TECHNICAL SPECIFICATION FOR 33/11 KV 5 MVA POWER TRANSFORMER

1.0 SCOPE
1.1 These specifications cover design, engineering, manufacturing at site of Sri Kedarnath Ji Dham,
testing/inspection before energization at site including packing, forwarding, transportation to site,
insurance (during transit), of three phase, 50 Hz, 5 MVA, 33/11 KV Outdoor ONAN Power transformer
complete with all accessories/fittings and spare parts as specified herein, for use in sub-transmission
and distribution system. The offered material shall be complete with all the accessories and components
necessary for their desired / effective and trouble free operation. Such components shall be deemed to
be within the scope of contractor’s supply irrespective of whether those are specifically brought out in
this specification and / or the contract / commercial order or not.
1.1.1 CLIMATIC CONDITIONS:
The equipment/material to be supplied against this specification shall be suitable for satisfactory
operation under the climatic Conditions as per clause No 2.0 of “General Requirement” of the tender.
The equipment shall be for use in moderately hot and humid tropical climate, conducive to rust and
fungus growth.
All the equipment under the project shall be suitable for satisfactory and continuous operation at an altitude upto
4000 m (above MSL) and ambient temperature upto (-) 400C
1.2 SPECIFIC TECHNICAL REQUIREMENTS (STANDARD CONDITIONS)
1. Rated MVA (ONAN rating) 5 MVA
2. No. of phases 3
3. Type of Installation Outdoor
4. Frequency 50 Hz
5. Cooling medium Insulating oil
6. Rated voltage:
a) High voltage winding 33 kV
b) Low voltage winding 11 Kv
7. Highest continuous system
voltage
a) HV Side 36 kV
b) LV side 12 Kv
8. Type of tap changer On-load tap changer
9. Range tapings +5% to -10% steps of
2.5% each on HV winding
10. Neutral terminal to be brought out On LV side only
11. Impedance on rated MVA at 75 oC 7.15 % with tolerance limits as per IS
12. Type of insulation Uniform
and insulation level
13. One-minute power frequency 33 kV 11kV
withstand test (KV rms) 95 35
14. Impulse withstand test voltage
(KV Peak) 170 75
15. Winding connection
a) HV Side Delta
b) LV Side Star
16. Winding material Electrolytic Copper-Current density not
to exceed 2.4 Amp/mm2 in all windings.
17. Vector group Dyn 11
18. Type of cooling ONAN
19. Neutral earthing LV neutral shall be solidly earthed
20. No load losses at rated voltage 4 (max.)
and frequency (kW)
21 Copper Losses at Principal Tap 23 (max.)
750c at (KW)
The above-mentioned losses are maximum permissible and there shall not be any plus tolerance above this
limit.
1
 Bids with higher losses than the above specified values would be treated as non-responsive. However, the
manufacturer can offer losses less than above though no cost benefit shall be given to the manufacturer.
1.2.1 MAXIMUM TEMPERATURE RISE OVER AN AMBIENT OF 45º C
a) Temperature rise of top oil (Measured by thermometer) 45ºC
b) Temperature rise of winding (Measured by resistance) 50ºC

The rise in temperature of top-oil and winding given above shall be reduced as per Clause 3.2 & 3.3 of
IS: 2026(Part-I) in case of increase in Ambient above 50 o C and an increase in altitude above 1000 m.

1.2.2 RATING & SERVICES

a) Over load capacity- As per IS:6600
1.2.3 MARSHALLING BOX
A metal enclosed, weather, vermin and dust proof marshalling box fitted with required glands, locks, glass
door, terminal board, heater with switch, illumination lamp with switch etc. shall be provided with each
transformer to accommodate temperature indicators, terminal blocks etc. It shall have a degree of
protection of IP 55 as per IS:2147 (Refer Clause 3.12).

1.3 PERFORMANCE
i) Transformer shall be capable of withstanding for two seconds without damage to any external short
circuit, with the short circuit MVA available at the terminals.
ii) The bidder has to submit the calculation sheet indicating the flux density of offered equipment so as
to evaluate the maximum flux density of offered equipment must be equal to or below 1.6 Tesla at
normal voltage and frequency.
iii) The maximum flux density in any part of the core and yoke at rated MVA, voltage and frequency
shall be such that the flux density under 12.5% over voltage condition shall not exceed 1.9 Tesla.
iv) Transformer shall under exceptional circumstances due to sudden disconnection of the load, be
capable of operating at the voltage approximately 25% above normal rated voltage for a period of
not exceeding one minute and 40% above normal for a period of 5 seconds.
v) The transformer may be operated continuously without danger on any particular tapping at the rated
MVA ±12.5% of the voltage corresponding to the tapping.
v) The thermal ability withstand short circuit shall be demonstrated by calculation.
vi) With combined voltage variation of +12.5% and frequency variation of -5%, the flux density shall
not exceed 1.9 Tesla.
vii) Transformer shall be capable withstanding thermal and mechanical stress caused by any
symmetrical and asymmetrical faults on any winding.
viii) DGA of oil shall be periodically monitored by the employer and the interpretation of DGA results
will be as per IEC – 599.
ix) The transformers shall be capable of being loaded in accordance with IS”:6600/ IEC-354. There
shall be no limitation imposed by bushings, tap changers etc. or any other associated equipment.
x) Transformers shall withstand, without injurious heating, combined voltage and frequency
fluctuations which produce the following over fluxing conditions:
125% for 1 – minute 140%
for 5 – seconds
i) Bidder shall indicate 150% and 170% over voltage withstand time.
AUXILIARY POWER SUPPLIES
The following power supplies shall be available at site:
i) AC, 3 phase, 400 volts, 50 Hz, earthed
ii) AC, 1 phase, 230 volts, 50 Hz, earthed
iii) 24V DC
1.4 DRAWINGS/DOCUMENTS INCORPORATING THE FOLLOWING
PARTICULARS SHALL BE SUBMITTED WITH THE BID
a) The contractor shall furnish, within fifteen days after issuing of Letter of Award, copies of the
drawings/documents incorporating name of project and transformer rating for approval.
b) All drawings / documents, technical data sheets and test certificates /results/ calculations

2
 shall be furnished.
c) Any approval given to the detailed drawings by the purchaser shall not relieve the contractor of the
responsibility for correctness of the drawing and in the manufacture of the equipment. The approval
given by the purchaser shall be general with overall responsibility of the manufacturer.
1.5 MISCELLANESOUS
i) Padlocks along with duplicate keys as asked for various valves, marshalling box etc.
shall be supplied by the contractor, wherever locking arrangement is provided.
ii) Foundation bolts for wheel locking devices of transformer shall be supplied by the
Contractor.
1.6 NAME PLATE
Transformer rating plate shall contain the information as given in clause 15 of IS-2026 (Part- I).
The details on rating plate shall be finalized during the detailed engineering. Further each
transformer shall have inscription of Purchaser name and clear mention of “Property of UPCL’.
2.0 GENERAL TECHNICAL REQUIREMENT

2.1 CODES AND STANDARDS

i) The design, material, fabrication, manufacture, inspection, testing before dispatch, erection, testing,
commissioning and performance of power transformers at site shall comply with all currently
applicable statutory regulations and safety codes in the locality where the equipment willbe installed.
The equipment shall also conform to the latest applicable standards and codes of practice. Nothing
in this specification shall be construed to relieve the contractor of this responsibility.
ii) Transformers shall conform to the current applicable standards and codes of practice as specified in
clause no. 2.2.
2.2 The equipment, materials and service covered by this specification shall conform to the latest
applicable provision of the following standards:
IS:5 Colour for ready mixed paints
IS:325 Three Phase Induction Motors
IEC60296 New insulating oil for transformers, Switchgears
IS;1271 Classification of insulating materials for electrical machinery and
apparatus in relation to their stability in services.
IS:2026(Part I to IV) Power transformer
IS:2071 Method of high voltage testing
IS:2099 High voltage porcelain bushings
IS:2147 Degree of protection
IS:2705 Current transformers
IS:3202 Code of practice for climate proofing of electrical equipment.
IS:3347 Dimensions for porcelain transformer bushings
IS:3637 Gas operated relays
IS:3639 Fittings and accessories for power transformers
IS:5561 Electric Power Connectors
IS:6600/BS:CP1010 Guide for loading of oil immersed transformers
IS:10028 Code of practice for selection, installation and
maintenance of transformers, Part I, II & III.
C.B.I.P. Publication Manual on transformers

If the standard is not quoted for any item, it shall be presumed that the latest version of Indian Standard shall be
applicable to that item. The equipment complying other internationally accepted standards, may also be
considered if they ensureperformance superior to the Indian standards.
NOTE: Power transformers shall be manufactured at site under this project. Such manufactured
transformers shall be free from the requirement of type test. However, site testing of these transformers
shall be carried out in presence of UPCL’s representatives.

3
3.0 GENERAL CONSTRUCTIONAL FEATURES
3.1 All material used shall be of best quality and of the class most suitable for working under the
conditions specified and shall withstand the variations of temperature and atmospheric
conditions without distortion or deterioration or the setting up of undue stresses which may
impair suitability of the various parts for the work which they have to perform.
3.2 Similar parts, particularly removable ones, shall be interchangeable.
3.3 Pipes and pipe sittings, screws, studs, nuts and bolts used for external connections shall be as
per the relevant standards. Steel bolts and nuts exposed to atmosphere shall be galvanized.
3.4 Nuts, bolts and pins used inside the transformers and tap changer compartments shall be
provided with lock washers or locknuts.
3.5 Exposed parts shall not have pickets where water can collect.
3.6 Internal design of transformer shall ensure that air is not trapped in any location.
3.7 Material in contact with oil shall be such as not to contribute to the formation of acid in
oil. Surface in contact with oil shall not be galvanized or cadmium plated.
3.8 Labels, indelibly marked, shall be provided for all identifiable accessories like relays,switches,
current transformers etc. All label plates shall be of in corrodible material.
3.9 All internal connections and fastenings shall be capable of operating under overloads and over
excitation, allowed as per specified standards without injury.
3.10 Transformer and accessories shall be designed to facilitate proper operation,
inspection, maintenance and repairs.
3.11 No patching, plugging, shimming or other such means of overcoming defects, discrepancies or
errors will be accepted.
3.12 Schematic drawing of the wiring, including external cables shall be put under the pros pane
sheet on the inside door of the transformer marshalling box.

3.13 Painting
3.13.1 All paints shall be applied in accordance with the paint manufacturer’s recommendations.Particular
attention shall be paid to the following:
a) Proper storage to avoid exposure as well as extremes of temperature.
b) Surface preparation prior to painting.
c) Mixing and thinning.
d) Application of paints and the recommended limit on time intervals between coats.
e) Shelf life for storage.
3.13.1.1 All paints, when applied in normal full coat, shall be free from runs, sags, wrinkles, patchiness,
brush marks or other defects.
3.13.1.2 All primers shall be well marked into the surface, particularly in areas where painting is evident,
and the first priming coat shall be applied as soon as possible after cleaning. The paint shall be
applied by airless spray according to the manufacturer’s recommendation. However, wherever
airless spray is not possible, conventional spray be used with prior approval of purchaser.
3.13.1.3 The supplier shall, prior to painting protect nameplates, lettering gauges, sight glasses, light fittings
and similar such items.
3.13.2 Cleaning and Surface Preparation:
3.13.2.1 Surface preparation for tank, pipes, etc.-
All surfaces of transformer tank, pipes etc. shall be thoroughly blast cleaned with sand or shot or
grit in accordance with ISO 8501 Part 1 to a minimum standard of Sa21/2 to make the surface free
from visible oil, grease and dirt, mill scale, rust, paint coatings and foreign matter. Machined areas
and threaded components etc. are to be covered during blasting to prevent damage.
The air that is used for blasting should be dry and free from oil. The flanges, angles, tank curbs and
other such areas shall be preferably blast cleaned prior to fabrication and paint these with onecoat of
primer. After adequate blast cleaning of each large surface where blasting time is more than three
hours, an overall blast cleaning is to be done on the entire surface once more so that entire surface
areas ie exposed as fresh for first coat of primer paint. The first coat of primer paint should be applied
not later than 3-4 hours after preparation of surface to avoid oxidation.

4
 3.13.2.2 Surface preparation for radiator-
All internal and external surfaces of radiator shall be thoroughly cleaned either by chemical cleaning
or by blast with sand or shot or grit in accordance with ISO 8501 Part 1 to make the surface free
from visible oil, grease and dirt, mill scale, rust, paint coatings and foreign matter. Suitable chemical
should be used for chemical cleaning,
if required. The air that is used for blasting should be dry and free from oil. After adequate
surface cleaning, the first coat of primer paint/varnish should be applied not alter than 3-4 hours
after preparation of surface to avoid oxidation.
3.13.2.3 Painting-external & internal surfaces-
Painting shall be carried out in closed and dust free area. The external surface shall be coated
with suitable layers of paint and to form an impermeable layer so that air and water cannot reach
the substrate. The paint selected shall be stable in outdoor condition such as rain, sunlight,
pollution etc. Paint used for primer, under coat and top or finish coat should be fromthe same
manufacturer and compatible to each other. In case in the rare event, paint used for primer, under
coat and finish coat are not from the same manufacturer the compatibility test of the paint from
different source shall be carried out. Painting shall be applied as per the recommendation of the
paint manufacturer. The number of coats shall be such that the minimum dry film thickness
(DFT) specified is achieved. The DFT of painted surface shall be checked with a measuring
gauge to ensure specified DFT. Complete painting scheme for the transformer is tabulated
below:

3.13.2.4 Painting-Transformer tank, pipes, radiator etc.-

Description Surface Primer coat Intermediate Finish Total Colour

preparation undercoat coat DFT shade
Tank, Blast cleaning Epoxy base Epoxy HB Aliphatic Min. 697
pipes etc. Sa2½ Zinc primer MIO (30-40 Polyurethane 155 μm shade
(External (30-40 μm) μm) (Min 50 as per
surfaces) μm) IS:5
Tank. Blast cleaning Hot oil - - Min. 30 Glossy
(Internal Sa2½ resistant, μm white for
surfaces) non- paint
corrosive
varnish or
paint or
epoxy
Radiator Chemical/blast Epoxy base Epoxy base PU paint Min. Matching
(External cleaning Zinc primer Zinc primer (Min. 50 110 μm shade of
surfaces) (Sa2½) (30-40 μm) (30-40 μm ) μm) tank./differ
ent shade
aesthetica
lly
matching
to tank
Radiator Chemical Hot oil - - - -
& pipes. Cleaning if proof, low
(Internal Required viscosity
surfaces) varnish,
flushing with
transformer
oil.

3.13.3 Surface preparation for control cabinets/Marshalling Boxes-

3.13.3.1 Surface preparation for all transformer control cabinets/Marshalling boxes shall be carried out
confirming to following Indian Standard in dust free area:
i) IS: 3618: Degreasing by solvent wiping: Phosphate Treatment of Iron & Steel for protection
against corrosion.
ii) IS:6005: Code of practice for phosphating of Iron and Steel
3.13.3.2 Chemicals: Suitable chemicals should be used and concentration of chemicals/ weight of
5
 phosphate coating should be regularly as per recommendation of the chemical manufacturer
and applicable IS.
3.13.4 Inspection: The surface for application of paint should be dry, free from oil, dirt, acid & loose
adhering powder and reasonably smooth in finish without uncovered areas, rusty surfaces and
roughness.
3.13.5 Painting: Control cabinets/Marshalling Boxes-enamel paint shall be used with total paint
thickness as minimum 80 microns.
3.13.6 Radiator inner coating must be Dr. Beck, Elmoluft-1A, Varnish uniformly painted inside with
gravity flow.
4.0 DETAILED DESCRIPTION
4.1 Tank
4.1.1 The transformer tank and cover shall be fabricated from high grade low carbon plate steel of
tested quality. The tank and the cover shall be of welded construction, the minimum thickness of
which shall be 5 mm for the side and 6 mm for the bottom with longer sides having a horizontal
length up to but not exceeding 1800 mm. In case the horizontal length exceeds 1800 mm, the min.
side plate thickness shall be 6 mm and the thickness of bottom plate shall be 8 mm. The tank
and the cover shall be of welded construction. All seams shall be welded and wherever
practicable they shall be double welded. Tanks stiffeners shall be continuously welded to the
tank and designed to prevent deformation.
4.1.2 The main body of the tank shall have sufficient strength to withstand a vacuum of 500 mm of
mercury
4.1.3 Tank shall be designed to permit lifting by crane or jacks of the complete transformer assembly
filled with oil. Suitable lugs and bosses shall be provided for this purpose.
4.1.4 All beams, flanges, lifting lugs, braces and permanent parts attached to the tank, shall be welded
and where practicable, they shall be double welded.
4.1.5 The main tank body of the transformer excluding tap changing compartments and radiators shall
be capable of withstanding pressure of 760mm of Hg.
4.1.6 Inspection hole(s) with welded flange(s) and bolted cover(s) shall be provided on the tank cover.
The inspection hole(s) shall be of sufficient size to afford easy access to the lower endsof the
bushings, terminals etc.
4.1.7 All bolted connections to the tank shall be fitted with suitable oil-tight single piece of Nitrile
butadiene rubber gaskets of grade 80C or equivalent which shall give satisfactory service under
the operating conditions for complete lift of the transformer. Special attention shall be given to
the methodsof making the hot oil-tight joints between the tank and the cover as also between
the tank cover and the bushings and all outlets to ensure that the joint can be remade
satisfactorily and with ease, with the help of semiskilled labour. Where compressible gaskets are
used, steps shall be provided to prevent over compression.
4.1.8 Suitable guides shall be provided for positioning the various parts during assembly or
dismantling. Adequate space shall be provided between the cores and windings and the bottom
of the bank for collection of any sediment.
4.2 TANK COVER
The transformer top shall be provided with a detachable tank cover with bolted flanged gasket
joint. Lifting lugs shall be provided for removing the cover. The surface of the cover shall be
suitably sloped (Min. 25 mm) so that it does not retain rain water.
4.3 UNDER CARRIAGE
4.3.1 The transformer tank shall be supported on steel structure with detachable plain rollers
completely filled with oil. Suitable channels for movement of roller with transformer shall be
spaced accordingly. Rollers Wheels shall be provided with suitable roller bearings, which will
resist rust and corrosion and shall be equipped with fittings for lubrication. It shall be possible to
swivel the wheels in two directions, at right angle to or parallel to the main axis of the
transformers.
4.3.2 Jacking pads shall be provided on the transformer. It shall be possible to change the direction of
the wheels through 90 degree when the transformer is lifted on jacks to permit movement of the
transformer both in longitudinal and transverse directions.
4.4 CORE
4.4.1 The core shall be mitered type with ABC type construction.
6
4.4.2 Stage level inspection for core construction shall be carried out by the owner.
4.4.3 Each lamination shall be insulated such that it will not deteriorate due to mechanical pressure
and the action of hot transformer oil.
4.4.4 The core shall be constructed either from high grade, non-aging Cold Rolled Grain Oriented
(CRGO) silicon steel laminations conforming to grade M4 Or better. The maximum flux density
in any part of the cores and yoke at normal voltage and frequency shall be such that the flux
density with + 12.5% voltage variation from rated voltage and frequency variation of
-5% shall not exceed 1.9 tesla. The bidder shall provide saturation curve of the core material
proposed to be used.
4.4.5 The bidder should offer the core for inspection and approval by the purchaser during the
manufacturing stage. Bidder’s call notice for the purpose should be accompanied with the
following documents as applicable as a proof towards use of prime core material:
a) Invoice of the supplier
b) Mills test certificate
c) Packing list
d) Bill of lading
e) Bill of entry certificate to customs
Core material shall be directly procured either from the manufacturer or through their accredited
marketing organization of repute and not through any agent.
4.4.6 The laminations shall be free of all burrs and sharp projections. Each sheet shall have an
insulating coating resistant to the action of hot oil.
4.4.7 The insulation structure for the core to bolts and core to clamp plates shall be such as to
withstand 2000V DC voltage for one minute.
4.4.8 The completed core and coil shall be so assembled that the axis and the plane of the outer
surface of the core assembly shall not deviate from the vertical plane by more than 25 mm.
4.4.9 All steel sections used for supporting the core shall be thoroughly shot or sand blasted, after
cutting, drilling and welding.
4.4.10 The finally assembled core with all the clamping structures shall be free from deformation and
shall not vibrate during operation.
4.4.11 The core clamping structure shall be designed to minimize eddy current loss.
4.4.12 The frame work and clamping arrangements shall be securely earthed.
4.4.13 The core shall be carefully assembled and rigidly clamped to ensure adequate mechanical
strength.
4.4.14 Oil ducts shall be provided, where necessary, to ensure adequate cooling inside the core. The
welding structure and major insulation shall not obstruct the free flow of oil through such ducts.
4.4.15 The design of magnetic circuit shall be such as to avoid static discharges, development of short
circuit paths within itself or to the earthed clamping structure and production of flux component
at right angle to the plane of the lamination, which may cause local heating. The supporting
framework of the cores shall be so designed as to avoid the presence of pockets, which would
prevent complete emptying of the tank through the drain valve or cause trapping of air during
filling.
4.4.16 The construction is to be of ‘core’ type. The core shall be provided with lugs suitable for lifting
the complete core and coil assembly. The core and coil assembly shall be so fixed in the tank
that shifting will not occur during transport or short circuits.
4.5 INTERNAL EARTHING
4.5.1 All internal metal parts of the transformer, with the exception of individual
laminations, core bolts and their individual clamping plates shall be earthed.

7
4.5.2 The top clamping structure shall be connected to the tank by a 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 direct metal to metal contact with the tank base.
c) By a connection to the top structure on the same side of the core as the main earth
connection to the tank.
d) The magnetic circuit shall be connected to the clamping structure at one point only and
this shall be brought out of the top cover of the transformer tank through a suitablyrated
insulator. A disconnecting link shall be provided on transformer tank to facilitate
disconnections from ground for IR measurement purpose.
4.5.3 Coil clamping rings of metal at earth potential shall be connected to the adjacent core clamping
structure on the same side as the main earth connections winding.
4.5.4 Winding shall be subjected to a shrinking and seasoning process, so that no further shrinkage
occurs during service. Adjustable devices shall be provided for taking up possible shrinkage in
service.
4.5.5 All low voltage windings for use in the circular coil concentric winding shall be wound on a
performed insulating cylinder for mechanical protection of the winding in handling and placing
around the core.
4.5.6 Winding shall not contain sharp bends which might damage the insulation or produce high
dielectric stresses. No strip conductor wound on edge shall have width exceeding six times the
thickness.
4.5.7 Materials used for the insulation of conductor used in windings shall be Thermally upgraded
material, insoluble, non-catalytic and chemically inactive in the hot transformer oil and shall not
soften or the otherwise affected under the operating conditions.
4.5.8 Varnish application on coil windings may be given only for mechanical protection and not for
improvement in dielectric properties. In no case varnish or other adhesive be used which will
seal the coil and prevent evacuation of air and moisture and impregnation by oil.
4.5.9 Winding and connections shall be braced to withstand shocks during transport or short circuit.
4.5.10 Permanent current carrying joints in the windings and leads shall be welded or brazed.
Clamping bolts for current carrying parts inside oil shall be made of oil resistant material which
shall not be affected by acidity in the oil steel bolts, if used, shall be suitably treated.
4.5.11 Terminals of all windings shall be brought out of the tank through bushings for external
connections.
4.5.11.1 The completed core and coil assembly shall be dried in thermostatic condition with lower
temperature limit 95° C and upper temperature limit not to exceed 110° C or vacuum at not
more than 0.5mm of mercury absolute pressure and shall be immediately impregnated with oil
after the drying process to ensure the elimination of air and moisture within the insulation.
Vacuum may be applied in either vacuum over or in the transformer tank.
4.5.11.2 The winding shall be so designed that all coil assemblies of identical voltage rating shall be
interchangeable and field repairs to the winding can be made readily without special equipment.
The coils shall have high dielectric strength.
4.5.11.3 Coils shall be made of continuous smooth high grade electrolytic copper conductor, shaped and
braced to provide for expansion and contraction due to temperature changes.
4.5.11.4 Adequate barriers shall be provided between coils and core and between high and low voltage
coil. End turns shall have additional protection against abnormal line disturbances.
4.5.11.5 The insulation of winding shall be designed to withstand voltage stress arising from surge in
transmission lines due to atmospheric or transient conditions caused by switching etc.
4.5.11.6 Tapings shall not be brought out from inside the coil or from intermediate turns and shall be so
arranged as to preserve as far as possible magnetic balance of the transformer at all voltage ratios.
4.5.11.7 Magnitude of impulse surges transferred from HV to LV windings by electromagnetic induction
and capacitance coupling shall be limited to B.I.L. of LV winding.
4.6 INSULATING OIL
4.6.1 The requirement relates to application of high grade insulating transformer oil in particular to a
naphthenic transformer oil composition.

8
4.6.2 The quantity of oil required for the first filling of the transformer and its full
specification shall be stated in the bid. The bidder shall quote with first filling of oil plus
10% extra.
4.6.3 The design and materials used in the construction of the transformer shall be such as to
reduce the risk of the development of acidity in the oil.
4.6.4 The naphthenic base transformer oil composition must meet the requirements of
IEC60296: the grade index requirement of I-40°C transformer oil (special application)
in 2012 standards.
4.6.5 The contractor shall warrant that oil furnished is in accordance with the following
specification:
Test
SL.No Characteristics Unit Guaranteed Data
Method
Min Max

1 Appearance Visual inspection of oil Clear free from sediment and

sample in transmitted suspended matter
light under a thickness
of 10 cm at ambient
temperature
2 Color ISO 2049 1.5
3 Density at 20 o C g /ml ISO 3675 or IEC 12185 0.895
4 Kinematic Viscosity at 40 o mm 2 ISO 3104 or ASTM D 12
C / sec 7042
at - 1800
30 o C
5 Flash Point, PMCC o C ISO 2719 135
6 Pour Point o C ISO 3016 -40
7 Inter Facial Tension at 25 mN / ASTM D 971 40
o
C m
8 Acidity mg IEC 62021-1or IEC 0.01
KOH/ 62021-2
g
9 Water Content, Bulk/ mg / IEC 60814 30 / 40
Drum, IBC kg
10 Breakdown Voltage IEC 60156
As Delivered / After kV 30 / 70
Treatment
11 Dielectric Dissipation IEC 60247 or IEC 0.005
Factor 61620
(Tan δ )at 90 o C & 40 to
60 Hz
12 Corrosive Sulphur DIN 51353 Not Corrosive Not Corrosive
Silver Strip, 100 o C, 18 ASTM D 1275
Hrs. Copper Strip , 150 o
C, 48 Hrs.
13 Potentially Corrosive IEC 62535 Not Corrosive
Sulphur
14 DBDS mg / IEC 62697-1 < 5 mg/kg
kg
15 Inhibitors according to % IEC 60666 ( U ) Uninhibited Oil
IS ( < 0.01 % )
13631 / IEC 60666
16 Metal Passivator mg / IEC 60666 < 5 mg/kg
additives according to kg
IS 13631 / IEC 60666
17 Other Additives Does not contain
18 Oxidation Stability at 120 IEC 61125 Method C
o
C, 164 Hrs.
Total Acidity mg 4.8.4 of IEC 1.2
KOH 61125:2018
/g 9
Sludge % 4.8.1 of IEC 0.8
61125:2018
DDF at 90 o C 4.8.5 of IEC 0.500
61125:2018
19 PCA Content % IP 346 3
 20 PCB Content mg / IEC 61619 < 2mg /kg
kg
21 2 – Furfural and related mg / IEC 61198 < 0.05 mg/kg
compounds kg for each individual compound
content

4.8 VALVES
i) Valves shall be of forged carbon steel up to 50 mm size and of gun metal or of cast iron
bodies with gun metal fittings for sizes above 50 mm. They shall be of full way type
with screwed ends and shall be opened by turning counter clockwise when facing the
hand wheel. There shall be no oil leakage when the valves are in closed position.
ii) Each valve shall be provided with an indicator to show the open and closed positions and
shall be provided with facility for padlocking in either open or closed position. All
screwed valves shall be furnished with pipe plugs for protection. Padlocks with duplicate
keys shall be supplied along with the valves.
iii) All valves except screwed valves shall be provided with flanges having machined faced
drilled to suit the applicable requirements. Oil tight blanking plates shall be provided for
each connection for use when any radiator is detached and for all valves opening to
atmosphere. Ifany special radiator valve tools are required, the contractor shall supply the
same.
iv) Each transformer shall be provided with following valves on the tank:
a) Drain valve so located to completely drain the tank.
b) Two filter valves on diagonally opposite corners of 32 mm size.
c) Oil sampling not less than 8mm at top and bottom of main tank.
d) One 15 mm air release plug.
e) Valves between radiators & tank

4.9 ACCESSORIES
4.9.1 Bushing
i) All porcelain used in bushings shall be anti-fog heavy duty homogeneous, non-
porous, uniformly glazed to brown colour and free from blisters, burns and other
defects.
ii) Stress due to expansion and contraction in any part of the bushing shall not lead to
deterioration.
iii) Bushing shall be designed and tested to comply with the applicable standards.
iv) Oil in oil-filled bushings shall meet the requirements of the transformer oil standards.
v) Bushing rated for 400A and above shall have non-ferrous flanges and hardware.
vi) Fittings made of steel or malleable iron shall be galvanized.
vii) Bushing shall be so located on the transformers that full flashover strength will be
utilized. Minimum clearances as required for the BIL shall be realized between live
parts and live parts to earthed structures.
viii) All applicable routine and type tests certificates of the bushings shall be furnished
for approval.
ix) Bushing shall be supplied with bi-metallic/terminal connector/clamp/washers
suitable for fixing to bushing terminal and the PURCHASER’S specified
conductors. The connector/clamp shall be rated to carry the bushing rated current
without exceeding a temperature rise of 55°C. The connector/clamp shall be
designed to be corona free at the maximum rated line to ground voltage.
x) Bushing of identical voltage rating shall be interchangeable.
xi) The insulation class of high voltage neutral bushing shall be properly coordinated
with theinsulation class of the neutral of the low voltage winding.
xii) Each bushing shall be so coordinated with the transformer insulation that all
flashover will occur outside the tank.
4.9.2 Protection & Measuring Devices
i) Oil Conservator Tank
10
(a) The conservator tank shall have adequate capacity between highest and lowest
visible levels to meet the requirement of expansion of the total cold oil volume in
the transformer and cooling equipment.
(b) The conservator tank shall be bolted into position so that it can be removed for
 cleaning purposes.
(c) The conservator shall be fitted with magnetic oil level gauge with low level
electricallyinsulated alarm contact.
(d) Plain conservator fitted with silica gel breather.
(e) Adequate sump area at lower part of conservator must be provided to avoid
deterioration of insulating oil.
ii) Pressure Relief Device
The pressure relief device provided shall be of sufficient size for rapid release of any
pressure that may be generated in the tank and which may result in damage of the
equipment. The device shall operate at a static pressure of less than the hydraulic test
pressure of transformer tank. It shall be mounted direct on the tank. A pair of electrically
insulated contacts shall be provided for alarm and tripping.
iii) Buchholz relay
A double float type Buchholz relay shall be provided. Any gas evolved in the transformer
shall collect in this relay. The relay shall be provided with a test cock suitable for a
flexible pipe connection for checking its operation. A copper tube shall be connected
from the gas collector to a valve located about 1200 mm above ground level to facilitate
sampling with the transformer in service. The device shall be provide with two
electrically independent potential free contacts, one for alarm on gas accumulation and
the other for tripping on sudden rise of pressure.
iv) Temperature Indicator- as detailed in clause 11.
4.9.3 Oil Preservation equipment
4.9.3.1 Oil Sealing
4.9.3.2 Aircell
The oil preservation shall be diaphragm type oil sealing in conservator to prevent
oxidation and contamination of oil due to contact with atmospheric moisture.
The conservator shall be fitted with aircell to prevent contamination of gas and moisture
and oil due to oxidation and hydrolysis. The bag is vented on the transformer through
flange type mounting so that it inflates or deflates to accommodate oil volume
displacement due to change in transformer temperature.
Material of aircell must be tested combination of nylon (Polyamide) followed by thick
coating of Elastomers like acrylonitrile butadiene rubber, Polychloroprene and Hypalon
(CSM)
Expansion Volume of aircell required minimum 500 Ltr, with aircell operating pressure
0.1 bar (10 KPa), and rapture pressure not more than 0.13 bar (13 Kpa).
A relief hole must be provided on the oil filled side of the conservator so that aircell can
freely expand.

A dehydrating breather with silica gel content in visible enclosure to be mounted not more
than 1400 mm above rail top level.
4.10 MARSHALLING BOX
i) Sheet steel, weather, vermin and dust proof marshalling box fitted with required glands,
locks, glass door, terminal board, heater wit switch, illumination lamp with switch, water tight
hinged andpadlocked door a suitable construction shall be provided with each transformer to
accommodate temperature indicators, terminal blocks etc. The box shall have slopping roof
and the interior and exterior painting shall be in accordance with the specification. Padlock
alongwith duplicate keys shall be supplied for marshalling box. The degree of protection shall
be IP55.
ii) The schematic diagram of the circuitry inside the marshalling box be prepared and fixed
inside thedoor under a pros pone sheet.
iii) The marshalling box shall accommodate the following equipment:
(a) Temperature indicators (Both WTI/OTI shall be analog type or digital)
(b) Space for accommodating Control & Protection equipment in future for the cooling fan
(for ONAF type cooling, may be provided in future).
11
(c) Terminal blocks and gland plates for incoming and outgoing cables.
All the above equipment except (c) shall be mounted on panels and back of panel wiring
shallbe used for inter-connection. The temperature indicators shall be so mounted that
they are not more than 1600 mm from the ground level and the door(s) of the
compartment(s) shall be provided with glazed window of adequate size. The
 transformer shall be erected on a plinth which shall be 2.5 feet above ground level.
iv) To prevent internal condensation, a metal clad heater with thermostat shall be provided. The
heater shall be controlled by a MCB of suitable rating mounted in the box.
v) All incoming cables shall enter the kiosk from the bottom and the gland plate shall not be less
than450 mm from the base of the box. The gland plate and associated compartment shall be
sealed in suitable manner to prevent the ingress of moisture from the cable trench.
vi) The control connection, wiring etc. shall be as per specification.

4.11 ON LOAD TAP CHANGER

The transformers shall be provided with an On-Load Tap Changer (OLTC) of well reputed and
of proven make as per technical requirement for varying the effective transformation ratio while
the transformer is ON load and without providing phase displacement. The salient features of
the OLTC shall be as under:
The tap changing mechanism should be suitable for automatic, remote control operation from
remote control panel in the control room in addition to being capable of local manual as well as
local electrical operation.
The On Load Tap Changer (OLTC) shall include the following:
a) An oil immersed tap selector and arcing switch on arc suppressing tap selector provided with
ohmic or resistor type high speed diverter switch, for reduction of make and break arcing
voltages, overloads and short circuits.
b) Diverter switch should be with snap action mechanism with energy accumulator mounted
directly on the diverter switch.
c) Separate oil compartment
d) Easy removable diverter switch unit.
i) Motor driven mechanism
ii) Control and protection devices
iii) Local tap changer position indicator
iv) Manual operation device
v) Make of OLTC – Indigenous make (type test certificates from (CPRI).
vi) Control voltage – Any of the auxiliary power supply voltage.

The on-load tap changer shall be designed so that the contacts do not interrupt are
within the main tank of transformer. The tap changer selector and arcing switch on arc
suppressing tap selector switch shall be located in one or more oil filled compartments.
The diverter switch
should be provided with gas vent and Buchholz relay. It shall be designed as to prevent
the oil in tap selector and diverter switch compartments from mixing with the oil in
transformer. The barrier board between OLTC and the transformer tank shall be made of
Silicon Bonded Resin Paper (SBRP)
The tap changer shall be capable of permitting parallel operation with other
transformers of the same type. The transformer shall give full load output on all taps
without exceeding the limit of permissible temperature rise in oil and winding. The manual
operation device shall be so located on the transformer that it can be operated by a man
standing at the level of transformer track. It shall be of robust construction and shall be
capable of frequent operations. It shall not be possible to operate the electric drive when the
manual operating gear is in use.
Necessary interlocks blocking independent control when the units are in parallel
shall beprovided.
The controls shall be so arranged as to ensure that when a tap change operation
has commenced, it shall be completed independently of the operation of control relays or
switches. Local or remote control switch shall cause one tap movement only, until the
control switch has returned to the off position between successive operations. Under
abnormal conditions such as may occur when the contractor controlling one tap change
sticks, the arrangement must be such as to switch off supply to the motor so that an out of
step condition is limited to one tap difference between the units./ Limit switches shall 12
be
provided to prevent over running of mechanism.
The transformer and the tap changing equipment shall be designed to permit full
rated operation with tap changing equipment temporarily installed in any intermediate
position. Details of out of step protection provided for the taps should be furnished in the
 tender.
The control scheme for the tap changer shall be provided for independent auto/non-
auto control of the tap changer when the transformers are in independent service. Voltage
relating relay should be designed for maximum operational simplicity for regulating the
secondary voltage of power transformer with OLTC. The required end band settings are
set by setting the nominal value and lower and upper levels independently.
In addition, provisions shall be made to enable non-auto/automatic parallel control
also so that the tap changers of two or more transformers will be operated simultaneously
when one unit is in parallel with another so that under normal conditions the tap changer
will not become out of step and this will eliminate circulating current. Additional features
like “Master / Follower” and visual indication, during the operation of motor shall also be
incorporated.

A mechanical tap position indicator shall be provided on the tap changer in

addition to remote indication equipment in the control room on remote control cubicle of
OLTC. Necessaryinterlocks, for independent control when the units are in parallel shall be
provided.

The whole of motor drive unit comprising the motor and its control gear including
contractors, indicator, local electrical push buttons, five digit operation counter, handle
for manual control etc. as well as terminals for the control and indication wiring shall be
housed in a dust proof kiosk mounted on tap changer, A heating element with thermostat
and MCB shall also be provided in kiosk for ensuring trouble free operation of the
drive in cold weather arrangement shall be made for padlocking the kiosk. Tap position
indication shall be visible bya number appearing in a small glass window on the front of
the kiosk. For remote indication, an indication type instrument or digital type shall be
provided on a panel on the 415 volts, 3 phase, 50 c/s external supply.
Any enclosed compartment not oil filled shall be adequately ventilated. All
contractors, relay coils or other parts shall be suitably protected against corrosion or
deterioration due to condensation, fungi etc.
The oil in the compartments of the main tap changing apparatus which do not
contain contacts used for making or breaking current shall be maintained under
conservator head bymeans of a pipe connection from the highest point of the chamber
to the conservator. This connection shall be controlled by a suitable valve and shall be
arranged so that any gas leaving the chamber will pass into the gas and oil actuated relay.
A separate oil Buchholz relay with trip contacts shall be provided for the On-Load Tap
Changer chamber. Each tap changer shall also be provided with a pressure relief valve
outside OLTC to protect against sudden pressure development on OLTC.
Each compartment in which the oil is not maintained under conservator head shall
beprovided with a suitable direct reading oil level gauge.
A permanently legible lubrication chart shall be fitted with the driving mechanism
chamber.
Local electrical control switches and the local operating gear shall be clearly
labeled in suitable manner to indicate the direction of operation of tap changer.
The remote control panel of OLTC gear to be installed in the control room should
match in colour and dimensions sheet steel size etc. with the purchaser’s transformer
control panel for which details would be furnished to the successful contractor.
In addition to the fittings, auxiliaries and accessories considered necessary by the
contractor the following shall be provided.

A. FOR LOCAL ELECTRICAL CONTROL

i) Raise lower selector switch with a intermediate ‘OFF’ position.
ii) Auxiliary transformer (if necessary) alongwith MCB s and links.
iii) Step by step contractor
iv) Thermal over load relay for the motor 13
v) Reversing contractor
vi) ON/OFF automatic trip air circuit breaker for motor supply
vii) Local/Remote change over selector switch.
B. FOR REMOTE ELECTRICAL INDEPENDENT / AUTO-CONTROL
 i) All equipment listed in (A) above.
ii) Tap position indicator for mounting on control panel in the control room.
iii) Signal lamp and buzzer, for indicating “Tap Change in Progress”.
iv) Raise lower switch push button type with intermediate off/position for remote control.
v) Emergency stop button (push button type) with visual indication.
vi) Visual and alarm indication for non completion of operation within pre-set time
vii) Provision of interlocking system for blocking independent control when the units are to
run inparallel by providing interlock able phase sequence selector switch.
viii) All audo-visual indications should be brought to the Remote Tap Changer Cubicle
(RTCC)panel.
ix) DC supply isolators, DC supply ‘ON’ indicator & DC failure, both alongwith cancellations.
x) All equipment and their connections in RTCC panel should be properly marked. The
buzzer/bell (industrial type) should be provided.
C. FOR SIMULTANEOUS PARALLEL OPERATION OF TRANSFORMER
i) All equipment listed in (B) above.
ii) Out of step relay alongwith auxiliary relays, contractors and other equipment including
a buzzer and signal lamp to indicate the out of step indication when transformers in one of pair
of group of rating in parallel are one tap out of step and also to trip the circuit breaker.
iii) Control selector switch to enable to run a transformer as Master/Follower or independent
in a group.
iv) Selection switches for individual/parallel operation.
v) DC supply, Isolators, DC supply, ‘ON’ indication & DC failure, hooter alongwith
cancellation.

4.12 FITTINGS
The following fittings shall be provided on the transformers:
i) Conservator with isolating valves, oil filling hole with cap and drain valve. The
conservatorvessel shall be filled with constant oil pressure diaphragm oil sealing system.
ii) Magnetic type oil level gauge (150 mm dia) with low oil level alarm contacts.
iii) Prismatic/toughened glass oil level gauge.

iv) Silica gel breather with oil seal and connecting pipe complete with first fill of activated
silica gel or alumina mounted at a level of 1400 mm above ground level.
v) A double float type Buchholz relay with isolating valve, bleeding pipe and a testing cock,
thetest cock shall be suitable for a flexible (pipe connection for checking its operation).
A 5 mmdia Copper pipe shall be connected from the relay test cock to a valve located
at a suitable height above ground level to facilitate sampling of gas with the transformer
in service. Interconnection between gas collection box and relay shall also be; provided.
The device shallbe provided with two electrically independent ungrounded contacts, one
for alarm on gas accumulation and the other for tripping on sudden oil surge. These
contacts shall be wired upto transformer marshalling box. The relay shall be provided
with shut off valve on the conservator side as well as on the tank side.
vi) Pressure relief devices (including pressure relief valve) and necessary air equalizer
connectionbetween this and the conservator with necessary alarm and trip contacts.
vii) Air release plugs in the top cover.
viii) Inspection cover, access holes with bolted covers for access to inner ends of bushing etc.
ix) Winding temperature (hot spot) indicating device for local mounting complete in all
respects. Winding temperature indicator shall have three sets of contacts to operate at
different settings:
a) To provide winding temperature ‘high alarm’
b) To provide temperature too high ‘trip’
x) Thermometer with pocket for oil temperature indicator with one
set ofalarm and one set of trip contacts and maximum reading pointer.
xi) Lifting eyes or lugs for the top cover, core and coils and for the complete transformer.
xii) Jacking pads
xiii) Haulage lugs 14
xiv) Protected type mercury/alcohol in glass thermometer and a pocket to house the same.
xv) Top and bottom filter valves on diagonally opposite ends with pad locking
arrangement onboth valves.
xvi) Top and bottom sampling valves.
xvii) Drain valve with pad locking arrangement.
 xviii) Rating and connection diagram plate.
xix) Two numbers tank earthing terminals with associated nuts and bolts for
connections topurchaser’s grounding strip.
xx) Bi-directional flagged rollers with locking and bolting device.
xxi) Marshalling Box (MB)
xxii) Shut off valve on both sides of flexible pipe connections between radiator bank and
transformer tank.
xxiii) Cooling accessories:
a) Requisite number of radiators provided with:
 One shut off valve on top
 One shut off valve at bottom
 Air release device on top
 Drain and sampling device at bottom
 Lifting lugs
b) Air release device and oil drain plug on oil pipe connectors.
xxiv) Terminal marking plates for Current Transformer and Main transformer.
xxv) a) ON-Load Tap Changer
xxvi) Oil Preservation equipment
xxvii) LA alongwith the fittings
xxviii) Oil Temperature indicator
Note:- (i) The fittings listed above are indicative and any other fittings which are generally
required for satisfactory operation of the transformer are deemed to be included in
the quoted price of the transformer.
(ii) The contacts of various devices required for alarm and trip shall be potential free
andshall be adequately rated for continuous, making and breaking current duties as
specified.

4.13 CONTROL CONNECTIONS AND INSTRUMENT AND WIRING

TERMINAL,BOARD AND FUSES
i) Normally no fuses shall be used anywhere instead of fuses MCBs (both in AC&DC
circuits) shall be used. Only in cases where a MCB cannot replace a fuse due to system
requirements, a HRC fuse can be accepted.
ii) All wiring connections, terminal boards, fuses MCBs and links shall be suitable for
tropical atmosphere. Any wiring liable to be in contact with oil shall have oil resisting
insulation and the bare ends of stranded wire shall be sweated together to prevent
seepage of oil along the wire’
iii) Panel connections shall be neatly and squarely fixed to the panel. All instruments and
panel wiring shall be run in PVC or non-rusting metal cleats of the compression type.
All wiring toa panel shall be taken from suitable terminal board.
iv) Where conduits are used, the runs shall be laid with suitable falls, and the lowest parts
of the run shall be external to the boxes. All conduit runs shall be adequately drained and
ventilated. Conduits shall not be run at or below ground level.
v) When 400 Volt connections are taken through junction boxes or marshalling boxes, they
shallbe adequately screened and 400 volts Danger Notice must be affixed to the outside
of the junction boxes or marshalling box. Proper colour code for Red, Yellow, Blue
wires shall be followed.
vi) All box wiring shall be in accordance with relevant IS. All wiring shall be of stranded
copper(48 strands) of 1100 Volt grade and size not less than 2.5 Sq.mm.
vii) All wires on panels and all multi-core cables shall have ferrules, for easy identifications,
which bear the same number at both ends, as indicated in the relevant drawing.
viii) At those points of interconnection between the wiring carried out by separate
contractors, where a change of number cannot be avoided double ferrules shall be
provided on each wire. The change of numbering shall be shown on the appropriate
diagram of the equipment.
ix) Stranded wires shall be terminated with tinned Ross Courtney terminals, claw washers
or crimped tubular lugs. Separate washers shall be suited to the size of the wire 15
terminated. Wiring shall, in general, be accommodated on the sides of the box and the
wires for each circuit shall be separately grouped. Back of panel wiring shall be arranged
so that access to the connecting items of relays and other apparatus is not impeded.
x) All circuits in which the voltage exceeds 125 volts, shall be kept physically separated
 from theremaining wiring. The function of each circuit shall be marked on the associated
terminal boards.
xi) Where apparatus is mounted on panels, all metal cases shall be separately earthed by
means ofstranded (48 no) copper wire of strip having a cross section of not less than 2
sq.mm where strip is used, the joints shall be sweated. The copper wire shall have green
coloured insulation for earth connections.
xii) All wiring diagram for control and relay panel shall preferably be drawn as viewed from
the back and shall show the terminal boards arranged as in services.
xiii) Terminal block rows should be spaced adequately not less than 100 mm apart to permit
convenient access to external cables and terminations.
xiv) Terminal blocks shall be placed with respect to the cable gland (at a minimum distance
of 200 mm) as to permit satisfactory arrangement of multicore cable tails.
xv) Terminal blocks shall have pairs of terminals for incoming and outgoing
wires. Insulating barriers shall be provided between adjacent connections. The height
of the barriers and the spacing between terminals shall be such as to give adequate
protection while allowing easy access to terminals. The terminals shall be adequately
protected with insulating dust proof covers. No live metal shall be exposed at the back
of the terminal board. CT terminals shall have shorting facilities.
The terminals for CTs should have provision to insert banana plugs and with isolating links.
xvi) All interconnecting wiring, as per the final approved scheme between accessories of
transformer and marshalling box is included in the scope of this specification and shall
be done by the Transformer supplier.
xvii) The schematic diagram shall be drawn and fixed under a transparent propane sheet on
the inner side of the marshalling box cover.
xviii) To avoid condensation in the Marshalling Box, a space heater shall be provided with an
MCB and thermostat.
xix) Suitable 11W, CFL light shall be provided in the Marshalling Box at lightning purpose.

4.14 INSPECTION AND TESTING

(i) All the instruments used in inspection and testing shall be calibrated and sealed once a
year. Calibration certificate when demanded by the inspecting officer shall be produced
for verification purpose. In case of dispute regarding calibration of instruments,
instruments shall be sealed and signed by the representative of supplier and purchaser
and will be sent to institution / laboratory of repute or its own laboratory for calibration
at the cost of supplier. The amount of such testing shall be bounding on the supplier.
(ii) The contractor shall carry out a comprehensive inspection and testing program during
manufacture of the transformer. An indicative of inspection is given under clause no.
4.1. This is, however, not intended to form a comprehensive program as it is contractor’s
responsibility to draw up and carry out such a program duly approved by the purchaser.
(iii) The purchaser reserves the right to draw required number of samples of raw materials.
These samples shall however be drawn and sealed in the presence of contractor’s
representative. The Nigam further reserves the right to get these samples tested from any
Govt. Test House Laboratory or any Govt. recognized test house / laboratory. The
supplier shall have to purchase requisite test certificates for major raw material /
accessories used in the transformer.
(iv) The purchaser reserves the right to depute his representative / agency for carrying out
stage inspection of any stage of manufacturing process for ensuring quality of
manufacturing and also the raw materials. The contractor shall offer all reasonable
facilities for such inspections. The contractors shall furnish detailed production
schedule including different phases of material procurement, manufacture and
fabrication to facilitate the purchaser for deputing his representative / agency for
carrying out stage inspection. The contractor shall inform the purchaser likely date of
assembly of core and readiness of HT & LT coils enabling the purchaser to depute his
officers for stage inspection or issuing waive off of stage inspection.
(v) Records shall be maintained of all the tests carried out by the suppliers on transformers
offered for inspection and testing and shall produce when demanded bythe inspecting 16
officer to satisfy that transformers are being offered after carrying out all the necessary
tests by the supplier.
(vi) The purchaser reserves the right of having other reasonable tests carried out at his own
expense either before dispatch or at site to ensure that the transformer complies with
the requirement of this specification.
 After all tests have been completed six certified copies of each test report shall be
furnished. Each report shall supply the following information:-
(a) Complete identification data including sl. no. of transformer.
(b) Method of application where applied duration and interpretation of results for each
test.
(c) Temperature data corrected to 75o C including ambient temperature.
(vii) The contractor shall carry out routine tests of the transformers on site as per Cl. 5.1.5
(viii) Utility reserves the right to carry type test on one no. of transformer of each rating. The
charges for conducting each of type tests shall be included in the bid price and no
separate type test charges shall be paid. (NOTE: The transformers shall be
manufactured at site hence type test requirement is not applicable for this project,
however site testing of transformers shall be done in presence of the UPCL
representatives).
(ix) The pre-shipment checks shall also be carried out by the contractor.
(x) The requirements on site tests are as listed in the specifications.
(xi) Certified test report and oscillograms shall be furnished to the Purchaser/Consultants
for evaluation as per the schedule of distribution of documents. The contractor shall
also evaluate the test results and rectify the defects in the equipment based on his and
the purchaser’s evaluations of the tests without any extra charges to the Purchaser
Manufacturer’s Test Certificates in respect of all associated auxiliary and ancillary
equipment shall be furnished.
(xii) The bidder shall state in his proposal the testing facilities available during
manufacturing process. In case full testing facilities are not available, the bidder shall
state the method proposedto be adopted so as to ascertain the transformer characteristics
corresponding to full capacity.
5.0 INSPECTION & TESTINGS
5.1 FACTORY TESTS
(i) Tank and Conservator
a) Inspection of major weld.
b) Crack detection of major strength weld seams by dye penetration test.
c) Check correct dimensions, demonstrate turning of wheels, through 90 º and further
dimensional check.
d) Leakage test of the conservator.
e) Oil sample taken from Power Transformers may be got inspected from NABL
accredited Lab for its conformance as per IEC 60296 instead of IS: 335. In addition to
the above the firm shall also submit a proof of purchase of oil as per IEC 60296 and
as per Cl.4.6.5 of this technical specification.
(ii) Core
a) Sample testing of core materials for checking specific loss properties, magnetization
characteristics and thickness.
b) Check on the quality of varnish if used on the stampings.
c) Check on the amount of burrs.
d) Visual and dimensional checks for straightness and roundness of core, thickness of
limbs and suitabilityof clamps.
iii) Insulating Material
a) Sample check for physical properties of materials.
b) Check for dielectric strength
c) Check for the reaction of hot oil on insulating materials.
iv) Winding
a) Sample check on winding conductor for mechanical and electrical conductivity.
b) Visual and dimensional checks on conductor for scratches, dent mark etc.
c) Sample check on insulating paper for PH value, electric strength.
d) Check for the bonding of the insulating paper with conductor.
e) Check for the reaction of hot oil and insulating paper. 17
f) Check and ensure that physical condition of all materials taken for windings is
satisfactory and free ofdust.
g) Check for absence of short circuit between parallel strands.
v) Oil
All standard test in accordance with IEC60296 shall be carried out on Transformer oil sample
before in the transformer.
vi) Test reports for bought out items
The contractor shall submit the test reports for all bought out/sub contracted items for approval.
a. Buchholz relay
b. Sudden pressure rise relay on Main Tank
c. Bushings
d. Bushing current transformers in neutral (if provided)
e. Marshalling box
f. On load tap changer
g. Any other item required to complete the works
h. Porcelain, bushings, bushing current transformers, wherever provided, winding
coolers, control devices, insulating oil and other associated equipment shall be tested
by the contractor in accordance with relevant IS. If such equipment is; purchased by
the contractor on a sub-contract, he shall have them tested to comply with these
requirements.
vii) Naphthenic base transformer oil as per relevant IS/IEC
viii) TANK TESTS
a) Oil leakage test:
The tank and oil filled compartments shall be tested for oil tightness completely filled
with air or oil of viscosity not greater than that of insulating oil conforming to IS:335
at the ambient temperature and applying a pressure equal to the normal pressure plus
35 KN/m2 measured atthe base of the tank. The pressure shall be maintained for a period
of not less than 12 hours for oil and one hour for air and during that time no leak shall
occur.
b) Vacuum test
The tanks designed for full vacuum shall be tested at an internal pressure of 3.33 KN
per m2 (25 mm of Hg.) for one hour. The permanent deflection of flat plates, after the
vacuum has been released shall not exceed the value specified below without affecting
the performance ofthe transformer: -
Horizontal length of flat plate Permanent Deflection
in mm in mm
Up to & including 750 5
751 to 1250 6.5
1251 to 1750 8
1751 to 2000 9.5
2001 to 2250 11
2251 To 2500 12.5
2501 To 3000 16
Above 3000 19

The permanent deflection of flat plates after the vacuum has been released shall not
exceed the value specified in C.B.I.P. Manual on Transformers (Revised 1999)
without affecting the performance of the transformers
5.1.1 The type test report(s) submitted by the bidder/ supplier for similar or higher rating shall
be as per IS: 2026 or latest amendment thereof and being performed at CPRI
Bhopal/Banglore, NTH Ghaziabad or ERDA Vadodara or any NABL lab within last
5 years counted from the date of opening of tender.
5.1.2 It may also be noted that the representative of the purchaser (SE, I&QA, UPCL)
reserves the right to conduct short circuit test and impulse voltage withstand test in
accordance with the IS, afresh on each ordered rating at purchaser’s cost, even if the
transformers of the same rating and similar design are already tested. This test shall 18
be
carried out on a transformer to be selected by representative of the purchaser (SE,
I&QA, UPCL) either at the manufacturer’s works when they are offered in a lot for
supply or randomly from the supplies already made to purchaser’s stores. The
manufacturer shall be informed of such intention of the purchaser in writing. The
findings and conclusions of these tests shall be final and binding on the supplier.
In case transformer does not confirm to the specification, following penal action shall also be taken
bypurchaser against the manufacturer:-
a. The order for the remaining supplies shall be cancelled.
b. The supplier will be debarred / blacklisted for consideration in participating in three
subsequent years for all ratings counted from the date of tests resulting into failure of
design.
c. Any other action as deemed fit by UPCL.

5.2 Routine Tests on Site:

Transformer routine tests shall include tests stated in latest issue of IS:2026 (PartI).
These tests shall also include but shall not be limited to the following:-
i) Measurement of winding DC resistance.
ii) Voltage ratio on each tapping and check of voltage vector relationship.
iii) Verification of impedance voltage vide calculations.
iv) Magnetic circuit test –
Each core shall be tested for 1 minute at 2 KV DC between all bolts, side plates and
structural steel work. Immediately prior to the assembly of the transformer.
v) Load losses (By Ohmic calculation method)
vi) Measurement of magnetizing current.
vii) Absorption index i.e. insulation resistance for 15 seconds and 60 seconds (R60/R15)
and polarization index i.e. Insulation Resistance for 10 minutes and one minute R10
mt/R1 mt.).
viii) Vector Group test.
ix) Separate source voltage withstand test (applied potential).
x) Break Down voltage of transformer oil.
xi) Tan delta and dissipation factor for winding.
xii) Magnetic balance test.
Certified test reports and oscillographs shall be submitted for evaluation prior to
commissioning of the equipment. The contractor shall also evaluate the test results and
shall correct any defect indicated by his and Purchaser’s evaluation of the tests without
charge to the Purchaser.

c) PRESSURE TEST
One transformer tank of each size shall be subjected to a pressure corresponding to
twice the normal head of oil or to the normal pressure plus 35 KN per m2 (5 Lb. Per sq.
inch.) whichever is lower measured at the base of the tank and will be maintained for
one hour. Thepermanent deflection of flat plates after the excess pressure has been
released shall not exceed the figure specified above.

d) The following type and routine Tests shall be carried out on the On load tap changer
and motor driver mechanism in accordance with IS: 8468 1977 or its latest version.
The type tests should not be more than 5 years old.

5.2.1 ON LOAD TAP CHANGER

I. Type Tests
Type tests shall be performed on the samples of the relevant tap changer or
components after their final development. The following shall constitute the type tests.
a) Mechanical Test
b) Auxiliary Circuit insulation tests.
c) Tests for temperature rise of contacts
d) Switching tests
e) Short circuit tests
f) Transition impedance test.
g) Mechanical life test 19
h) Dielectric test
II. ROUNTINE TESTS:
The following shall constitute the routine tests:
a) Mechanical test
b) Auxiliary Circuit insulation tests
c) Dielectric Tests.
5.2.2 MOTOR DRIVEN MECHANISM
I) Type Tests.
The following shall constitute the type tests.
a) Mechanical tests
b) Auxiliary Circuit insulation tests.
c) Mechanical load test
d) Over run test
e) Protection of Motor Driver Cubicle.

II) ROUTINE TESTS

The following shall constitute the routine tests
a) Mechanical Tests
b) Auxiliary Circuit insulation tests.
• PRESHIPMENT CHECK AT MANUFACTURS WORKS
• Check for proper packing and preservation of accessories like CRGO laminations,
windings, insulating pressboards, oil-ducts, PCB blocks, coil compression rings,
radiators, bushings, Tank, fabricated items, dehydrating breather, rollers, buchholz
relay, marshelling box, control circuits etc.
• Check for proper provision of bracing to arrest the movement of material.
• Gas tightness test to conform tightness.
• INSPECTION AND TESTING AT SITE:
The contractor shall carry out detailed inspection covering areas right from the receipt of material
uptocommissioning stage. An indicative program of inspection as envisaged by the
engineer is given blow. This is however not intended to form a comprehensive
program as it is contract’s responsibility to draw up and carry out such a program.
5.4.1 Receipt and Storage checks
i) Check and record condition of each package visible parts of the transformers etc. for
anydamage.
ii) Check and record the gas pressure in the transformer tank as well as in the gas cylinder.
iii) Visual check of core and coils before filling up with oil and also check condition of core
and winding in general.

5.4.2 Installation checks

i) Inspection and performance testing of accessories like tap changers etc.
ii) Check choking of the tubes of heat exchangers.
iii) Test on oil samples taken from main tank top and bottom and cooling system. Samples
should betaken only after the oil has been allowed to settle for 24 hours.
iv) Check the whole assembly for tightness, general appearance etc.
v) Oil leakage tests.
5.4.3 Pre-commissioning tests
After the transformer is installed, the following pre-commissioning tests and checks shall be done
before putting the transformer in service.
i) Dry out test
ii) Megger test
iii) DC Resistance measurement of windings
iv) Ratio test on all taps
v) Phase relationship test (Vector grouping test)
vi) Buchholz relay alarm & surge operation test
vii) Low oil level (in conservator) alarm
viii) Temperature indicators
ix) Marshalling kiosk
x) Protective relays 20
xi) Magnetizing current
xii) Tests on OLTC
5.4.4 In to order to have checks on manufacturing procedure and
quality, bidder shall be furnish the following calculation.
 Flux density calculations
 Heat dissipation calculations,
 Short circuit calculations for Thermal ability and
 Load loss calculations.
5.4.5 The following additional checks shall be made:
i) All oil valves are in correct position closed or opened as required.
ii) All air pockets are cleared
iii) Thermometer pockets are filled with oil
iv) Oil is at correct level in the bushing, conservator, diverter switch & tank etc.
v) Earthing connections are made
vi) Colour of Silica gel is blue
vii) Bushing arcing horn is set correctly and gap distance is recorded.
viii) CT polarity and ratio is correct.

• PERFORMANCE
The performance of the transformer shall be measure on the following aspects:
• The transformer shall be capable of being operated without danger on any tapping at
the rated KVA with voltage variation ± 10% corresponding to the voltage of the
tapping.
• The maximum flux density in any part of the cores and yokes at normal voltage and
frequency shall be such that the flux density on any taps position with + 12.5% voltage
variations and –5% frequency variations, shall not exceed 1.9 wb/m2 .
• Ratio interference and Noise Level
• The transformer shall be designed with particular attention to the suppression of third
and fifth harmonics so as to minimize interference with communication circuits.
• FAULT CONDITIONS
(a) The transformer shall be capable of withstanding for two (2) seconds
without damages any external short circuit to earth.
(b) Transformers shall be capable of withstanding thermal and mechanical stresses
conveyed by symmetrical or asymmetrical faults on any winding.
(c) Transformers shall accept, without injurious heating, combined voltage and frequency
fluctuation which produce the 125% over fluxing condition for one minute.
• REJECTION
The purchaser may reject any transformer if during tests or service any of the following
conditions arise:
• Impedance value exceeds the guaranteed value by +10% or more.
• When actual losses during testing are found in excess of maximum guaranteed figures.
• The difference in impedance values of any two phases during single phase short circuit
impedance test exceeds 2% of the average value guaranteed by the vendor.
• Oil or winding temperature rise exceeds the specified value.
• Transformer fails on impulse test
• Transformer fails on Power Frequency Voltage withstand test
• Transformer is proved to have been manufactured not in accordance with the agreed
specification.

6.0 SPARES: -
6.1 The Tenderer shall quote separately for the following spares.
6.2 HV Bushings
6.3 LV Bushings
6.4 LV Neutral Bushings
6.5 Plain oil gauge
6.6 Oil and winding temperature indicator
6.7 Set of Gaskets
6.8 Pressure Relief valve
6.9 Schedule of Guaranteed and other Technical particulars be supplied as per alongwith tender.
21
6.10 Deviation from specification should be clearly listed and brought out separately.
7.0 INSTRUCTIONS MANUAL
7.1 Eight sets of the instruction manuals shall be supplied at least four (4) weeks before the
actual dispatch of equipment. The manuals shall be in bound volumes and shall contain
 all the drawings and information required for erection, operation and maintenance of
the transformer. The manuals shall include amongst other the following particulars:
a) Marked erection prints identifying the components parts of the transformer as dispatched
with assembly drawings.
b) Detailed dimensions assembly and description of all auxiliaries.
c) Detailed views of the core and winding assembly, winding connections & tappings, tap
changer construction etc. These drawings are required for carrying are required for
carrying out overhauling operation at site.
d) Salient technical particulars of the transformers.
e) Copies of all final approved drawing.
f) Detailed O & M instructions with periodical check lists and performance etc.
7.2 COMPLETENESS OF EQUIPMENT
i) All fittings and accessories, which may not be specifically mentioned in the
specification but which arenecessary for the satisfactory operation of the plant, shall be
deemed to be included in the specification and shall be furnished by the contractor
without extra charges. The equipment shall be complete in all details, whether such
details are mentioned in the specification or not, without any financial liability to the
Purchaser under any circumstances.

ii) All deviations from this specification shall be separately listed under the requisite
schedules, in the absence of which it will be presumed that all the provision of the
specification are complied with by thebidder.
8.0 TOOLS & TACKLES
All the necessary tools and tackles required for normal operation & maintenance shall be
supplied by the contractor.
9.0 STAGE INSPECTION:
The purchaser reserves the right for stage inspection of one or all the transformers during the
course of manufacture to ensure that the internal details are in accordance with the
data / information supplied / G.T.P.‘s as per Contract/P.O.

10.0 ACCESSORIES AND FITTINGS:

Each transformer shall be provided with the following in accordance with details to the extent these
arespecified in IS 2026-1977/relevant IEC: -
a) Inspection cover with lifting lugs
b) Rating Plate
c) Diagram Plate
d) Two earthing terminals
e) Lifting Lugs
f) Jacking Lugs
g) Conservator Tank with drain plug and oil filling hole
h) Dehydrating Breather
i) 1. Thermometer (dial type) with one pair of contacts for top oil over ` temperature
alarm.
2. Thermometer (dial Type) with two pairs of contacts for winding over temperature Alarm & Trip
and for On & OFF Motor Blower / Cooling fans.
j) Thermometer Pockets
k) One No. Magnetic oil level gauge mounted on conservator tank for main transformer tank
with 3 positions marked as follow:-
Min -400 C,
00 C and
Maximum 800 C for main tank.
l) One No. Plain Sight Glass Oil Level Gauge for OLTC Tank with Min.& Max. Oil Level Markings.
m) Oil filling hole with cap.
n) Air release device.
o) Pressure relief device 22
p) i. Gas & oil actuated relay with alarm and trip contacts and shut off valves on conservator as
well as main tank side for Main tank.
ii -do- with one pair of trip contacts for OLTC tank also
q) Filter valves (lower valve to be used as a drain valve)
 r) Terminal marking plate
s) Marshalling box
t) Necessary oil for the first filling
u) Bottom mounting channel
v) Flanged bi-directional rollers (four Nos.)
w) Studs & pulling eyes in both directions.
11.0 Direct real time measurement of winding temperature & Oil temperature. (Optical fiber sensors not
required)
12.0 SPECIAL TOOLS:
Any special tools required for erection and for maintenance work shall be provided along with
each transformer. Any special tools if required & recommended by the bidder shall be supplied
however cost of such tools be mentioned clearly in price bid.

13.0 GUARANTEE (MAINTENCE PERIOD):

13.1 The manufacturers of the transformer shall provide a guarantee of FIVE years from the
date of commissioning. In case the transformer fails within the guarantee period the
Concerned Executive Engineer of Electricity Distribution Divisionwill immediately inform
about the Damage to the supplier. The supplier shall take back the failed transformerwithin
15 days from the date of the intimation at his own cost and shall offer for inspection of
repaired transformer to SE(I&QA) within 45 days from the date of intimation and UPCL
shall resume the right to either waive off the inspection or conduct the same preferably
within 15 days time. Supplier shall ensure delivery of repaired/replaced transformer
within 7 days of waiver /inspection of transformers. All the routine tests will be
conducted free of cost at the supplier premises.
13.2 The outage period i.e. period from the date of failure till unit is repaired/replaced shall
not be counted for arriving at the guarantee period.
13.3 If damaged transformers are not replaced/repaired within above period the purchaser
shall recover an equivalent amount plus 15% supervision charges. In the event of the
supplier’s inability to adhere to the aforesaid provisions, suitable penal action will be
taken against the supplier which may inter alia include blacklisting of the firm for future
business with the purchaser for a certain period.

23
 TECHNICAL SPECIFICATION FOR THREE PHASE BIS MARKED LEVEL-2, 11/0.433 KV, 2000 KVA
COPPER WOUND DISTRIBUTION TRASFORMERS

1. SCOPE:

1.1 This specification covers design, engineering, manufacture, assembly, stage testing, inspection and testing before
supply and delivery at site of oil immersed, naturally cooled BIS marked 3 phase 11/0.433 kV, 2000 KVA distribution
transformers for outdoor use.

1.2 It is not the intent to specify completely herein all the details of the design and construction of equipment. However, the
equipment shall conform in all respects to high standards of engineering, design and workmanship and shall be capable of
performing in continuous commercial operation, in a manner acceptable to the purchaser, who will interpret the
meanings of drawings and specification and shall have the power to reject any work or material which, in his judgment is
not in accordance therewith. The offered equipment shall be complete with all components necessary for their
effective and trouble-free operation. Such components shall be deemed to be within the scope of bidder’s supply
irrespective of whether those are specifically brought out in this specification and / or the commercial order or not.

1.3 The transformer and accessories shall be designed to facilitate operation, inspection, maintenance and repairs. The
design shall incorporate every precaution and provision for the safety of equipment as well as staff engaged in
operation and maintenance of equipment.

1.4 All outdoor apparatus, including bushing insulators with their mountings, shall be designed so as to avoid any
accumulation of water.

2. STANDARD RATINGS:

2.1 The standard ratings shall be 2000 KVA for 11 kV distribution transformer.

3. STANDARDS:

3.1 The materials shall conform in all respects to the relevant Indian/International Standards, with latest amendments
thereof unless otherwise specified herein. Some of them are listed below:
Indian Title International and Internationally
standard Recognized standards
IS -2026 Specification for Power Transformers IEC 76
IS-1180 Outdoor distribution Transformer up to and including 100 kVA
IS 12444 Specification for Copper wire rod ASTM B-49
IS-335 Specification for Transformer Oil BS 148, D-1473,
D-1533-1934, IEC 60296
IS – 5 Specification for colors for ready mixed paints
IS – 104 Ready mixed paint, brushing zinc chromate, priming
IS – 2099 Specification for high voltage porcelain bushing
IS – 649 Testing for steel sheets and strips and magnetic circuits
IS – 4257 Dimensions for clamping arrangements for bushings
IS – 7421 Specification for Low Voltage bushings
IS – 3347 Specification for Outdoor Bushings DIN 42531 to 33
IS – 5484 Specification for Al Wire rods ASTM B - 233
IS – 9335 Specification for Insulating Kraft Paper IEC 554
IS – 1576 Specification for Insulating Press Board IEC 641
IS – 6600 Guide for loading of oil Immersed Transformers IEC 76
IS – 2362 Determination of water content in oil for porcelain bushing of transformer
IS – 6162 Paper covered conductor
IS – 6160 Rectangular Electrical conductor for electrical machines
IS – 5561 Electrical power connector
IS – 6103 Testing of specific resistance of electrical insulating liquids
IS – 6262 Method of test for power factor and dielectric constant of electrical insulating
Liquids
IS – 6792 Determination of electrical strength of insulating oil
IS - 10028 Installation and maintenance of transformers. 24
 3.2 Material conforming to other internationally accepted standards, which ensure equal or better quality than the
standards mentioned above, would also be acceptable. In case the bidders who wish to offer material conforming to
other standards, the bidder shall clearly bring out the salient points of difference between the standards adopted and
the specific standards in relevant schedule. Four copies of such standards with authentic English translations shall be
furnished along with the offer.

4. SERVICE CONDITIONS:

4.1 The Distribution Transformers to be supplied against this Specification shall be suitable for satisfactory continuous
operation under the following climatic conditions as per IS 2026 (Part - I).

i) Location At various locations

: in Uttarakhand
ii) Maximum ambient air temperature (0C) : 50
iii) Minimum ambient air temperature (0C) : -40
iv) Maximum average daily ambient air temperature (0C) : 40
v) Maximum average ambient temperature over 24 hour
period(0C) 45
vi) Maximum yearly weighted average ambient temperature (0C) : 32
vii) Maximum altitude above means sea level (meters) : 4000

Note:
1. The climatic conditions specified above are indicative and can be changed by the user as per requirements.
2. The equipment shall generally be for use in moderately hot and humid tropical climate, conducive to rust and fungus
growth unless otherwise specified.

5. PRINCIPAL PARAMETERS:
5.1 The transformers shall be suitable for outdoor installation with three phase, 50 Hz, 11 kV system in which the neutral is
effectively earthed and they should be suitable for service with fluctuations in supply voltage upto plus 12.5% to minus
12.5%.
The transformers shall conform to the following specific parameters:
Sl. No. Item 11 kV Distribution Transformers
1 System voltage (max.) 17.5 kV
2 Rated voltage HV 11 kV
3 Rated voltage LV 433 – 250 V
4 Frequency 50 Hz +/- 5%*
5 No. of Phases Three
6 Connection HV Delta
7 Connection LV Star (Neutral brought out)
8 Vector group Dyn-11
9 Type of cooling ONAN

Audible sound levels (decibels) at rated voltage and frequency for liquid immersed distribution transformers shall
be as below (NEMA Standards):

KVA rating Audible sound levels (decibels)

2000 61

6. TECHNICAL REQUIREMENTS:

CORE MATERIAL – CRGO

6.1 CRGO Material

25
6.1.1 The core shall be stack type of high grade cold rolled grain oriented annealed steel lamination having low loss
and good grain properties, coated with hot oil proof insulation, bolted together and to the frames firmly to prevent
vibration or noise. The core shall be stress relieved by annealing under inert atmosphere if required. The complete design
 of core must ensure permanency of the core loss with continuous working of the transformers. The value of the
maximum flux density allowed in the design and grade of lamination used shall be clearly stated in the offer. The
maximum Flux density in any part of the core and yoke at rated KVA, voltage and frequency shall be
1.5 Tesla. The core grade shall be MOH/HIB/ZDKH of thickness .27 mm or Less. Bidder should clearly
mention thickness of core and core losses in W/kg in their GTP.
6.1.2 The bidder should offer the core for inspection and approval by the purchaser during manufacturing stage. The bidder
shall have the facility to measure the core losses in naked core at the time of stage inspection.
6.1.3 The transformers core shall be suitable for over fluxing (due to combined effect of voltage and frequency) up to 12.5%
without injurious heating at full load conditions and shall not get saturated. The bidder shall furnish necessary design data in
support of this situation.
6.1.4 No-load current shall not exceed 2% of full load current and will be measured by energizing the transformer at 433
volts, 50 Hz on the secondary. Increase of voltage of 433 volts by 12.5% shall not increase the no-load current by 5%
(maximum) of full load current.
6.1.5 Material shall be directly procured either from the primary manufacturer or through their accredited marketing
organization of repute and not through any agent. The documental proofs of the purchases will be submitted by the
tenderer and should provide the name of the country from where the core material is purchased.
6.1.6 The tenderer should have preferably the in house core cutting facility and annealing facility, if the tender has
not this facility then he will intimate the place of core cutting, name of firm and date for core cutting. UPCL
may send their representative to check this core cutting process.

7. WINDINGS:
7.1 Material:
7.1.1 HV and LV windings shall be wound from Thermally upgraded Paper covered copper conductor.
7.1.2 LV winding shall be such that neutral formation will be at top.
7.1.3 The winding construction of single HV coil wound over LV coil is preferable.
7.1.4 Inter layer insulation shall be Nomex /Epoxy dotted Kraft Paper.
7.1.5 Proper bonding of inter layer insulation with the conductor shall be ensured. Test for bonding strength shall be
conducted.
7.1.6 Dimensions of winding coils are very critical. Dimensional tolerances for winding coils shall be within limits as
specified in Guaranteed Technical Particulars (GTP).
7.1.7 Current density for HV and LV winding should not be more than 2.8 Ampere per sq mm.
7.1.8 The core/coil assembly shall be securely held in position to avoid any movement under short circuit conditions.
7.1.9 Joints in the winding shall be avoided. However, if jointing is necessary the joints shall be properly brazed and the
resistance of the joints shall be less than that of parent conductor. In case of foil windings, welding of leads to foil
can be done within the winding.
7.1.10 Bidder should submit the calculated sheet regard flux density as per their GTP.

8. REQUIREMENT OF AXIAL DUCT:

8.1 LV winding shall be in form of even layers so that the neutral formation will be at top.
8.2 The winding shall be of one or more rectangular conductors insulated from each other to reduce eddy
current losses. The tolerances on the size of the conductor shall be as per IS-6160, specification for rectangular
conductors. If the active axial length of the coil is more than 350 mm, an axial duct, of 4 mm is provided between
the LV coil layers. The materials used for providing duct shall be non-compressible material. Any joints in the
HV/LV winding shall not be allowed except in HV tap zone.
8.3 Transformer rating 200KVA and above, an axial duct of 3 mm is to be provided if the radial thickness of coils
is more than 50 mm and/or the axial length of individual coil is more than 80 mm. The radial duct shall be
adequate for free circulation of oil as well as to withstand voltage between adjacent coils.
9. TAPS:
ON LOAD TAP CHANGER of reputed make is required for HV variation of +5% to -15% @ 2.5% each.
The On Load Tap Changer (OLTC) shall include the following:
e) An oil immersed tap selector and arcing switch on arc suppressing tap selector provided with ohmic or
resistor type high speed diverter switch, for reduction of make and break arcing voltages, overloads and
short circuits.
f) Diverter switch should be with snap action mechanism with energy accumulator mounted directly on the
diverter switch. 26
 g) Separate oil compartment
h) Easy removable diverter switch unit.
i) Motor driven mechanism
ii) Control and protection devices
iii) Local tap changer position indicator
iv) Manual operation device
v) Make of OLTC – Indigenous make (type test certificates from (CPRI).
vi) Control voltage – Any of the auxiliary power supply voltage.
10. OIL
10.1 The requirement relates to application of high grade insulating transformer oil in particular to a
naphthenic transformer oil composition. The quantity of oil required for the first filling of the transformer
and its full specification shall be stated in the bid. The bidder shall quote with first filling of oil plus 10%
extra.
10.1.1 The design and materials used in the construction of the transformer shall be such as to reducethe risk of
the development of acidity in the oil.
10.1.2 The naphthenic base transformer oil composition must meet the requirements of IEC60296: the grade
index requirement of I-40°C transformer oil (special application) in 2012 standards.
10.1.3 The contractor shall warrant that oil furnished is in accordance with the following specification:
SL. Test Guaranteed
Characteristics Unit
No Method Data
Min Max

1 Appearance Visual inspection of oil Clear free from

sample in transmitted sediment and
light under a thickness suspended matter
of 10 cm at ambient
temperature
2 Color ISO 2049 1.5
3 Density at 20 o C g /ml ISO 3675 or IEC 12185 0.895
4 Kinematic Viscosity at 40 o C mm 2 / ISO 3104 or ASTM D 12
sec 7042
at - 30 o C 1800
5 Flash Point, PMCC o C ISO 2719 135
6 Pour Point o C ISO 3016 -40
7 Inter Facial Tension at 25 o C mN / m ASTM D 971 40
8 Acidity mg IEC 62021-1or IEC 0.01
KOH/ g 62021-2
9 Water Content, Bulk/ Drum, IBC mg / kg IEC 60814 30 / 40
10 Breakdown Voltage IEC 60156
As Delivered / After Treatment kV 30 / 70
11 Dielectric Dissipation Factor IEC 60247 or IEC 0.005
(Tan δ )at 90 o C & 40 to 60 Hz 61620
12 Corrosive Sulphur DIN 51353 Not Corrosive Not
Silver Strip, 100 o C, 18 Hrs. ASTM D 1275 Corrosive
Copper Strip , 150 o C, 48 Hrs.
13 Potentially Corrosive Sulphur IEC 62535 Not Corrosive
14 DBDS mg / kg IEC 62697-1 < 5 mg/kg
15 Inhibitors according to % IEC 60666 ( U ) Uninhibited Oil
IS ( < 0.01 % )
13631 / IEC 60666
16 Metal Passivator additives mg / kg IEC 60666 < 5 mg/kg
according to
IS 13631 / IEC 60666
17 Other Additives Does not contain
18 Oxidation Stability at 120 o C, IEC 61125 Method C
164 Hrs. 27
 Total Acidity mg 4.8.4 of IEC 1.2
KOH /g 61125:2018
Sludge % 4.8.1 of IEC 0.8
61125:2018
DDF at 90 o C 4.8.5 of IEC 0.500
61125:2018
19 PCA Content % IP 346 3
20 PCB Content mg / kg IEC 61619 < 2mg /kg
21 2 – Furfural and related mg / kg IEC 61198 < 0.05 mg/kg
compounds for each individual
content compound
11. INSULATION LEVELS:
Sl. Voltage (kV) Impulse Voltage (kV Peak) Power Frequency Voltage (kV)
No.
1 0.433 - 3
2 11 95 36
12. LOSSES:

12.1 The bidder shall guarantee individually the no-load loss and load loss without any positive tolerance. The bidder
shall also guarantee the total losses at 50% and 100% load condition (at rated voltage and frequency and at 75 0C).
12.2 NO LOAD LOSSES:
Capacity in KVA 2000
Maximum No Load Losses in watts 2000

12.3 The maximum allowable losses at rated voltage and rated frequency permitted at 750C for 11/0.433KV transformers are
indicated below:
Voltage Rating (kVA) Max. Losses at 50% Max. Losses at 100%
ratio loading loading
(Watts) (Watts)
11000/433 - V 2000 4790 14100

12.4 Bids with higher losses than the above specified values would be treated as non-responsive. However, the
manufacturer can offer losses less than above though no cost benefit shall be given to the manufacturer.

12.5 In case resultant losses of transformer during type test are lower than guaranteed losses (as given in table
12.3), then maximum losses offered shall not exceed resultant losses of transformer during type test plus
5% subject to maximum losses in table 12.3. In no case losses beyond the guaranteed losses (as given in
table 12.3) will be acceptable. Firm should submit the GTP accordingly.
13. TOLERANCES:
No positive tolerance shall be allowed on the maximum losses displayed on the label for both 50% and 100%
loading values.

14. PERCENTAGE IMPEDANCE:

The value of impedance of transformers at 750C shall be 6.25%.
15. TEMPERATURE RISE:
The temperature rise over ambient shall not exceed the limits given below:
15.1 Top oil temperature rise measured by thermometer : 400 C
15.2 Winding temperature rise measured by resistance method : 450 C
Bids not meeting the above limits of temperature rise will be treated as non-responsive.
15.3 The transformer shall be capable of giving continuous rated output without exceeding the specified temperature rise.
Bidder shall submit the calculation sheet in this regard.
15.4 During test, temperature rise of the transformer should not exceed beyond specified limits of temperature rise as
defined above on total losses as per specification (as mention in table 11.2). Bidder shall submit the calculation sheet
in this regard for dissipation of heat of rated total losses as per specification. However, to fulfill 28this
requirement positive tolerance in the type tested size of tank or radiators shall be allowed
16. PENALTY FOR NON PERFORMANCE:

16.1 During testing works if it is found that the actual measured losses are more than the guaranteed losses, the
purchaser shall reject of particular transformer and he shall also have right to reject the complete lot in case number
of rejected transformers exceeds 50% of offered quantity.

16.2 Purchaser shall reject the entire lot during the test at supplier’s works, if the temperature rise exceeds the
specified values.

16.3 Purchaser shall reject any transformer during the test at supplier’s works, if the impedance values differ from the
guaranteed values including tolerance.

16.4 If the material is rejected in acceptance tests during inspection at manufacturer works for first time,
expenditure incurred in re-inspection and testing shall be recovered from the supplier.

16.5 If the material is rejected in acceptance tests during inspection at manufacturer's works for consecutive second
time, order of balance quantity shall be cancelled and firm shall be debarred for participation in any tender of
sa me item of any capacity in UPCL for two years from the date of rejection of material along with forfeiture of
Security Deposit submitted by the supplier against the order.

17. INSULATION MATERIAL:

17.1 Electrical grade insulation epoxy dotted Kraft Paper/Nomex and pressboard of standard make or any other superior
material subject to approval of the purchaser shall be used.

17.2 All spacers, axial wedges / runners used in windings shall be made of pre compressed Pressboard-solid, conforming to
type B 3.1 of IEC 641-3-2. In case of cross-over coil winding of HV all spacers shall be properly sheared and dovetail
punched to ensure proper locking. All axial wedges / runners shall be properly milled to dovetail shape so that they pass
through the designed spacers freely. Insulation shearing, cutting, milling and punching operations shall be carried out in such a
way, that there should not be any burr and dimensional variations.

18. TANK:

18.1 The internal clearance of tank shall be such, that it shall facilitate easy lifting of core with coils from the tank without
dismantling LV bushings.
18.1.1 All joints of tank and fittings shall be oil tight and no bulging should occur during service.
18.1.2 Inside of tank shall be painted with varnish/hot oil resistant paint. The top cover of the tank shall be slightly sloping to
drain rain water. It should be extended upto minimum 50 mm on all 4 sides & shall be tapered downwards.
18.1.3 The tank plate and the lifting lugs shall be of such strength that the complete transformer filled with oil may be lifted
by means of lifting shackle.
18.2 Manufacturer should carry out all welding operations as per the relevant ASME standards and submit a copy of the
welding procedure and welder performance qualification certificates to the customer.
18.3 PLAIN TANK:

18.3.1 The transformer tank shall be of robust construction rectangular in shape and shall be built up of electrically tested
welded mild steel plates of thickness for the bottom and top 6 mm and side 4 mm. Tolerances as per IS1852 shall be
applicable.
18.3.2 The corners shall be fully welded at the corners from inside and outside of the tank to withstand a pressure of 0.8
kg/cm2 for 30 minutes.
18.3.3 The tank shall be reinforced by welding angle 50 mm x 50 mm x 6 mm as stiffeners on all the outside walls on the
edge of the tank.
18.3.4 Permanent deflection: The permanent deflection, when the tank without oil is subjected to a vacuum of 500 mm of
mercury for rectangular tank and 760 mm of mercury for round tank, shall not be more than the values as given
below: (All figures in mm)
Horizontal length of flat plate Permanent deflection
Up to and including 750 5.0
751 to 1250 6.5 29
 1251 to 1750 8.0
1751 to 2000 9.5
2001 to 2250 11.0
2251 to 2500 12.0
2501 to 3000 16.0
Above 3000 19.0

18.3.5 The tank shall further be capable of withstanding a pressure of 0.8 kg and a vacuum of 0.7 kg without
any deformation.
18.3.6 The radiators can be fin type to achieve the desired cooling to limit the specified temperature rise.
18.3.7 Explosion Vent: Explosion Vent shall be provided on Transformers. Explosion Vent shall be opening towards
ground from LV Bushing side with
18.3.8 M.S. mesh having Pipe Diameter of minimum 50 mm with 0.025 mm copper shim sheet/Bakelite thick sheet of
0.4 mm thick as diaphragm shall be provided on the top of the cover of the tank such that the pressure released
should be directed to the ground & it should be inserted in the top cover of tank, welded outside & inside of top
cover. Length of the explosion vent should be minimum 700 mm. Nut bolts of flange of Explosion Vent should
be tag welded. The other end of the vent pipe shall be guarded with wire mesh for preventing the entry of worms
and nesting. The diaphragm shall burst at a pressure of 0.76 to 0.80 Kg/cm2. There shall be minimum 140 mm
clearance between live part of HV Bushing to Explosion Vent.

19. MARSHALLING BOX

i) Sheet steel, weather, vermin and dust proof marshalling box fitted with required glands, locks,
glass door, terminal board, heater wit switch, illumination lamp with switch, water tight hinged
and padlocked door a suitable construction shall be provided with each transformer to
accommodate temperature indicators, terminal blocks etc. The box shall have slopping roof and
the interior and exterior painting shall be in accordance with the specification. Padlock along
with duplicate keys shall be supplied for marshalling box. The degree of protection shall be
IP55.
ii) The schematic diagram of the circuitry inside the marshalling box be prepared and fixed inside
thedoor under a pros pone sheet.
iii) The marshalling box shall accommodate the following equipment:
(a) Temperature indicators ( Both WTI/OTI shall be digital with SCADA compatible features)
(b) Space for accommodating Control & Protection equipment in future for the cooling fan
(for ONAF type cooling, may be provided in future).
(c) Terminal blocks and gland plates for incoming and outgoing cables.
All the above equipment except (c) shall be mounted on panels and back of panel wiring shallbe used
for inter-connection. The temperature indicators shall be so mounted that they are notmore than 1600
mm from the ground level and the door(s) of the compartment(s) shall be provided with glazed window
of adequate size. The transformer shall be erected on a plinth which shall be 2.5 feet above ground level.
iv) To prevent internal condensation, a metal clad heater with thermostat shall be provided. The
heater shall be controlled by a MCB of suitable rating mounted in the box.
v) All incoming cables shall enter the kiosk from the bottom and the gland plate shall not be less
than 450 mm from the base of the box. The gland plate and associated compartment shall be
sealed in suitable manner to prevent the ingress of moisture from the cable trench.
vi) The control connection, wiring etc. shall be as per specification.

20. CONSERVATOR:
20.1 The conservator shall be provided on transformers.
20.2 When a conservator is provided, oil gauge and the plain or dehydrating breathing device shall be fitted to the
conservator which shall also be provided with a drain plug and a filling hole [32 mm (1¼”)] normal size thread with
cover. In addition, the cover of the main tank shall be provided with an air release plug.
20.3 The dehydrating agent shall be silica gel. The moisture absorption shall be indicated by a change in the colour of the
silica gel crystals which should be easily visible from a distance. Volume of breather shall be suitable for 1 kg of
silica gel conforming to IS 3401.
20.4 30 and
The capacity of a conservator tank shall be designed keeping in view the total quantity of oil and its contraction
 expansion due to temperature variations. The total volume of conservator shall be such as to contain10% quantity of the
oil. Normally 3% quantity the oil shall be contained in the conservator.
20.5 The cover of main tank shall be provided with an air release plug to enable air trapped within to be released, unless the
conservator is so located as to eliminate the possibility of air being trapped within the main tank.
20.6 The inside diameter of the pipe connecting the conservator to the main tank should be within 20 to 50 mm and it
should be projected into the conservator so that its end is approximately 20 mm above the bottom of the conservator so as
to create a sump for collection of impurities. The minimum oil level (corresponding to -5 0C) should be above the sump
level.

21. SURFACE PREPARATION AND PAINTING:

21.1 GENERAL
21.1.1 All paints, when applied in a normal full coat, shall be free from runs, sags, wrinkles, patchiness, brush marks or
other defects.
21.1.2 All primers shall be well marked into the surface, particularly in areas where painting is evident and the first priming
coat shall be applied as soon as possible after cleaning. The paint shall be applied by airless spray according to
manufacturer’s recommendations. However, where ever airless spray is not possible, conventional spray be used
with prior approval of purchaser.

21.2 CLEANING AND SURFACE PREPARATION:

21.2.1 After all machining, forming and welding has been completed, all steel work surfaces shall be thoroughly cleaned of
rust, scale, welding slag or spatter and other contamination prior to any painting.

21.2.2 Steel surfaces shall be prepared by shot blast cleaning (IS9954) to grade SO 2.1/2 of ISO 8501-1 or chemical cleaning
including phosphating of the appropriate quality (IS 3618).

21.2.3 Chipping, scraping and steel wire brushing using manual or power driven tools cannot remove firmly adherent mill-
scale. These methods shall only be used where blast cleaning is impractical. Manufacturer to clearly explain such areas in
his technical offer.

21.3 PROTECTIVE COATING:

As soon as all items have been cleaned and within four hours of the subsequent drying, they shall be given suitable
anti- corrosion protection.

21.4 PAINT MATERIAL:

21.4.1 Following are the types of paint which may be suitably used for the items to be painted at shop and supply of
matching paint to site: Heat resistant paint (Hot oil proof) for inside surface

21.4.2 For external surfaces one coat of thermo setting powder paint or one coat of epoxy primer followed by two coats of
synthetic enamel/polyurethane base paint. These paints can be either air drying or stoving.

21.4.3 For highly polluted areas, chemical atmosphere or for places very near to the sea coast, paint as above with one coat of
high build Micaceous iron oxide (MIO) as an intermediate coat may be used.

21.5 PAINTING PROCEDURE:

21.5.1 All prepared steel surfaces should be primed before visible re-rusting occurs or within 4 hours, whichever is sooner.
Chemical treated steel surfaces shall be primed as soon as the surface is dry and while the surface is still warm.

21.5.2 Where the quality of film is impaired by excess film thickness (wrinkling, mud cracking or general softness) the
supplier shall remove the unsatisfactory paint coating and apply another coating. As a general rule, dry film thickness
should not exceed the specified minimum dry film thickens by more than 25%.

21.6 DAMAGED PAINTWORK:

21.6.1 Any damage occurring to any part of a painting scheme shall be made good to the same standard of corrosion
protection and appearance as that was originally applied. 31
21.6.2 Any damaged paint work shall be made good as follows:

21.6.2.1 The damaged area, together with an area extending 25 mm around its boundary, shall be cleaned down to
bare metal.

21.6.2.2 A priming coat shall be immediately applied, followed by a full paint finish equal to that originally applied and
extending 50 mm around the perimeter of the original damage.

21.6.2.3 The repainted surface shall present a smooth surface. This shall be obtained by carefully chamfering the paint
edges before and after priming.

21.7 DRY FILM THICKNESS:

21.7.1 To the maximum extent practicable the coats shall be applied as a continuous film of uniform thickness and free
of pores. Overspray, skips, runs, sags and drips should be avoided. The different coats may or may not be of the
same colour.
21.7.2 Each coat of paint shall be allowed to harden before the next is applied as per manufacturer’s recommendation.

21.7.3 Particular attention must be paid to full film thickness at the edges.

21.7.4 The requirements for the dry film thickness (DFT) of paint and the materials to be used shall be as given below:

Sl.No. Paint type Area to be No. of Total dry film

painted coats Thickness (min.) (microns)
1. Thermo setting powder inside 01 30
Paint outside 01 60
2. Liquid paint
a) Epoxy (primer) outside 01 30
b) P.U. Paint (Finish coat) outside 02 25 each
c) Hot oil paint/ Varnish inside 01 35/10

21.8 TESTS FOR PAINTED SURFACE:

21.8.1 The painted surface shall be tested for paint thickness.

21.8.2 The painted surface shall pass the cross hatch adhesion test and impact test as acceptance tests and Salt spray test
and Hardness test as type test as per the relevant ASTM standards.

21.8.3 Transformer tank shall be painted with grey color paint.

Note: Supplier shall guarantee the painting performance requirement for a period of not less than 5 years.
22. BUSHINGS:

22.1 The bushings shall conform to the relevant standards specified and shall be of outdoor type. The bushing rods and nuts
shall be made of brass material 12 mm diameter for HT and 3000 Amp. Epoxy flat type copper LT bushings. The tests as
per latest IS 2099 and IS 7421 shall be conducted on the transformer bushings.

22.2 Bushing class shall be as per IS 2099 for HV Bushing and IS 7421-1974 for LV Bushing.

22.3 Bushing can be of porcelain/epoxy material. Polymer insulator bushings conforming with relevant IEC can also be used.

22.4 HV Bushing and LV Bushing shall be providing on the side of the tank to facilitate cable box termination.

22.5 Bushings of plain shades as per IS 3347 shall be mounted on the side of the Tank and not on top cover.

22.6 Dimensions of the bushings of the voltage class shall conform to the Standards specified and dimension of clamping
arrangement shall be as per IS 4257
22.7 Minimum external phase to phase and phase to earth clearances of bushing terminals shall be as follows: 32
 Voltage Clearance
Phase to phase Phase to earth
11 kV 255 mm 205 mm
LV 75 mm 55 mm

22.8 Brazing of all inter connections, jumpers from winding to bushing shall have cross section larger than the
winding conductor. All the Brazes shall be qualified as per ASME, section – IX.

22.9 The bushings shall be of reputed make supplied by those manufacturers who are having manufacturing and
testing facilities for insulators.

22.10 The terminal arrangement shall not require a separate oil chamber not connected to oil in the main tank.
23. TERMINAL CONNECTORS:

The LV and HV bushing stems shall be provided with suitable cable boxes as per IS 5082 so as to connect the
jumper without disturbing the bushing stem. Connectors shall be with eye bolts so as to receive conductor for
HV. Terminal connectors shall be type tested as per IS 5561.

24. TERMINAL MARKINGS:

High voltage phase windings shall be marked both in the terminal boards inside the tank and on the outside with
capital letter 1U, 1V, 1W and low voltage winding for the same phase marked by corresponding small letter 2u,
2v, 2w. The neutral point terminal shall be indicated by the letter 2n. Neutral terminal is to be brought out and
connected to local grounding terminal by an earthing strip.

25. FITTINGS:
The following standard fittings shall be provided:
i. Rating and terminal marking plates, non-detachable.
ii. Earthing terminals with lugs - 2 Nos.
iii. Lifting lugs for main tank and top cover – 2 Nos.
iv. Lifting lugs to lift core assembly – 2 Nos.
v. Terminal connectors on the HV/LV bushings (For bare terminations only).
vi. Thermometer pocket with cap - 1 No.
vii. Air release device
viii. HV bushings - 3 Nos.
ix. LV bushings - 4 Nos.
x. Pulling lugs-4 Nos
xi. Stiffener
xii. Radiators - If radiator is required as per heat dissipation calculations/corrugations as defined in clause no
14.4)- No. and length of radiators may be mentioned if radiator has been provided.
xiii. OLTC
xiv. One drain cum sampling valve of 32 mm having narrow orifice with locking arrangement on the
bottom of the tank. A plate shall also be welded in front of drain valve so that the same cannot be
opened.
xv. One filter valve of 32 mm having narrow orifice with locking arrangement on the bottom of the tank.
A plate shall also be welded in front of drain valve so that the same cannot be opened.
xvi. Prismatic oil level gauge with minimum, average & maximum marking as -20 0C, 20 0C & 800C respectively.
xvii. Oil filling hole having p. 1- ¼ ‘’ thread with plug.
xviii. Silica gel Breather: Volume of breather shall be suitable for 2 kg of silica gel confirming to IS 3401.
xix. Base channel 100x50 mm, with holes to make them suitable for fixing on a platform or plinth.
xx. Pressure relief device or explosion vent.
xxi. 4 Nos. Rollers.
xxii. HV/LV cable boxes
26. FASTENERS:
26.1 All bolts, studs, screw threads, pipe threads, bolt heads and nuts shall comply with the appropriate Indian Standards for
metric threads, or the technical equivalent.
26.2 Bolts or studs shall not be less than 6 mm in diameter except when used for small wiring terminals. 33
26.3 All nuts and pins shall be adequately locked.

26.4 Wherever possible bolts shall be fitted in such a manner that in the event of failure of locking resulting in the nuts
working loose and falling off, the bolt will remain in position.
26.5 All ferrous bolts, nuts and washers placed in outdoor positions shall be treated to prevent corrosion, byhot dip galvanizing,
except high tensile steel bolts and spring washers which shall be electro-galvanized/plated. Appropriate precautions shall be
taken to prevent electrolytic action between dissimilar metals.
26.6 Each bolt or stud shall project at least one thread but not more than three threads through the nut, except when otherwise
approved for terminal board studs or relay stems. If bolts and nuts are placed so that they are inaccessible by means of
ordinary spanners, special spanners shall be provided.
26.7 The length of the screwed portion of the bolts shall be such that no screw thread may form part of a shear plane between
members.
26.8 Taper washers shall be provided where necessary.
27. Protective washers of suitable material shall be provided front and back of the securing screws.
28. OVERLOAD CAPACITY:
The transformers shall be suitable for loading as per IS 6600.
29. TESTS:
NOTE: Distribution transformers shall be manufactured at site under this project. Such manufactured
transformers shall be free from the requirement of type test. However, site testing of these transformers
shall be carried out in presence of UPCL’s representatives.

29.1 UPCL reserves right to get equipment type tested by the bidder or his collaborator as per the relevant standards
including the additional type tests. The type test must have been conducted on a transformer of similar or higher
rating/class design during the last five years at the time of bidding. The bidder shall furnish copy of type test
reports along with the offer. Offers without type test reports will be treated as non-responsive. Type test required as
per BIS standard only.
29.2 Special tests other than type and routine tests, as agreed between purchaser and bidder shall also be carried out as per
the relevant standards.
29.3 The requirements of site tests are also given in this clause.
29.4 The test certificates for all routine and type tests for the transformers and also for the bushings and transformer
oil shall be submitted with the bid.
29.5 The procedure for testing shall be in accordance with IS1180/2026 as the case may be except for temperature rise
test.
29.6 Before dispatch each for the complete assembly of transformers shall be subjected to the following tests at the
manufacturer’s works and at site
29.7 INSPECTION & TESTINGS
29.7.1 FACTORY TESTS
(i) Tank and Conservator
a) Inspection of major weld.
b) Crack detection of major strength weld seams by dye penetration test.
c) Check correct dimensions, demonstrate turning of wheels, through 90 º and further dimensional
check.
d) Leakage test of the conservator.
e) Oil sample taken from Power Transformers may be got inspected from NABL accredited Lab for its
conformance as per IEC 60296 instead of IS: 335. In addition to the above the firm shall also submit
a proof of purchase of oil as per IEC 60296 and as per Cl.4.6.5 of this technical specification.
(ii) Core
a) Sample testing of core materials for checking specific loss properties, magnetization characteristics
and thickness.
b) Check on the quality of varnish if used on the stampings. 34
c) Check on the amount of burrs.
 d) Visual and dimensional checks for straightness and roundness of core, thickness of limbs and
suitabilityof clamps.
ix) Insulating Material
a) Sample check for physical properties of materials.
b) Check for dielectric strength
c) Check for the reaction of hot oil on insulating materials.
x) Winding
a) Sample check on winding conductor for mechanical and electrical conductivity.
b) Visual and dimensional checks on conductor for scratches, dent mark etc.
c) Sample check on insulating paper for PH value, electric strength.
d) Check for the bonding of the insulating paper with conductor.
e) Check for the reaction of hot oil and insulating paper.
f) Check and ensure that physical condition of all materials taken for windings is satisfactory and
free ofdust.
g) Check for absence of short circuit between parallel strands.
xi) Oil
All standard test in accordance with IEC60296 shall be carried out on Transformer oil sample
before in the transformer.
xii) Test reports for bought out items
The contractor shall submit the test reports for all bought out/sub contracted items for approval.
a. Buchholz relay
b. Sudden pressure rise relay on Main Tank
c. Bushings
d. Bushing current transformers in neutral (if provided)
e. Marshalling box
f. On load tap changer
g. Any other item required to complete the works
h. Porcelain, bushings, bushing current transformers, wherever provided, winding coolers, control
devices, insulating oil and other associated equipment shall be tested by the contractor in
accordance with relevant IS. If such equipment is; purchased by the contractor on a sub-contract,
he shall have them tested to comply with these requirements.
xiii) Naphthenic base transformer oil as per relevant IS/IEC
xiv) TANK TESTS
29.7.1.1 Oil leakage test:
The tank and oil filled compartments shall be tested for oil tightness completely filled with air or oil of
viscosity not greater than that of insulating oil conforming to IS:335 at the ambient temperature and
applying a pressure equal to the normal pressure plus 35 KN/m2 measured atthe base of the tank. The
pressure shall be maintained for a period of not less than 12 hours for oil and one hour for air and during
that time no leak shall occur.
e) Vacuum test
The tanks designed for full vacuum shall be tested at an internal pressure of 3.33 KN per m2 (25 mm of
Hg.) for one hour. The permanent deflection of flat plates, after the vacuum has been released shall not
exceed the value specified below without affecting the performance ofthe transformer: -
Horizontal length of flat plate Permanent Deflection
in mm in mm
Up to & including 750 5
751 to 1250 6.5
1251 to 1750 8
1751 to 2000 9.5
2001 to 2250 11
2251 To 2500 12.5
2501 To 3000 16
35
Above 3000 19
The permanent deflection of flat plates after the vacuum has been released shall not exceed the
value specified in C.B.I.P. Manual on Transformers (Revised 1999) without affecting the
performance of the transformers
5.2.2 The type test report(s) submitted by the bidder/ supplier for similar or higher rating shall be
as per IS: 2026 or latest amendment thereof and being performed at CPRI
Bhopal/Banglore, NTH Ghaziabad or ERDA Vadodara within last 5 years counted from
the date of opening of tender.

Bidder shall quote transformer losses as per requirement of this specification. If, they wish to quote
losses higher than type tested losses upto the permissible losses as given in table 1.2, their offer
shall be opened subject to condition that they will get one number transformer type tested at CPRI
Bhopal/ Bangalore, NTH Ghaziabad or ERDA Vadodara at their own cost before submission of
GTP without affecting the delivery schedule. Losses of this type test will be final.

5.2.3 It may also be noted that the representative of the purchaser (SE, I&QA,UPCL) reserves
theright to conduct short circuit test and impulse voltage withstand test in accordance with
the IS,afresh on each ordered rating at purchaser’s cost, even if the transformers of the
same rating and similar design are already tested. This test shall be carried out on a
transformer to be selected by representative of the purchaser (SE, I&QA,UPCL) either at
the manufacturer’s works when they are offered in a lot for supply or randomly from the
supplies already made to purchaser’s stores. The manufacturer shall be informed of such
intention of the purchaser in writing. The findings and conclusions of these tests shall be
final and binding on the supplier.
In case transformer does not confirm to the specification, following penal action shall also be taken by
purchaser against the manufacturer:-
d. The order for the remaining supplies shall be cancelled.
e. The supplier will be debarred / blacklisted for consideration in participating in three
subsequent years for all ratings counted from the date of tests resulting into failure of
design.
f. Any other action as deemed fit by UPCL.

5.3 Routine Tests on Site:

Transformer routine tests shall include tests stated in latest issue of IS:2026 (PartI). These tests
shall also include but shall not be limited to the following:-
i) Measurement of winding DC resistance.
ii) Voltage ratio on each tapping and check of voltage vector relationship.
iii) Verification of impedance voltage vide calculations.
iv) Magnetic circuit test –
Each core shall be tested for 1 minute at 2 KV DC between all bolts, side plates and structural steel
work. Immediately prior to the assembly of the transformer.
v) Load losses (By Ohmic calculation method)
vi) Measurement of magnetizing current.
vii) Absorption index i.e. insulation resistance for 15 seconds and 60 seconds (R60/R15)
and polarization index i.e. Insulation Resistance for 10 minutes and one minute R10 mt/R1
mt.).
viii) Vector Group test.
ix) Separate source voltage withstand test (applied potential).
x) Measurement of power consumed by fans & oil-pumps if required.
xi) Break Down voltage of transformer oil.
xii) Tan delta and dissipation factor for winding.
xiii) Magnetic balance test.
Certified test reports and oscillographs shall be submitted for evaluation prior to
commissioning of the equipment. The contractor shall also evaluate the test results36
and
 shall correct any defect indicated by his and Purchaser’s evaluation of the tests without
charge to the Purchaser.

f) PRESSURE TEST
One transformer tank of each size shall be subjected to a pressure corresponding to twice
thenormal head of oil or to the normal pressure plus 35 KN per m2 (5 Lb. Per sq. inch.)
whichever is lower measured at the base of the tank and will be maintained for one hour.
Thepermanent deflection of flat plates after the excess pressure has been released shall not
exceed the figure specified above.

g) The following type and routine Tests shall be carried out on the On load tap changer
and motor driver mechanism in accordance with IS: 8468 1977 or its latest version.
The type tests should not be more than 5 years old.

5.2.3 ON LOAD TAP CHANGER

I. Type Tests
Type tests shall be performed on the samples of the relevant tap changer or components
after their final development. The following shall constitute the type tests.
i) Mechanical Test
j) Auxiliary Circuit insulation tests.
k) Tests for temperature rise of contacts
l) Switching tests
m) Short circuit tests
n) Transition impedance test.
o) Mechanical life test
p) Dielectric test
II. ROUNTINE TESTS:
The following shall constitute the routine tests:
a) Mechanical test
b) Auxiliary Circuit insulation tests
c) Dielectric Tests.
5.2.4 MOTOR DRIVEN MECHANISM
III) Type Tests.
The following shall constitute the type tests.
a) Mechanical tests
b) Auxiliary Circuit insulation tests.
c) Mechanical load test
d) Over run test
e) Protection of Motor Driver Cubicle.

IV) ROUTINE TESTS

The following shall constitute the routine tests
a) Mechanical Tests
b) Auxiliary Circuit insulation tests.
• PRESHIPMENT CHECK AT MANUFACTURS WORKS
• Check for proper packing and preservation of accessories like CRGO laminations, windings,
insulating pressboards, oil-ducts, PCB blocks, coil compression rings, radiators, bushings,
fabricated items, dehydrating breather, rollers, buchholz relay, marshelling box, control
circuits etc.
• Check for proper provision of bracing to arrest the movement of material.
• Gas tightness test to conform tightness.
• INSPECTION AND TESTING AT SITE:
The contractor shall carry out detailed inspection covering areas right from the receipt
37of
 material uptocommissioning stage. An indicative program of inspection as envisaged by the
engineer is given blow. This is however not intended to form a comprehensive program as it
is contract’s responsibility to draw up and carry out such a program.

30. TESTING OF TRANSFORMER OIL:

To ascertain the quality of the transformer oil, the original manufacturer’s tests report should be submitted at the time
of inspection. Arrangements should also be made for testing of transformer oil, after taking out the sample from the
manufactured transformers and tested in the presence of purchaser’s representative.
The purchaser reserves the right to send the sample for testing to a reputed institute at the purchaser’s
cost and the test result shall be binding on the manufacturer. In case of test results found beyond the GTP
or in case the transformer fails in any test, then the complete lot supplied against this order shall be rejected
& any payment made before shall be adjusted against bank guarantee.
30.1 To ensure about the quality of transformers, the inspection shall be carried out by the purchaser’s representative at
following two stages to verify that all the provisions made in the specification and technical particulars given
are being complied with:-
a) Check for dimensions of transformers.
b) Internal and external construction of transformer.
c) Workmanship
d) Check for genuineness of raw material.
30.1.1 Stage inspection - Online anytime during receipt of raw material and manufacture/ assembly whenever the
purchaser desires.
30.1.2 Final inspection - At finished stage i.e. transformers are fully assembled assembly and are ready for installation at
site.
30.1.3 Inspection shall be carried out only after routine test results are submitted to SE (I&QA) and Sl. No. of
transformers are given.
30.2 After the main raw-material i.e. core and coil material and tanks are arranged and transformers are taken for
production on shop floor and a few assembly have been completed, the firm shall intimate the purchaser in this
regard, so that an officer for carrying out such inspection could be deputed, as far as possible within 15 days
from the date of intimation. The purchaser reserves the right for stage inspection of the transformer in which
assembly of core and winding could be inspected. During the stage inspection a few assembled core shall be
dismantled (only in case of CRGO material) to ensure that the CRGO laminations used are of good quality. Further, as and
when the transformers are ready for dispatch, an offer intimating about the readiness of transformers, for final
inspection for carrying out tests as per relevant IS shall be sent by the firm along with Routine Test Certificates. The
inspection shall normally be arranged by the purchaser at the earliest after receipt of offer for pre-delivery
inspection.
The inspector(s) authorized by Purchaser shall have the right for checking the records pertaining to receipt
and issue of all the major items of raw materials including transformer oil. The supplier shall also have to
produce requisite test certificates for each and every consignment of transformer oil and other major items of
material.
The purchaser reserves the right to draw required number of samples of transformer oil and other major items
of raw material. These samples shall however be drawn and sealed in the presence of contractor. The
purchaser further reserves the right to get these samples tested from some Govt. /recognized Test House /
Laboratory.

30.3 In case of any defect/defective workmanship observed at any stage by the purchaser’s Inspecting Officer, the
same shall be pointed out to the firm in writing for taking remedial measures. Further processing should only be done after
clearance from the Inspecting Officer/ purchaser.
30.4 For physical check only one transformer will be opened in one lot, for pilot 10:1. For others also one piece per
offered lot per inspection.
Each and every lot of the transformer shall be inspected by the inspecting team.
30.5 All tests and inspection shall be carried out at the place of manufacture unless otherwise specifically agreed upon by
the manufacturer and purchaser at the time of purchase. The manufacturer shall offer the Inspector representing the
Purchaser all reasonable facilities, without charges, to satisfy him that the material is being supplied in accordance
with this specification. This will include Stage Inspection during manufacturing stage as well as Active Part
Inspection during Acceptance Tests. 38
 30.6 The manufacturer shall provide all services to establish and maintain quality of workman ship in his works and that
of his sub-contractors to ensure the mechanical /electrical performance of components, compliance with drawings,
identification and acceptability of all materials, parts and equipment as per latest quality standards of ISO 9000.

30.7 Purchaser shall have every right to appoint a third party inspection to carryout the inspection process.
30.8 The purchaser has the right to have the test carried out at his own cost by an independent agency wherever there is
a dispute regarding the quality supplied. Purchaser has right to test 1% of the supply selected either from the stores
or field to check the quality of the product. In case of any deviation purchaser have every right to reject the entire lot or penalize
the manufacturer, which may lead to blacklisting, among other things.
30.9 INSPECTION OF TESTING INSTRUMENTS: All the measuring instruments e.g. watt meter, voltmeter,
ammeter, CT & PT and other instruments should be properly calibrated ands sealed once in every year. Calibration
certificate, when demanded by the inspecting officer, shall be produced for verification purpose. In case of any
dispute regarding calibration of instruments, instruments will be sealed and signed by the representative of the
“manufacturer” and the “Purchaser” and will be sent to an institution / lab or repute or its own lab for calibration
at the cost of the supplier.
30.10 After successful inspection, the inspecting officer shall seal all the inspected transformers by numbered seals on
diagonally opposite sealing bolts of top cover for identification. Before sealing, the inspecting officer will ensure that
all the offered transformers are complete and duly fitted with rating & terminal marking plate (on side wall) and
guarantee & identification plate (on the tank ) of transformers as specified in this specification. Any further sealing
requirement as deemed fit by inspecting officer to ensure pilfer proof sealing arrangement shall also be made.
30.11 This inspection may be carried out by UPCL or third party.

31. QUALITY ASSURANCE PLAN:

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

31.2 Statement giving list of important raw materials, names of sub-suppliers for the raw materials, list of standards
according to which the raw materials are tested, list of tests normally carried out on raw materials in the presence of
bidder’s representative, copies of test certificates.
31.3 Information and copies of test certificates as above in respect of bought out accessories.

31.4 List of manufacturing facilities available.

31.5 Level of automation achieved and list of areas where manual processing exists.
31.6 List of areas in manufacturing process, where stage inspections are normally carried out for quality control and details of
such tests and inspection.
31.7 List of testing equipment available with the bidder for final testing of equipment along with valid calibration
reports. These shall be furnished with the bid. Manufacturer shall posses 0.1 accuracy class instruments for
measurement of losses.
31.8 Quality Assurance Plan (QAP) with hold points for purchaser’s inspection.
31.9 The successful bidder shall within 30 days of placement of order, submit following information to the purchaser :
31.9.1 List of raw materials as well as bought out accessories and the names of sub-suppliers selected from those
furnished along with offer.
31.9.2 Type test certificates of the raw materials and bought out accessories.
31.9.3 The successful bidder shall submit the routine test certificates of bought out accessories and central excise passes
for raw material at the time of routine testing.
32. DOCUMENTATION:
32.1 The bidder shall furnish along with the bid the dimensional drawings of the items offered indicating all the fittings.
32.2 Dimensional tolerances.
32.3 Weight of individual components and total weight.
32.4 An outline drawing front (both primary and secondary sides) and end elevation and plan of the tank and terminal
gear, wherein the principal dimensions shall be given.
32.5 Typical general arrangement drawings of the windings with the details of the insulation at each point and core
construction of transformer.
32.6 Typical general arrangement drawing showing both primary and secondary sides and end-elevation and plan of the 39
transformer.
 33. PACKING AND FORWARDING:
33.1 The packing shall be done as per the manufacturer’s standard practice. However, it should be ensured that the
packing is such that, the material would not get damaged during transit by Rail / Road / Sea.
33.2 The marking on each package shall be as per the relevant IS.

34. MANADATORY SPARES:

Mandatory spares shall be supplied as per the purchaser’s requirement.
35. GUARANTEE
35.1 The manufacturers of the transformer shall provide a guarantee of FIVE years from the date of
commissioning.

36. RATING AND TERMINAL MARKING PLATES:

Each transformer shall be provided with a non-detachable rating and terminal marking plate(s) of weather
proof material, fitted in visible position, mentioning complete information as given in clause 15.1 and 15.2
of latest version of IS: 2026(part-I). Name of firm, Serial number of transformers, capacity, total losses at
50% & 100% loading, PO No., terminal marking diagram and guarantee period must also be engraved on the
diagram plate. The entries on the rating & terminal marking plate shall be invariably marked (by etching,
engraving or stamping). Plate should be firmly riveted with tank so that it may not be detached afterwards.
37. Guarantee & Identification plate: Manufacturer shall also provide a separate plate of size (20.0cm. x 10.0cm. x
0.3cm) continuously welded on the transformer tank. The plate should contain the following details punched on the
plate:

UNIQUE NO.
PROPERTY OF UPCL
DATE OF FINAL INSPECTION OFFER
GUARANTEE PERIOD: 2 YEARS
GAURANTEED UP TO (MONTH/YEAR)
Above plate should be welded on the tank of each transformer and guarantee period should be clearly
visible on it. Inspecting agency deputed by UPCL shall ensure the compliance of same at the time of
inspection.

Unique ID on Transformer: Each Transformer shall be clearly marked / engraved with the 18 digit unique ID code on
name plate and Top Cover / Top Channel of the transformer as follows:
3 digit 10 digit PO code 5 digit running Serial No.
Company code
0 0 0 0 1 to
0 0 4 0 0

40
Technical Specification of ELECTRO-ATMOSPHERIC FIELD PROTECTOR:
SCOPE: The Electro-Atmospheric field protector is designed to protect using counter
measures that control and compensate the electroatmospheric effects
produced by climate change, industrial, meteorological or solar
electromagnetic pollution, manifested in the form of electrical storms,
electromagnetic pulses, etc. The lightning Protector is permanently
protecting its coverage area to correct the effects of electromagnetic
disturbances according to their origin, frequency, voltage and intensity.
Compensating, stabilizing the current of the electric charges in its
environment, draining them to earth in harmless milliamperes, minimizing
the formation of the lightning in its protection area upto 120 meter.
All the equipment under the project shall be suitable for satisfactory and
continuous operation at an altitude upto 4000 m (above MSL) and ambient
temperature upto (-) 400C

S No. Parameters MODEL offered Electro-Atmospheric field protector

It is a passive sensor system designed to balance and deionize at all times the
1 Working Principle
effects of atmospheric phenomena through multiple compensators,
generating a protective shield in its coverage area, its operating principle is
based on compensating, stabilizing the existing electric field in its
environment, in this way it cancels the formation of the ascending tracer
neutralizing the lightning draining the electric charges to earth, in harmless
milliamperes.
Meet Nikola Tesla Institute HV Lab Belgrade case study 322053.
2 Function The technology should not allow a lightning strike to occur within a protected
area and provide 24/7 protection.

3 Overvoltage It does not generate overvoltage.

4 Protected area upto 120m (depending upon model 25m,55m,120m) x multiple devices can
be installed to cover a bigger area.
5 Electromagnetic field It complies with Decree 10071/07 of the Secretary of the Environment
protection SEAM Paraguay on the protection of electromagnetic fields
6 Electromagnetic Does not generate Electromagnetic Compatibility effects.
Compatibility
7 For protection levels I, II, Defined according to IEC 62305, the rolling sphere method must be used
III and IV
Electric and magnetic 0 to 300 Gz
8 fields in the
frequency range
International Electric field: 10 kV / m (occupational exposure), 100 μT (public exposure)
9 Commission on Non- Magnetic field: 500 μT (occupational exposure), 5 kV / m (public exposure)
ionizing Radiation
Protection (ICNIRP)
10 Radioactive It is not radioactive and is manufactured according to the RoHS regulations.
11 Coverage Area upto 120m (depending upon model 25m,55m,120m)
 ISO 9001-2015 Certificate by DNV-GL, INTN Product
12 Certificate Certificate (National Institute of Technology and
Standardization and Metrology)
 Qualified to CE, UKCA, NATO, ISO, IEC test Standards
 Maximum working voltage without lightning discharge 840KV. at
one meter, according to high voltage laboratory tests ITE
o (UNE 21186:2011// NF C17-102:2011).
41
 MOUNTING  Mechanical Properties: Trinorm quality tubes: ASTM A53/A53M,
13 PROVISION  ASTM A106/A106M and API 5L PSL 1, Grade B
STANDARDS:  Dimensional Tolerance: ASTM A 53 /A 53M.
 The post will consist of four bodies, with assembly by flanges as
detailed in the plans, anticorrosive epoxy resin will be applied to the
entire body of the post, joint and assembly accessories, such as
flanges, joints, anchor bolts.
 The entire joint assembly, assembly flanges, anchor bolts and
assembly must withstand winds of 90Km/h

1. Supply, erection of 50 sq mm cross section down conductor of bare

copper cable as per the length requirement.
2. Supply, erection, testing and commissioning of supporting guyed
14 mast structure, to support the Multiple Electric Field Compensator
Installation
at 03 metres height above the structure/building area to be protected
or as per required level of protection. The structure should be made
of medium class GI pipe of 4" dia with base plate, guying kit and
mounting accessories complete. It should be of support tower type
structure 3 to 5 meters in length, suitable to withstand pressure &
velocity of the wind pressure during lightning, storm and rains. The
guyed mast should be suitable for fixing / holding the above Multiple
Electric Field Compensator. The rate also includes any other
accessories, excavation or RCC work necessary to install the guyed
mast.
3. Grounding /Earthing system, resistance r<=5 ohm.
4. One technician required for support assistance.

42