be blanked off with gasketted bolted-on plates or plugs.

Rating and Diagram Plates

Rating and diagram plates shall be to IEC 76, BS 171 or equivalent specification stamped or
embossed on brass, or stainless steel. They shall show the Employer's Order Number and shall
have a blank space for the Employer's Serial Number. The diagram plate shall show the internal
connections and the voltage vector relationship of the windings in addition to a plan view of the
transformer giving the correct physical relationship of the terminals and indication of winding
material.

Where applicable, rating or diagram plates shall show locations, ratio, rating and accuracy class
of current transformer. Rating and diagram plates shall be approved by the Project Manager.

Skid Underbase

Skid underbase, where specified, shall be reinforced to permit moving the transformer in
direction perpendicular to the base. Hauling eyes shall be provided on the underbase.

Wheels

Wheels, where specified, shall be plain, flanged uni-directional or bi-directional, whichever is

specified in Scope of Works and Supply.

Wheels fitted to transformer shall be provided with grease nipples or cups for lubricating the
wheel bearings.
 18

Bi-directional wheels shall be designed so that it is possible to change the direction of the wheels
without removing them from the transformer, and provision shall be made for locking the
wheels parallel or at right angles to the major axis. Grease nipples or cups shall be provided for
lubricating the swivel bearings. The wheel gauge will be provided by the Employer.

Transformer Protector

The transformer shall be equipped with an adequately sized transformer protector in the event of
an explosion or fire outbreak.

VOLTAGE CONTROL EQUIPMENT

On-Load Tap Changers

The transformer's voltage control equipment shall be of the tap changing type for varying its
effective transformation ratio whilst the transformer is on load and without producing phase
displacement. The on-load tap changing equipment shall comply with BS 4571, IEC 214 or
other approved and equivalent standards. The tappings shall be arranged in the electrical centre
of the higher winding.

The tap changing equipment shall be of the 3-phase resistor type, preferably with combined
diverter and selector switches and shall be designed so that it will not be possible for the main
transformer winding to be open circuited or for a portion thereof to be short circuited, except
through a transition impedance.

Generation from any type of control shall cause one tap movement only.

The equipment shall be so arranged as to ensure that when a tap change has commenced, it shall
be completed independently of the operations of the control relays or switches. Failure of the
auxiliary supply during a tap change operation must not inhibit the independent completion of
the tap change operation.

An auxiliary supply of 400/230 volts, 50 Hz, 3-phase 4-wire A.C. will be available for operating
the tap changing equipment and all its accessories. All equipment shall operate correctly at any
voltage between the limits of 85% and 115% of nominal value.

Tap changing equipment shall be capable of carrying the same currents due to external short-
circuit as the transformer windings and shall withstand the impulse and dielectric tests of the
associated winding. The tap changer connection and switches shall be capable of handling
continuously currents at least 20% above the highest operating current in order no to limit
overloading.

It shall not be possible for the insulating oil in those compartments which contain contacts for
making or breaking current to mix with the oil in the main transformer tank or with the oil in
compartments containing contacts not used for making or breaking current. This requirement
shall not apply where mercury switches are used to make and break current.

Drop-down tanks which necessitate the provision of pits in the foundations are not acceptable.
 19

Where it is necessary to remove parts, or the whole of the on-load tap-changer for transport
purpose, it shall be possible to complete erection on site with the transformer windings covered
with oil.

Construction

The number of the tappings in use shall be indicated mechanically at the transformer and
electrically at the local control room panel. A potentiometer shall be provided for the local
control room panel indication. The potentiometer switch shall be of the make-before-break type.

The tap-changing switches and mechanism shall be mounted in an easily accessible cabinet on
the transformer tank and shall be supported from the main tank or its base.

The oil compartment for the tap changing switch shall be fitted with its own over-pressure
device and Conservator; the conservator shall be dimensioned such that the expansion rates as
specified in 4.2 can be met, together with suitable oil level indication and drain valves.

All switches forming part of the main tap-changing apparatus shall be oil immersed and readily
accessible and it shall be possible to examine or repair such apparatus without lowering the oil
level in the main transformer tank.

Each compartment in which the oil level is not maintained from the conservator shall be
provided with an oil gauge of approved design.

Limit switches shall be provided to prevent the over-running of the mechanism and shall be
connected directly in the circuit of the operating motor. In addition, mechanical stops or other
approved devices shall be provided to prevent the overrunning of the mechanism under any
condition. The tap changer should be so designed that a mechanical device, through necessary
relays, should trip the transformer if the tap changer is stuck in an intermediate position

Approved means shall be provided to protect the motor and control circuits.

The whole tap-changing equipment shall be of robust design and capable of giving satisfactory
service without undue maintenance under the conditions to be met in service, including frequent
operation.

An externally visible mechanical recorder shall be fitted to the mechanism to indicate the
number of tap-change operations completed by the equipment. At least five digits must be
provided. No provision for resetting the counter is to be made.

Operation

330/220/11 kV, Auto-Transformer:

The tap changer shall be operated in the following modes:

- Directly on the motor control cabinet in the switchyard (local control)

- From the control room in the substation (remote control)
- From the National Control Centre [NCC] (supervisory control).

A blocking switch shall be provided on the motor control cabinet with two positions:
local/remote (supervisory).
 20

When the switch is in local position, control can only take place from the control cabinet on the
transformer and vice versa for the other position.

All the necessary equipment like relays, contactors, etc. shall be provided, wired up to terminal
blocks to facilitate the functions outlined above. A potentiometer switch of the make before
break type shall be provided for remote and supervisory tap position. The numbers shall range
from 1 upwards, the lowest number representing a tapping position corresponding to the
maximum number of high voltage winding turns, i.e. the highest plus-percent positions. The
lowest minus-percent position shall be represented by the highest number.

Unless specifically asked for in this document, all equipment for control and indication required
in the control room shall be provided by the supplier of the control room equipment

Facilities shall also be provided to prepare the transformer for parallel operation with one or
more transformers on the master - slave principle. An out-of-step device shall be provided and
arranged to prevent further tap changing after a definite time interval when the transformer on
parallel control is one tap out of step.

Alarms and Trip Signal

The following alarms shall be provided, wired up to terminal blocks in the transformer cabinet:

- Tap changer not operating.

- Transformer on parallel control are out of step.
- Partial or complete failure of the voltage transformer supply to the voltage
regulating relay. This alarm shall be inoperative when the transformer is on non-
automatic control.
- Fan failure, alarm.
- Gas relay transformer, alarm.
- Gas relay transformer, trip.
- Protective relay OLTC, trip.
- Oil gauge low level transformer, alarm.
- Oil gauge low level transformer, trip
- Oil gauge low level OLTC, alarm.
- Oil gauge low level OLTC, trip.
- Pressure relief device transformer operated, trip.
- Pressure relief device OLTC operated, trip.
- Top oil temperature high, alarm.
- Top oil temperature critical, trip.
- Winding temperature high, alarm (on both sides).
- Winding temperature critical, trip (on both sides).
- Tap changer AC supply fail
- Tap changer DC supply fail
- Group 1 fans, supply fail
- Group 2 fans, supply fail
 21

Local Tap Changer Control Cubicles and Wiring

The power transformer shall be provided with a weatherproof local mechanism/control cubicle
for control of the on-load tap changer. The cubicle shall preferably be mounted on the side of
the transformer tank but for larger units, a separate free-standing marshalling kiosk would be
considered.

A separate cabinet, also preferably mounted on the transformer shall be provided to facilitate
connection of all wiring required for indication, control, alarm and trip signals in addition to the
control of the cooling equipment.

All cubicles and cabinets shall be complete with the requisite front panels. Bidder shall provide
in their Bid a complete list of all control, alarm, protection and indication facilities and
equipment included in the Bid price each item to be identified with its function.

Outdoor cubicles, cabinets and enclosed compartments shall be adequately ventilated to prevent
condensation. All contactor or relay coils and other susceptible parts shall be suitably protected
against corrosion.

All control cubicles and cabinets shall be identical in respect of all secondary control circuits and
equipment. All cubicles shall be equipped with removable gland plates, and terminals to
approval.

A voltmeter, suitably calibrated and indicating the secondary voltage shall be fitted on the panel
of each remote control cubicle.

All suppliers wiring shall be carried out in PVC or similar insulated wire supported clear of the
panel surface and identified by ferrules at all terminations; in addition colour identification may
be used. No ferrule number shall appear on more than one circuit and the ferrule number shall
change at every break in the circuit, i.e. all switches, coils contacts, etc. Particular attention shall
be paid to ensuring that ferrule numbers conform to those on the wiring diagram.

Terminals should be arranged so that terminations of any incoming wiring provided at site under
separate contract are directly visible.

Terminal boards shall be placed in accessible positions adjacent to the incoming cable entries.

Terminations shall be grouped according to their functions and labels shall be provided on the
fixed portion of the terminal boards showing the functions of the groups. All terminal boards
shall have a minimum of 20% spare terminals.

All incoming and outgoing connections shall be terminated at a terminal block. Direct
termination on to auxiliary switches will not be accepted.

All indicating analogue instruments shall be flush mounting and the dials shall preferably be not
less than 100 mm diameter if circular or, if rectangular have no side less than 100 mm.

Low energy heaters shall be provided in each cubicle and cabinet to prevent condensation and
the internal design shall be such as to permit free circulation of air without the ingress of dust or
vermin; a manual heater control switch shall be provided inside the cubicle.

Doors shall be provided with integral handles and shall have provision for padlocking.
 22

A stay shall be provided for holding the door open without impeding access to the cubicle while
work is being done in the cubicle.

An easily removable undrilled gland plate shall be supplied.

An indelible chart showing lubrication points and specifying recommended lubricants and
frequency of application shall be provided in all mechanism cubicles.

One set of drawings for the tap changer control shall be placed in the tap changer local control
cubicle.

COOLING

Definitions

The types of cooling shall be designated by the IEC lettering symbols:

a. Natural Air Circulation (ONAN)

By radiators directly attached to the tank.

b. Forced Air Circulation (ONAF)

By fan cooled radiators attached directly to the tank.

Declaration of Ratings

The Bidder shall declare in the Schedule of Technical Guarantees the rated power available
under the operating conditions ONAN or ONAF and the ratings shall be indicated on the rating
plate. The rating plate shall also indicate the corresponding loss in transformer capacity in the
event of loss of one cooling bank.

Radiators

Where detachable radiators are fitted, suitable valves, with blanking plates shall be provided at
the inlet and outlet of each radiator so that it may be removed without draining oil from the tank.
Inlet and outlet valve "OPEN" and "CLOSED" positions shall be clearly marked. The valves
shall be readily accessible and easy to operate. Lifting facilities, a drain cock and an air release
vent shall be provided on each radiator.

Radiators shall be designed so that it is possible for the whole of the cooling surface to be
cleaned and, if necessary, subsequently painted by brushing and spraying. They shall also be
designed so that they shall withstand dry-out vacuum without distortion or causing leakage of
hot oil.

Supplementary Cooling Plant

Where supplementary cooling is specified for transformer the following requirements shall
apply:

Natural cooling with additional Forced-Air Cooling ONAN/ONAF

 23

Where mixed cooling is specified the natural (ONAN) rating shall generally not be less than
60% of the total specified forced-cooling capacity, unless otherwise specified.

The forced-cooling equipment shall be designed to operate automatically from winding-

temperature relay control at predetermined temperatures recommended by the Contractor. The
equipment shall be designed to start in 2 stages at preset temperatures.

Indicate setting values are as follows:

On Off
Stage 1 65°C 50°C
Stage 2 75°C 60°C

The cooler arrangement must allow for the maintenance or failure of any one fan or radiator
without losing more than 20% of the total cooling capacity.

Fans

All fans shall operate as a unit. Fan blades and fan ducting shall be of aluminium alloy, stainless
steel, galvanised steel, or other corrosion-resistant metal and shall be designed to keep noise and
vibration to a minimum. All fans shall be provided with galvanised wire-mesh guards. It shall
be possible to remove fan assemblies complete without dismantling other equipment.

The transformer nameplate diagram should show the corresponding reduction in transformer
capacity in the event of loss of one bank of cooler fans.

Cooler Control Equipment

All the necessary automatic control, motor contactors, protective devices and switches for the
forced-cooling equipment shall be assembled in a dust-proof, weatherproof and vermin-proof
cabinet preferably mounted on the transformer.

The cooler control equipment shall include:-

- An isolating switch rated to carry and break full-load current for each group of fan and
pump motors.
- A "Cooler Auto" - "Cooler-Manual" changeover switch.
- Magnetic contactor for each group of fan motors. Contactor coil leads shall be wired to
the terminal board.
- Overload and single-phasing relays for each motor with a set of normally-closed contacts
for alarm purposes.
- Fuses, links and terminal boards to approval to make a complete assembly.

One set of drawings for the cooling control shall be placed in the local cooler control cubicle.

SPARES

The Contractor shall supply all spares specified in Scope of Supply and these shall be included
in the Bid. In addition Bidders are requested to state their recommendations at the time of
 24

Biding for extra spares bearing in mind that the transformer shall be in continuous uninterrupted
operation for 25 years.

Spares shall be delivered with the associated equipment and, in order that spares may be placed
on order at short notice, full details including Catalogue and/or spare part numbers of all spares
should be supplied with Bid.

Spares shall be priced item-wise.

Spares shall be strictly interchangeable with the corresponding parts supplied with the original
equipment. Spares for identical transformers shall be strictly interchangeable and to the highest
extent possible also between the different transformers.

Each spare part shall be labelled with the following:

- The number of the Authority Order on which the part was supplied.
- The Item No. on the Order which specified the part.
- The serial number of the equipment for which the part may be used.
- The part number.

All spares must be packed to be suitable for indefinite storage and special precautions must be
taken to ensure that insulating materials included in the spares do not deteriorate during storage.

Cases in which spares are packed shall be indelibly marked with the applicable Authority order
numbers.

Bidders must positively state how long they anticipate that replacement spares will be available
in stock.

OIL

The oil shall be of the uninhibited mineral type and comply to BS 148, IEC 296 or equivalent
standard. The Contractor shall demonstrate that the transformer oil shall not change its chemical
composition and characteristics during continuous full load operation, in such a way that the
resultant chemicals or properties accelerate or trigger insulation failure beyond what is normally
and conventionally expected.

Oil shall preferably be supplied in bulk from within Zambia and dried and cleaned on site. If oil
is provided in drums, these shall have a volume of approximately 210 L and be full. A separate
price shall be quoted for transformer oil. The Contractor shall positively submit the names of the
proposed supplier and manufacture of transformer oil for ZESCO’s approval. No transformer oil
shall be accepted before suppliers and manufacturers are approved.

INSPECTION AND TESTS

Inspection/Witnessing of Tests

ZESCO's representative, the Project Manager, reserves the right to inspect the transformer at any
stage of manufacture or to be present at any of the tests specified. Such inspection shall not
relieve the Contractor of his responsibility for meeting all the requirements of the specification,
and it shall not prevent subsequent rejection if such material or equipment is later found to be
defective.
 25

The Contractor shall in good time inform when testing will take place and shall give the
Employer/Project Manager not less than several weeks’ notice in advance. No transformer shall
be tanked, or dispatched from the Contractor's works without approval of ZESCO's
Representative. Based on the Contractor's manufacturing programme, factory inspection will
take place as required by the Employer/Project Manager.

Bushing Tests

Note shall be taken that the bushings shall have adequate insulation level for operating at 1500
m above sea level. It is not required to perform separate bushing tests if the Contractor selects
bushings which have insulation levels compensated for the altitude. Nevertheless, the
Contractor shall submit for approval test records and data for all bushings. These records shall
show the test performed on the bushings including but not necessarily restricted to the following
tests:

- Standard, one minute, 50 Hz dry withstand tests for all bushings.

- Type test of impulse withstand voltage.

All recorded test figures shall be given with the bushings serial number.

- For the 330 kV, 220kV and 11 kV bushings including any spare bushings:
Internal pressure and terminal cap pressure. Power factor and capacitance measurements.
- Power factor measurement
- Capacitance measurements between conductor and test tap and between the tap and
earth.

Transformer Tests

Routine Tests

Routine tests as far as applicable shall be carried out according the IEC Publication 76.

The following routine tests shall be applied to all transformers:

- Resistance measurements of all windings for all tappings.

- Ratio tests for all tappings and vector relationship tests.
- Measurement of no-load losses and currents.
- Measurements of impedance voltages (at maximum, principal and minimum tappings),
short circuit impedances and load losses. Load losses shall be measured at both rated
currents when ONAN and ONAF cooling are specified.
- Determination of efficiencies at 50%, 75%, 100% and 120% load at maximum
temperature of the winding and 0.8 power factor lagging and unity power factor for all
ratings (ONAN, ONAF ratings).
- Zero sequence impedance measurement.
- Induced voltage and separate source voltage withstand power frequency, dielectric tests
on all windings on all phases including neutral points.
- Full wave impulse withstand tests. The transformer shall be subjected to a complete
series of tests. Such tests shall be applied to the HV winding line terminal of each phase
as well as to the neutral points.
- Tests on on-load tap changers.
- Routine tests on all transformer accessories such as motors, contactors wiring, etc.
 26

- Partial discharge measurements (corona testing) during the power frequency dielectric
tests. The test procedures shall be as described in NEMA Publications 107, 1964 or
other approved method to be agreed between the Contractor and the Project Manager.
- Measurements of capacity between the windings and each winding and ground.
- Oil leakage test. The complete oil filled transformer with bushings and radiators fitted
and any other attachment normally in contact with oil shall be tested at a positive
pressure measured at the tank bottom of twice the column of oil in the transformer when
the transformer is cold, but in any case not less than 70 kPa. Alternatively the radiators
may be tested separately with the same pressure. The test period shall be not less than
12 hours.
- Core insulation test, 2 kV, 50 Hz for one minute.
- Sweep Frequency Response Analysis (SFRA)

Type Tests

The following type tests shall be carried out the transformer:

- Temperature rise test. Details of the test procedure shall be agreed between Contractor
and Project Manager before testing commences.
- Noise measurements.
- Chopped wave impulse test. The test shall be carried out in conjunction with the full
wave test as described in IEC 76-4.
- Vacuum test. The transformer tank and radiators filled with oil shall be subjected to a
vacuum test to comply with Clause 4.6. Bushings need not be fitted and the radiators
and conservator may be tested as separate units
- Switching impulse test according to method 2 in IEC 76-4.

Site Tests

Testing at site by the Contractor shall be carried out to prove that the transformer in all
respects complies with provisions and guarantees set forth in the Contract.

Tests shall include but not be limited to the following:

- Dielectric oil tests.

- Insulation dryness by an agreed method.
- Electrical and functional control of voltage control equipment and cooling
system.
- Core to tank insulation.

Test Certificates

Two copies of test certificates showing the results of all routine and type tests performed shall be
supplied to the Project Manager PRIOR to the despatch of the transformer from the Contractor's
works.

All test certificates shall be in English.

 27

ERECTION

Erection shall be carried out by the Contractor under supervision by the Project Manager or his
representative. The Contractor shall ascertain that the transformer have been erected according
to the Terms of Contract before commissioning takes place.

The Contractor shall be fully responsible for the quality and timing of the works. The
Contractor shall ensure the safety of every person employed or working at the site and this shall
include routine inspection of all temporary installations and portable equipment.

All heavy erection equipment like lifting cranes and other equipment to be used for erection
purpose shall be provided by Contractor. The Contractor shall also provide all special
equipment for erection and testing purpose. Such equipment shall be listed in the Bid.

DELIVERY AND TRANSPORT

The dimensions of the transformer shall be such that when packed for transport, they will
comply with the requirements of the South African Railways, Mozambique Railways, National
Railways of Zimbabwe, Namibian Railways and National Railways of Zambia with respect to
systems loading and clearance gauges. Or alternatively the transport must be in accordance with
the rules for road transport in the respective countries. If any special investigations, permits or
arrangements are necessary for the road transport these have to be arranged for by the
Contractor. Cost for such shall be included in the price.

Shipment of transformer in any position other than the upright one is not permissible.

All shafts, bearings and machined surfaces exposed for transport to the site shall be given a
temporary protective coating to prevent corrosion.

If it is necessary to remove bushings or radiators for transport blanking-off plates and a spare set
of gaskets shall be provided.

Where the supply of oil is included in the contract, and transport weight limitations permit, the
transformer shall preferably be transported with sufficient oil to cover the core and windings.
The tank shall be sealed for transport to prevent all breathing. The remainder of the oil to be
supplied separately at the time of delivery shall be in transportable storage tanks.

Alternatively, where the above method is not applicable or practicable, the transformer shall be
transported filled with dry nitrogen under slight positive pressure. This pressure and the
temperature at the time of filling shall be communicated to the Project Manager and a pressure
gauge suitably protected is to be fitted to each transformer to facilitate inspection of the gas
pressure on arrival at site. Every precaution shall be taken to ensure that the transformer arrive
at site in a satisfactory condition so that subsequent to oil filling, they may be put into service
without the necessity for further drying out. Should the positive gas pressure disappear during
transport and the transformer allowed to breathe, additional drying out at site if required shall be
the responsibility of the Contractor.

All accessories and spares which are shipped separately must be clearly marked for
identification with the transformer for which they are intended. All pipework and valves shall
have further markings showing the correct points of assembly which shall also be shown on
assembly drawing to be supplied.
 28

Full details must be supplied on methods of drying out the windings, if found necessary, on
arrival and on the method to be adopted for oil filling and oil purification on site. Any special
apparatus required for oil filling must be supplied as part of this contract.

Full details of the proposed methods of transport shall be submitted for approval.

EVALUATION OF LOSSES

Guaranteed Output and Losses, Liquidated Damages

Failure to meet the guaranteed outputs and losses will be dealt with as follows:

Transformer Output

If the guaranteed continuous output at rated voltage of any transformer has to be reduced below
the guaranteed value in order to maintain the temperature rises of any part of the transformer
within the guaranteed limits, liquidated damages shall be paid at the rate of USD 4000 per kVA.

Transformer Losses

If the total transformer losses of the transformer, as determined by these, without any tolerances,
at rated voltage, frequency and 100% rated kVA (on principal tapping) exceed the guaranteed
total losses, the excess in losses shall be capitalised at the rates stated in Sub-clause 14.12.2
below and the resulting amount shall be paid as liquidated damages.

The payment on account of failure of the transformer to meet the guaranteed output and
guaranteed losses shall be applied individually, as the case may be, and shall therefore be
understood to be cumulative.

Rejection Limits

Should the transformer fail to meet the guaranteed output by more than 5% (five per cent) or the
total losses should exceed the total guaranteed losses by more that 1/5 (one fifth), and should the
Contractor fail within a reasonable time to modify the transformer in order to increase the output
and/or reduce the losses sufficiently, the Purchaser shall have the option to reject the
transformer.

Evaluation of Losses

Transformer losses will be evaluated based on the following:

Reference to ITB 25.3(d) (i) (ii) and corresponding paragraph in Bid Data Sheet. In the Bid
Evaluation, particular attention will be executed to the functional guarantees related to:

Calculated load loss (also referred to as copper losses) and no load losses (also referred to as
iron losses) shall be given in the Bid. The load loss and the no load loss shall be measured as
routine tests.

For bid evaluation of the transformers, the lowest offered losses in kW will be used as a
reference. The load losses for the transformers will be evaluated at the rate of USD 2000/kW
(excess) per transformer and added to the bid price of the particular bidder. The excess in no
 29

load losses will correspondingly be evaluated at the rate of USD 4000/kW per transformer and
added to the bid price of the particular bidder.

The losses in kW are the guaranteed values in the Technical Specifications (Technical
Particulars and Guarantees section of the bid document). These same figures per kW are to be
used in the application of liquidated damages for non-compliance to guaranteed values for full
load and no load losses of the successful bidder.

Load losses will be evaluated based on the ONAN rating for transformers with combined
ONAN/ONAF cooling.
SCHEDULE B: TO BE FULLY COMPLETED BY THE BIDDER

S/N TECHNICAL DATA UNITS DATA

1 Type of transformer
2 Rated power MVA
3 Nominal Primary Voltage kV
4 Highest system voltage - primary kV
5 Nominal Secondary Voltage kV
6 Highest system voltage - kV
secondary
7 Nominal Tertiary voltage kV
8 Highest system voltage - tertiary kV
9 Vector Group
10 Phases
11 Type of cooling
12 Type of insulating oil
13 PCB content (attach specification
without fail)
14 Frequency Hz
15 Winding Material
16 Impedances %
0
17 Temperature rise Winding C
at rated voltage Top oil 0
C
and power
18 Losses at rated No load loss
voltage and Load loss
frequency
19 Lightning impulse withstand kV
level at primary
20 Lightning impulse withstand kV
level at secondary
21 Power Frequency withstand kV
voltage - primary
22 Power Frequency withstand kV
voltage – secondary
23 Altitude above sea level m
24 Relative humidity (maximum) %
0
25 Operating ambient temperature C
26 Tap changer
27 Tapping range
 30

28 Equipped with mounting holes

29 Equipped with Jacking pads
30 Equipped with lifting lugs
31 Buccholz relay for main
transformer
32 Buccholz relay for tap changer
33 Temperature Gauges (Windings)
34 Temperature Gauge (oil)
35 Pressure Release Valve (oil tank)
36 Skid under base
37 Type winding core construction
38 Volume of oil
39 Weight of oil (Kgs)
40 Weight of windings (Kgs)
41 Total weight (Kgs)
42 Applicable standards
43 Have the drawings showing the
dimensions of the transformers
offered the arrangement of
connections including the name
plate details and the position of
the tapping switch been provided
with the bid?
44 Have details of previous Type
test results, been provided with
the bid?
45 Do transformers comply with
IEC 76?

46 Will surge arrester bracket be

fitted to the transformer tank?
47 Are the tanks of the transformers
on offer constructed in such a
manner as to discourage cutting
by vandals as outlined in the
ZESCO technical requirement
(Under other requirements)? If
yes illustrate with drawing.
48 Has the Quality Assurance
Certificate been provided with
the bid?
49 Transformer Protector
50 Complete transformer test
equipment
51 Mandatory spares Refer to section VI schedule of
requirement Lot 1 item 4
52 Training: (i) tap changer
installation and maintenance(2
technicians/technologists for ten
days) (Cost to cover: Air ticket,
Meals, Hotel Accommodation
 31

and Per diems) (ii) transformer

testing and maintenance three
Engineers for ten days(Cost to
cover: Air ticket, Meals, Hotel
Accommodation and Per diems)
53 First Stage Factory Acceptance 4 Zesco
Tests (inspection of core and Staff
winding before Transformer (Three
Tanking) (Cost to cover: Air Enginee
ticket, Meals, Hotel rs and
Accommodation and Per diems) one
for five (5) days procure
ment
officer)
54 Second Stage Factory 3 Zesco
Acceptance Tests (At completion Staff
of transformer assembling) (Engine
(Cost to cover: Air ticket, Meals, ers)
Hotel Accommodation and Per
diems) for seven (7) days