DMRC Electrical Standards & Design Wing DMES-

0002/TRANSF-02

SPECIFICATIONS FOR TRACTION TRANSFORMER Draft-4.

30/10/2017

DELHI METRO RAIL CORPORATION LIMITED

DMRC ELECTRICAL STANDARDS & DESIGN WING (DESDW)

SPECIFICATION NO.
DMES-T/0002/DMRC-E-PS-TRANSF-02

SPECIFICATIONS FOR

TRACTION TRANSFORMER

Issued on:

Date Stage
17th May 2017 Draft-1.
31st august 2017 Draft-2.
20th sept 2017 Draft-3.
30th Oct 2017 Draft-4.

DELHI METRO RAIL CORPORATION LTD.

7th Floor, B-Wing, Metro Bhawan, Fire Brigade Lane,
Barakhamba Road, New Delhi –110 001

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Previous Record of specification

Stage Date
Draft -1. 17-May-17
Draft -2 31-Aug-17
Draft -3 20-Sep-17
Draft -4 30-Oct-17

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Contents
Traction Transformer.................................................................................................................................... 4
1.1 Standards ...........................................................................................................................4
1.2 Abbreviations .....................................................................................................................5
2.1 Characteristics:- ..................................................................................................................5
2.2 Rated power .......................................................................................................................5
2.3 Service condition ................................................................................................................6
2.4 Overload capacity ...............................................................................................................6
2.5 Rated voltages ....................................................................................................................6
2.6 On-load tap changer ............................................................................................................7
2.7 Cooling system ...................................................................................................................8
2.8 Short-circuit withstand capability ..........................................................................................8
2.9 Iron core ............................................................................................................................9
2.10 Transformer losses ..............................................................................................................9
2.11 Windings .........................................................................................................................10
2.12 Terminals and connections .................................................................................................10
2.13 Tank and radiators ............................................................................................................11
2.14 Oil expansion vessel ..........................................................................................................12
2.15 Control and protection .......................................................................................................12
2.16 Control and monitoring cabinets .........................................................................................13
2.17 Metal work and Paint-work ................................................................................................14
2.18 Particular dispositions, Installation ......................................................................................15
3.1 Fire Protection & Suppression system:- ...............................................................................16
3.2 Fiber Optic Winding Hot Spot Temperature Monitor:- ..........................................................19
3.3 Ester oil filled transformers: ...............................................................................................21
TEST SHEET and GTP SHEETS ..............................................................................................21
5.1 Type tests: .......................................................................................................................21
5.2 Routine tests.....................................................................................................................22
5.3 BOM of sample ................................................................................................................24

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TRACTION TRANSFORMER
SCOPE

These specifications are applicable to Traction Transformer of 2-phase 220 kV / 132 kV / 110 kV /
66 kV (for line 2A) primary voltage and 1-phase, 27.5KV secondary voltage. Traction Transformer
shall be designed for outdoor installation and for operation at frequencies of 50 Hz.
The Traction Transformer shall be complete with all Parts, Fittings, and oil for the first filling, and
accessories necessary for its efficient operation, including mounting frame work of steel. All such
Parts, Fittings and Accessories shall be deemed to be within the scope of this Specification, whether
specifically mentioned or not. The Traction Transformer shall be of proven design.
1. Governing Specifications
The Traction Transformers shall comply with the standards of the International Electro
Technical Commission (IEC60076) or equivalent Indian standards

1.1 Standards
The Traction Transformer shall satisfy the requirements given below and shall also comply
with standards in force when they are manufactured, particularly which are in the following
table. (unless otherwise stipulated in the specifications, the latest version of the following
standards shall be applicable): -
S. No. Specification No. Title of Specification
1. IEC:60076-1,2,3,4,5 &7 Power Transformer
2. IEC : 60214 Tap changer for power transformer
3 IEC 60296 Insulating oil for Transformer
IS 12463:1988 along with
Insulating oil for Transformer (revise for Ester
3A additional requirements of
Oil)
RDSO
3B IEC 61099 Synthetic Ester Oil (SEO) for power transformers
3C IS16081 Synthetic Ester Oil (SEO) for power transformers
4 IS335 Insulating oil for Transformer
5 IEC 60028 Conductor for Insulated cable
6 IEC 60137 Insulating Bushing for rated Voltage above 1KV
7 IEC 617-2 Earthing terminal

IEC 60 721-2-5 Specification for painting:- Environmental

8
condition
9 ISO12944-5 Protective Paint system

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1.2 Abbreviations
 TT- Traction Transformer
 IEC- International Electro-technical Commission
 IS- Indian Standard
 OLTC- On Load Tab Changer
 ONAN- Oil Natural Air Natural
 ONAF- Oil Natural Air Force
 NIFPS –Nitrogen Injection Fire Protection System

2. Technical Requirement
2.1 Characteristics:-
The Traction Transformers at TSS shall meet the following characteristics:
- 2-phase Primary winding of 220kV/132kV/110kV/66kV (for line 2A)
- 1-phase secondary winding 0f 27.5KV
- Entirely submerged in mineral oil tank
- Outdoor type, suitable for tropical conditions, satisfying the climatic conditions of
Mumbai.
- On load tap changer on primary windings
- Possibility of various overload conditions
- Separated oil conservator with aircell.
- Cooling by natural oil circulation and banks of radiators mounted on the tank
- Both transformers shall be identical
- Transformer noise level should not exceed 75dB measured at a distance of 1.5 m
- The Vector group shall be I. i.
- Should have symphonic filter.
- The two transformers at any Traction Substation are not meant to work in parallel

2.2 Rated power

The 220kV or 132kV or 110 or 66kV/27.5kV(for line 2A) transformers shall be
manufactured and guaranteed so as to perform satisfactorily with a power rating, measured
across the secondary winding, of the following value under load with cooling system in
operation (ONAN/ONAF mode).

Cooling System Rating (MVA)

ONAN/ONAF As specified in the Particular Specification

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2.3 Service condition

The normal service conditions for the transformer are as follows:

The normal service conditions for the transformer are as follows:

 Altitude: A height above sea-level not exceeding 1 000 m (3 300 ft).
 Temperature of ambient air and cooling medium
A temperature of ambient air not below –5 °C and not above +55 °C.
 Wave shape of supply voltage
A supply voltage of which the wave shape is approximately sinusoidal. The
deformation shall neither exceed 5 % total harmonic content nor 1 % even harmonic
content.
 Installation environment very heavy as per
An environment with a pollution severity level as very heavy as per IEC 60815.

2.4 Overload capacity

After constant operation at continuous full load, the transformer shall have a guaranteed
minimum overload capacity of:
- 50% for a duration of 15 minutes,
- 100% for a duration of 5 minutes
After overload the temperature rise shall not be more than:
65°C above ambient temperature for oil.
75°C above ambient temperature for windings

2.5 Rated voltages

The primary winding voltage shall be 220kV or 132kV or 110kV or 66kV as applicable at a
power frequency of 50 Hz, on the main tapping.
Operating voltage may increase to + 10% or drop to -15% for the traction transformers. The
primary winding shall be fitted with on-load tap changer offering 16 steps ensuring the
primary voltage compensation from -15% to +10% of primary voltage. The secondary
winding voltage shall be 27.5 kV at a power frequency of 50 Hz, one end being connected
to the rails and the earth.
S.
Description 220 kV 132 kV 110 kV 66 kV
No.
Primary winding rated insulation
1 245 kV 145 kV rms 123 kV 72.5 kV
voltage
Impulse withstand voltage for
2 950 kVP 650 kVP 550 kVP 325 kVP
primary
3 Power frequency withstand 395 kV rms 275 kV rms 230 kVrms 140 kV rms

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voltage for primary

Secondary winding rated
7 52 kV 52 kV 52 kV 52 kV
insulation voltage
Impulse withstand voltage for
8 250 kV 250 kV 250 kV 250 kV
Secondary winding
Power frequency withstand
9 95 kV 95 kV 95 kV 95 kV
voltage for secondary winding
10 Maximum flux density 1.55 Tesla 1.55 Tesla 1.55 Tesla 1.55 Tesla

2.6 On-load tap changer

Voltage shall be substantially constant at the untapped windings (secondary windings) and
variable at the tapped winding (primary winding).The category of regulation applied shall
be constant-flux variable voltage type (CFVV)
The on-load tap changer shall be single-phase enclosure type, installed in a separate oil tank,
offering 16 steps (+6step, normal and -9step), each representing 1.667% of the nominal
voltage.
The tap changer shall have the following characteristics:
- 50 000 operations without any attention
- Motor and hand-driven possibility
- Tap position indicators
- Commutation current compatible with the short duration transformer over-current.
- Diverter switches shall be designed for high speed operation and shall be interlocked
to ensure that there is no possibility of an operation stopping in mid-position. Arcing
contacts shall be of tungsten alloy material.
- Devices for ease of extraction for maintenance purpose
- Manual/Automatic, Local/Remote, Control & Monitor of OLTC from RSS control
room and OCC.
The oil volume of the on-load tap changer unit must be separated from the tank for core and
winding oil.
The power circuit of the on-load tap changers shall be connected to the primary windings
and shall enable the required voltage variations as mentioned in the annexed technical sheet.
The full technical description shall be given as regards power and auxiliary circuits;
periodicity for checking and over hauling the power circuit shall be indicated in the
transformer maintenance Manual. The servomechanism settings shall be designed and
executed to avoid too many actuations
The manufacturer shall provide mechanical and electrical diagrams. A suitable protection
relay shall be connected on the oil pipe between the on-load tap changer and the expansion
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vessel. The voltage ratio shall be checked according to the guaranteed figures and the
tolerances stipulated in the standards.

2.7 Cooling system

The Traction Transformer shall be designed to operate in ONAN/ONAF mode (mineral oil
natural / air natural/air forced). The oil along with inhibitor to be used for the transformer
must be in conformity with the IEC 296 standard, or IS 335 (with latest amendments) and of
the highest inflammability degree.

Spare oil for at least 10% of each transformer shall be provided.

The maximum temperature allowable at nominal rating shall never exceed:
- 50°C above ambient temperature for mineral oil
- 55°C above ambient temperature for the copper winding and the iron core.
Dielectric strength of the oil during test should be more than 55 kV /2.5 mm; the contractor
shall mention the method and the referenced standard employed.
The transformer shall be rejected in case the temperature rise exceeds the guaranteed values
by more than five degrees centigrade’s.
The contractor shall give full description of the design, operation and maintenance of the
proposed air cooling system for ONAN/ONAF and indicate the air flows needed for
ventilating the cubicle and the air cooling units.
In case of fire detection into the transformer cubicle, the air cooling system shall be
immediately and automatically switched off

2.8 Short-circuit withstand capability

Short-circuit on H.V. side
The transformer shall be designed and constructed so as to withstand without damage, or
impairment in its performances, any external short-circuit.
The primary winding of the transformer shall be designed for carrying the full symmetrical
short circuit current, for 3 sec. The full symmetrical short circuit current shall be calculated
in accordance with IEC after taking into account the system impedance on the primary
voltage of the transformer.
The design of the primary side bushings of the Transformers shall withstand the
symmetrical current for three seconds during short-circuit on primary voltage (40 kA/1 s for
220 kV, 31.5 kA/1s for 132 kV, 110 kV and 66 kV) as specified in IEC 60076-5.
To limit the short-circuit symmetrical current to an allowable value; the impedance voltage
shall never be less than twelve percent (12%). At rated power and frequency on the main
tapping, the impedance voltage shall be equal to about twelve point five percent (12.5%).

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Short-circuit on L.V. side

The maximum short circuit current at the output of feeder station has to be limited at 16 kA
to comply with the rolling stock on board circuit breakers breaking capacity, (compared to
distribution network) only limited by the internal transformer leakage impedance.
Consequently transformers must be designed taking into account this current short circuit
limit, as well as electrodynamics and thermal constraints.
The contractor shall specify a guaranteed value and tolerances according to the standards
and requirements

2.9 Iron core

The magnetic core, frame assembly, clamping and general structure of the transformer shall
be mechanically sturdy so as to be capable of withstanding shocks which may happen
during transport or during short-circuits and over-voltages.
Cores and magnetic circuit shall consist of cold-rolled grain-oriented silicon steel sheets of
the best quality, offering every guarantee of durability, heat and oil resistance
The core tightening bolts shall be suitably insulated and the grounding of the magnetic
circuit shall employ generously sized copper connections and links.
The keying and compression of the laminations, together with the induction value, shall be
designed so as to keep vibrations to a minimum and to reduce, in particular, the third and
fifth harmonics influences.Calculation sheets to establish maximum flux density (i.e. 1.55
Tesla) shall also be submitted with Design to employer. The contractor shall submit
complete technical data of the system to the employer

2.10 Transformer losses

The transformers shall be designed for minimum losses.
When comparing between different tenders the present value of the capitalized cost of losses
in the transformers shall be added to their financial bid by the following formula
PW = K*365*24* C (Wir + b² Wcu)/1000
Where
- PW is the present worth (in IR) of annual capitalized cost of losses at 10% rate of
interest over 25 years
- K is the present worth factor (10% interest, 25 years) = {(1+0.1)25 – 1}/{0.1*(1+0.1)25}
= 9.077
- C is the cost of the kWh (in Indian Rupees) = Rs.8
- Wir is the iron losses in Watts at normal voltage and main tapping
- Wcu is the full load copper losses in Watts at normal voltage and main tapping at 95°C
- b is the load factor of transformer = 50 %

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ThusThus PW = 9.077*365*24* 8 (Wir + b² Wcu)/1000

PW = 636.12 (Wir + 0.25 Wcu)

In case the transformer losses during tests are found greater than the values guaranteed in
the offer, a consolidated penalty shall be paid by the contractor, according to the following
formula (for the tolerance permissible according to IEC standard):

636.12 (d Wir + 0.25 d Wcu )

Where:
- d Wir and d Wcu are the differences between the test values of iron losses at full voltage
and copper loses at full load on one transformer at main tapping and the values
guaranteed in the offer.

2.11 Windings
The winding conductors shall be made of best quality high conductivity electrolytic copper,
in compliance with the standard (IEC 60028) requirements.
Both windings, primary and secondary, shall be designed to withstand over-voltages and
over-currents in case of direct short-circuit across the medium voltage terminals with the
primary winding line for three seconds.
Construction shall take into account electrodynamics and thermal constraints specific to
railway traction duty.
The adjustments windings shall be designed specifically to withstand direct short-circuit of
all part of the adjustment turns that may occur at the contact plates of the on-load tap
changer. The windings, connections and terminal links shall be properly brazed so as to
withstand the shocks and vibrations that may occur during transport or short-circuit.
Tests on samples shall be carried out and results submitted for approval before starting
assembly of the transformer windings. Current density for each winding shall be not more
than 2.5 A/mm². The insulation material used for the transformer windings and connections
shall be at least of class A.

2.12 Terminals and connections

The primary and secondary connections shall be realized through porcelain/polymeric
bushings insulators as applicable. The porcelain shall be brown glazed. It shall be unaffected
by atmospheric conditions like fumes, ozone acids, alkaline, dust, sand storms or rapid
change in temperature between 0°C and 75°C under working conditions and the prevailing
environmental conditions.
In order to avoid damages to tank in case of disruptive discharge, bushing base should be
connected to the earth.Creepage distance for one bushing should be 3.1 cm/kV. Bushings
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shall be realized in conformity with the IEC 60137 standard. Special care shall be taken
against transmission of vibrations by employing a damping system and suitable fittings.
The design shall take into account the ease of overhaul. It should be possible to withdraw
and to remove the transformer at ease. Interchangeability between transformers shall be
achieved through the use of identical elements.
The link between secondary terminals of the transformer and the 25 kV switchgear shall be
made by cables connected directly at the outside of the secondary bushing. Bushings shall
be realized in conformity with the IEC 60137 standard.
NOTE: -Employer may go for primary and secondary connections through Dry plug
type termination on the transformer as applicable. The vendor may quote the price
separately in the addition/deletion items given in the BOQ for the change in the
transformer tank design suitable for this type arrangement and cost of dry plug type
termination inplace of porcelain bushing.

2.13 Tank and radiators

The transformer tank shall be made of high quality boiler plate steel with stiffening frame
and girders. The thickness of sections shall be suitably sized so that it is possible to
dismantle by grinding and re-do welding at least three times, before it becomes necessary to
condemn the sections and refabricate.
The thickness of the tank should not be less than 10 mm, with reinforcement in order to
withstand full vacuum, and mineral oil pressure. Tank shall only be connected to the earth
through current transformer. In case of separated radiators, they shall be earthed separately
and consequently pipes network shall be mounted with insulating joints.
The tank itself, the pipe work, valves, joints and gaskets shall be airtight, watertight and oil-
tight. The junction shall be capable of withstanding the temperature of a fire without causing
any leak as per IEC 60076 standards. The tank shall be fitted with hooking points to enable
it being lifted in balance by means of an overhead travelling crane, either as the main
package or in form of the complete unit, fully equipped and filled with mineral oil. The
frame shall enable the transformer being laid normally on a slab or foundation block,
without rollers. Each dismountable tank and radiators element shall be equipped with the
following auxiliary devices:
- flanged oil drainage valves,
- oil sampling cocks at top and bottom of the tank with suitable oil flanges,
- flanged valves suitable to connect the oil filtering unit,
- hooking points
and overall shall be equipped with:
- special pockets for checking by thermometers,
- earthing terminals according to IEC 617-2 standard

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- Frame to ease the transportation

- swivelling removable rollers with locking devices.
- overpressure relief device provided with electrical contacts
- manholes on the tank cover so as to obtain access to the core winding assembly, tap
changer mechanism, terminal, the lower ends of all bushings etc. for purpose of repair
without lifting the core winding assembly
Each transformer shall be equipped with the suitable lockable ladder to reach top of tank for
inspection & Maintenance.
Name plate to be provided with all technical particulars

2.14 Oil expansion vessel

The transformer shall be equipped with an oil expansion vessel placed above the transformer
on a specific support.
It shall be partitioned so as to avoid mixing between the on-load tap changer oil and the core
and winding oil.
Each partition shall:
- be connected to the transformer through all the necessary pipe-works, fitted with
flexible metal joints and gaskets; the connecting pipe shall over-extend vertically
inside the vessel (at least 8 cm)
- be provided with, easy to reach, drainage valves, oil sampling devices and relief valve.
- be equipped with a dehydrating breathermade of transparent glass materialshall
containSilica gel or equivalent fitting and checking glass shall be accessible easily to
change the dehydrating product during operation of the transformer.
- be provided with an oil level indicator having auxiliary contacts and easily observable
from ground level.
The oil volume should be above the minimum level, when the ambient temperature is 0°C or
below. Similarly the oil volume should be below the maximum level when the ambient
temperature is 55°C or above.

2.15 Control and protection

The transformer shall be delivered with "buchholz", thermal and earth fault protections, all
connected to the control and monitoring cabinet
"Buchholz"
The term "buchholz" protection denotes the gas-sampling device and relay for gas fault
detection and storage for analysis
The relay shall comprise of two thresholds as follow:

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- alarm in case of minor fault such as local overheating of windings or core (small gas
discharge),
- tripping-out in case of major fault (violent gas discharge) and excessive oil leakage.
Both transformer and load-tap changer oil circuits shall be equipped with "buchholz"
protection.They shall be connected to the oil pipe between the tank and the expansion
vessel, without any flat part and any less than 50mm bend.
It shall be free for access and maintenance; a by-pass system shall be provided to enable oil
flow without interrupting operation during maintenance checks.In order to ease gases
chemical analysis, the gas-sampling device shall be accessible during transformer operation,
at man’s working level.
Thermostat
The thermostat itself shall be installed in the monitoring box, while the indicator on it facade
and the thermal probe shall be installed into the tank with appropriate pocket.

Earth fault
The insulated tank shall only be connected to the earth through a resin cast core/ring type
current transformer as per GTP, which shall be linked to the control system via monitoring
cabinet terminal block.

2.16 Control and monitoring cabinets

Made of stainless steel-sheets, grade-304 totally enclosed dust-proof and watertight type
(IP55) suitable for outdoor applications it shall be equipped with:
a) For transformer
- Access doors with padlocks
- 415 /230 V protection and power circuits.
- 110 V dc control and monitoring relays
- Internal lighting monitored by the door position.
- Heating thermostat with indicators and contacts
- Information terminal block
- Remote control and monitoring multi-pin connector
b) For On-load tap changer
- Access doors with padlocks
- 415 /230 V protection and power circuits.

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- 110 V DC or 415 V AC (3 ph) or 220 V AC (1ph) motor, control and monitoring

relays
- Internal lighting monitored by the door position.
- On-load tap changer operating equipment and control
- Counter
- Information terminal block
- Remote control and monitoring multi-pin connector
OLTC tap position should operate based on voltage level of primary side voltage of
Transformer. This provision shall be provided with PLC based logic and PLC should be
installed in the RTCC indoor Panel and should have adjustable time & voltage settings for
OLTC tap operation feature. Operation of OLTC shall be possible from OCC.
Control of Auto / Manual and Local/Remote selector switch shall also be possiblefrom OCC
/Local SCADA.
All control and monitoring cabinets used in indoor shall conform to the following minimum
specifications

Material Steel
3 mm for front cover & base frame
Minimum thickness of Steel sheets 2 mm for rear door
1.6 mm for roof plate, bottom plate & side covers
Powder Coating :
Exterior RAL 7032, Texture finish
Interior RAL 7032, Texture finish
Base frame Black
Thickness Min. 80 microns of Power coating

The Contractor shall submit to the Employer, the complete details of the Control &
Monitoring Cabinets, including details of the structure, process of finish and painting,
wiring, terminal blocks, cubicle illumination heating etc, for Employer’s approval.
The details adopted for Control and Relay panels, Bay Control and Protection units,
Transformer and On-load tap changer cubicles and all other Control and Monitoring
Cabinets, located inside the RSS Control Room shall be identical to project an aesthetically
good appearance

2.17 Metal work and Paint-work

Painting should be suitable for salty seaside atmosphere and has to comply with IEC 60
721-2-5 standard. The entire surface (Internal as well as External) to be painted shall be
prepared by Shot blasting to cleanliness level, SA21/2 as per ISO 8501/SIS 055900. Ensure
that the cleaned surface is free of oil or grease, scales rust and other residue. Surface profile
of the blasted surface should be approximately 40-60 microns.
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All the external surface of the transformer shall be given first coat of Epoxy zinc rich
(having minimum 83% metallic zinc) primer (Min.50 microns thickness), first intermediate
coat of epoxy zinc phosphate paint (Min.60 microns thickness), intermediate coat of Epoxy
high build MIO (Min.80 microns thickness), and final coat of glossy Aliphatic Acrylic
polyurethane (Min.50 microns thickness). The total dry film thickness (DFT) of the paints
shall be minimum 240 microns and should withstand 120°C. The shade of paint shall be
gray shade 631 as per IS: 5.
All steel surfaces which are in contact with insulating oil shall be painted with heat resistant
oil- insoluble insulating varnish.
After baring, all metal surfaces shall receive anti-corrosion process:
- natural stainless for Bolts & screws
- hot dip galvanization for radiators
- rust-proofing and anti-corrosion paint for tank, oil expansion vessel and other metal
surfaces.
The transformer and its accessories shall be completely painted in plant. The necessary
touch-ups shall be executed on-site after erection.This protection shall be fully guaranteed
for five years starting from provisional taking over. Should any noticeable deterioration by
rust or corrosion appear before this time elapses, the contractor shall be responsible for
repainting at his own expense and for renewing his guarantee for the work performed.
The painting and preserving of panels for transformer protection should be similar match
with that of other control and relay panels provided in the control room.

2.18 Particular dispositions, Installation

Transport
For transport either by road, ship or rail, the transformer shall be filled with oil up to
windings top and then with Nitrogen at recommended pressure up to the tank top or
alternatively the transformer may be filled with Nitrogen, in full, during transportation.
The bushing, breather, wheels and all other external parts shall be removed on condition that
they can be mounted at site.
Installation
The Transformers are to be installed in Substation on two running rails, and consequently
must be delivered with a set of swiveling rollers. These rollers shall be mounted, electrically
insulated from tank and with locking devices.
Material layout and volume shall be such that it shall be possible to remove parts without
dismounting other parts. The contractor shall indicate the method
3. Additional Requirement

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3.1 Fire Protection & Suppression system:-

In terms of CEA (safety regulations), 2010 “transformers of 10 MVA and above rating or
in case of oil filled transformers with oil-capacity of more than 2000 litters are provided
with fire fighting system as per IS - 3034: 1993 or with Nitrogen Injection Fire Protection
system”;
In view of above, transformer shall be provided with “Nitrogen Injection Fire Protection
System”. The specifications of “Nitrogen Fire Protection System” are detailed as below:-
Nitrogen injection fire protection system designed for oil filled transformers shall prevent
tank explosion and the fire during internal faults resulting in an arc, where tank explosion
will normally take few seconds after arc generation and also extinguish the external oil fires
on transformer top cover due to tank explosion and/or external failures like, bushing fires,
OLTC fires and fire from surrounding equipments.
The system shall work on the principle of DRAIN AND STIR and on activation: it shall
drain a pre- determined quantity of oil from the tank top through outlet valve to reduce the
tank pressure and inject nitrogen gas at high pressure from the lower side of the tank
through inlet valves to create stirring action and reduce the temperature of top oil surface
below flash point to extinguish the fire.Conservator tank oil shall be isolated during bushing
bursting, tank explosion and oil fire to prevent aggravation of fire. Transformer isolation
shall be an essential pre-condition for activating the system. The system shall be designed to
operate automatically. However it shall be designed for manual operation, in case of failure
of power supply.
The system shall consist of following equipments:
1. Fire extinguishing cubicle placed on a plinth at about 5-10 meter away from the
transformer.
2. Control box placed in the control room.
3. Pre- stressed non return valve in the conservator pipe.
4. Required number of fire detectors on the tank top cover.
5. Signal box fitted on the tank top or tank side wall

SCOPE
Notwithstanding the technical specifications and requirements mentioned herewith any
modification can be incorporated for correct operation of nitrogen injection fire protection
system without extra cost. The full details of the same are required to be submitted to
DMRC for approval.

OPERATIONAL CONTROLS
The system shall be provided with automatic control for fire prevention and fire extinction.
Besides automatic control remote electrical push button control on control box and local
manual control in the fire extinguishing cubicle shall be provided. Spare interlocks are to be
provided for ensuring that it should not be possible to close HV or LV circuit breakers to
energize the transformer after the activation of the fire prevention and, fire extinction

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system.

SYSTEM ACTIVATING SIGNALS

Transformer isolation shall be an essential pre-condition for activating the system.
Transformer isolation through Master trip relay or circuit breaker (HV and LV side in series)
has to be incorporated. Besides, two electrical signals to be provided in series, for activating
the system as under:

For Prevention:
- Differential relay,
- Buchholz relay paralleled with pressure relief valve

For Extinction:
- Fire detector.
- Buchholz relay paralleled with pressure relief valve

SYSTEM EQUIPMENTS

A. Fire Extinguishing Cubicles (FEC), placed on plinth at about minimum 5 meter away
from the transformer shall consist of:

1 Nitrogen Gas cylinder with regulator and failing pressure electrical contact
manometer.
2 Oil drain pipe with mechanical quick drain valve.
3 Electro mechanical control equipments for oil drain and pre determined regulated
nitrogen release.
4 Pressure monitoring switch for backup protection for nitrogen release.
5 Limit switches for monitoring of the system.
6 Flanges on top panel for connecting oil drain and nitrogen injection pipes for
transformer.
7 Panel lighting
8 Oil drain pipe extension of suitable sizes for connecting pipes to oil pit.
B. Control box with activating, monitoring devices and line faults indicators. (To be placed
in control room). It should have audio visual alarm indication and push button switches.
C. Pre-stressed non return valve (PNRV) to be fitted in the conservator pipe line, between
conservator and buccholz relay operating mechanically on transformer oil flow rate with
electrical signals for monitoring.
D. Fire detectors to be fixed on transformer tank up cover and On Load tap Changer for
sensing fire.
E. Signal box to be fixed on transformer side wall for terminating cable connections from
fire detectors and PNRV
F. All other consumables necessary for complete system.

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OTHER REQUIREMENTS FOR SYSTEM INSTALLATIONS

A. Oil drain and Nitrogen openings with gate valves on transformer tank at suitable
locations.
B. Flanges with dummy pipes in conservator pipe between Buccholz relay and conservator
tank for fixing PNRV.
C. Fire detector brackets on transformer top cover.
D. Spare potential free contacts for system activating signals i.e. differential relay, buccholz
relay, pressure relief valve, transformer isolation (master trip relay).
E. Status of Fire Protection System Operated, NIFPS out of service, PNRV/TCIV valve
close, Fire detector initiation alarm/trip, Nitrogen cylinder pressure low, Visual/Audio
Alarm for NIFPS system and Visual/Audio Alarm of NIFPS for DC supply fail shall be
available on the Local/OCC SCADA.
F. Pipe connections between transformer to fire extinguishing cubicles and fire
extinguishing cubicle to oil pit.
G. Cabling on transformer top cover all fire detector to be connected in parallel and inter
cabling between signal box to control box and control box to fire extinguishing cubicle.
H. Plinth for fire extinguishing cubicle. Oil pit with suitable capacity.

TECHNICAL DETAILS
Fire extinction period
 On commencement of Nitrogen injection : Maximum 30 seconds
 On system activation up-to post cooling : Maximum 3 minutes
 Fire detectors heat sensing temperature : 141 degcelcius
 Heat sensing areas : 800 mm radius
 Pre-stressed non-return valve setting for operation : Minimum 60 ltr per minute
 Power Source :
 Control Box :110 V DC
 Fire fighting cubicles for lighting : 240 V AC

CABLING:
Fire survival cables, able to withstand 750 degcelcius, of appropriate size & core for
connection of fire detector in parallel shall be used. The test certificates for the cables
shall be submitted.
Fire retardant low smoke AC/DC cable as applicable (FRLS) cable of appropriate Sizes &
core for connection between transformer signal box/marshalling kiosks box to control box
and further from control box to fire extinguishing connection shall be used.

PREVIOUS EXPERIENCE FOR QUALIFYING SUPPLIER:

The supplier shall have a minimum experience of two years in the design, manufacturing,
erection, testing and commissioning of nitrogen injection fire protection system on power
transformers of similar or higher rating. At least 2 sets of the system shall be in successful
operation for a minimum period of the 2 years. The supplier shall furnish the details of
nitrogen injection fire protection system supplied by them so far, giving order reference,
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name and address of the customer, indicating the dates of commissioning as well as
performance certificate of successful and satisfactory operation for minimum two years
from the customers.

TESTS

TYPE TEST
Type Test reports including that for detectors along with declared response time shall be
submitted within the tender. The system shall be tested by reputed international testing
body or a national testing body (BIS) recognized laboratory). TAC approval, if any, shall
be submitted with the tender.

FACTORY TEST
Tests will be carried out on individual equipment of the system and the total system in the
supplier’s workshop in presence of purchaser’s representatives.

PERFORMANCE TEST
Performance test of the complete system shall be carried out after complete erection at site
by the supplier’s representatives. These tests shall include simulation and verification of the
response of the complete system without actual draining of the oil and injection of the
nitrogen gas. In addition to above, additional tests as required necessary shall be conducted.

DRAWINGS AND MANUALS

Detailed layout drawings along with the equipment drawing to be given in the proposal
along with the complete bill of materials. After awarding of contract, detailed dimensional
drawing of the system complete bill of materials including location and size of plinth for
cubicles and recommended capacity of oil soak-pit shall be submitted for purchaser’s
approval. After approval 10 (ten) sets of all above drawings and 5 (five) sets of operation
and maintenance instruction manual (bound) shall be submitted for purchaser’s use.

SPARES
One full set of spares nitrogen gas filled cylinder, 50 % of the installed no. of fire detectors
(heat sensing element) shall be provided in addition to additional other recommended
spares. The list of recommended spares is to be submitted along with the proposal of
vendor approval.
3.2 Fiber Optic Winding Hot Spot Temperature Monitor:-
Fiber optical winding hot spot temperature monitor to be provided with transformer
windings connected in parallel of the winding temperature indicator to measure
transformer‐winding hot spots in real time and activate control of the cooling system. The
Fiber to be given high strength casing through rugged jacketing and fiber to be securely
routed till the tank wall plate. Temperature readings shall be available on SCADA and FO
sensor shall have IEC 61850 compliant port to communicate with SCADA.

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Specification for Fiber Optic Temperature Measurement System:

Fiber optic based temperature measurement of Oil and windings shall be done using Fiber
Optic sensors meeting following criteria:
1. System shall be of proven technology. The temperature sensing tip of the fiber optic
shall be ruggedized. The probes shall be directly installed in each winding of power
transformer to measure the winding hot spot and at the top oil temperature. There shall
be at least 4 probes inside the transformer.
2. Out of the 4 probes one probe shall be used for top oil temperature measurement and the
balance will be placed in the LV, HV and Tap Changer winding (One probe per
winding).
3. Probes shall be able to be completely immersed in hot transformer oil they shall
withstand exposure to hot vapour during the transformer insulation drying process, as
part of Vacuum Phase Drying (VPD). The probes shall meet the requirement to
eliminate the possibility of partial discharge in high electric stress areas in the
transformer. Probes shall have certified Weidman testing for electrical parameters as per
ASTM D 3426 and ASTM D 149 that is current (not more than 1 5 year old). Test
results and studies to be submitted by the transformer manufacturer along with the first
unit of a certain type of traction transformer.
4. Temperature range of the system should be up to +200°C without any need of
recalibration. Probes must connect to the tank wall plate with threaded connectors
containing a Viton o ring to prevent against oil leakage.
5. Probes shall be of material inert to mineral and ester oils, multiple jacketed (Kevlar
preferred), perforated outer jacket to allow complete oil filling and mechanical strength.
6. System should include analog outputs for each measurement channel. Temperature
resolution of the analog outputs shall be ±0.1°C and precision of +/ 1°C and the
system shall offer user programmable temperature alarm outputs with 8 relays (along
with 1 Form C system status relay). The cooling system (Fans &Pumps) should be
operated through these relays. The temperature settings for the relays shall be made as
per the end user request.
7. All inputs and outputs of the system shall meet the Requirements of surge test of IEEE
C37.90.12002 in which a 4000 V surge is applied to all the inputs and outputs without
permanent damage to the instrument. The system should electronically store testing
records of components and allow for on board diagnostics and instructions, including a
signal strength reading to verify integrity of fiber optic connections. System should
contain a battery for date/time stamp of data readings. The system should contain
IEC61850 protocol, along with DNP3.0, Modbus, TCP/IP and ASCII.
8. The transformer manufacturer should submit data showing that the probes are located in
the hottest point of the winding, while submitting drawings for approval.

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9. The controller shall be housed in cooler cubicle or in a separate enclosure having ingress
protection IP 55.
10. Temperature Rise Test Measurements shall be made with the Fiber Optic Thermometers.
The equipment shall be operational during temperature tests and be demonstrated during
these tests. During probe verification, the hottest probes for each phase shall be
identified, and temperature data for all probes recorded and reported in the test report.
11. All temperatures probes should be compatible with SCADA communicability.

3.3 Ester oil filled transformers:

If the employer requires ester oil filled transformer, the contractor shall submit detailed design of
the transformer along with relevant extracts of applicable International/Indian standards. Any
savings in size due to ester oil shall be clearly specified. The contractor shall submit the credentials
to assist proven-ness of the design. Transformer shall be designed with thermally upgraded papers
and OLTC other accessories shall be designed with high temperature rises, so as to minimize the
size of the transformers. The adjustment price of transformer with synthetic ester oil is to be quoted
in pricing/BOQ document(this includes the supply of spare ester oil drums in place of mineral oil, if
ester oil filled transformers are chosen)

4. Maintenance & Life

The Traction Transformer should be designed for trouble free service of minimum 30 years
for all types of installation methods & environmental conditions prescribed.
5. TESTING
TEST SHEET and GTP SHEETS
All type tests and routine tests of Transformer, ON load tap Changer and Bushings as per
relevant IEC standards specified in technical specifications shall be carried out. Short circuit
withstand test shall be conducted on one each type and rating of transformer to validate the
design and quality unless such test has been conducted within last five years on the
transformer of same design. In case there is change in design before five years, the new
transformer design shall be validated by carrying out short circuit withstand test. All the
type test report shall be valid at the time of vendor approval.The BOM of the transformer
which is type tested earlier and the report of which is submitted shall meets the present
specifications, else the earlier report of type test conducted within 5 years will not be
acceptable.
5.1 Type tests:
The list of Type tests is as follows:

S.no Name of Type test Remarks

Transformer
1 Temperature rise test

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S.no Name of Type test Remarks

2 Measurement of Harmonics of No-Load as per IS 2026-1
3 Determination of sound level for each method of cooling. Please refer GTP
4 Measurement of power taken by Fans
5 Short-circuit withstand test
6 Line terminal AC withstand voltage test (LTAC) For 220kV only
7 Vacuum deflection test on liquid immersed transformers
8 Pressure deflection test on liquid immersed transformers
Bushings
1 AC Long Duration Test
2 Dry lightning impulse voltage withstand test
3 Temperature Rise test
4 Thermal Short-Time current withstand
5 Cantilever Load Withstand Test
6 Tightnesstest on liquid-filled
7 Dimensions Verifications
OLTC
1 Temperature rise of contacts
2 Service duty test
3 Breaking capacity test
4 Short-circuit current test
5 Mechanical endurance test
6 Millivolt test

5.2 Routine tests

The list of Routine tests is as follows

S.no Name of Routine test Remarks

Transformer
1 Measurement of winding resistance
2 Measurement of voltage ratio and check of phase
displacement
3 Measurement of short-circuit impedance and load loss
4 Measurement of no-load loss and current
5 Full wave lightning impulse test for the line terminals (LI) Not for 220 kV
Transformer
6 Chopped wave lightning impulsetest for the line terminals Applicable for
(LIC) 220kV Transformer
7 Switching impulse test for the line terminal (SI) only
8 Applied voltage test (AV)
9 Induced voltage test with PD measurement (IVPD)

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S.no Name of Routine test Remarks

10 Line terminal AC withstand voltage test (LTAC) Not applicable for
220kV Transformer
11 Auxiliary wiring insulation test
12 Tests on on-load tap-changers operation test
13 Leak testing with pressure for liquid-immersed transformers
(Tightness test)
14 Check of core and frame insulation for liquid immersed
transformers with core or frame insulation
15 Check the insulation between the Transformer body & Earth
and provision of the insulation Pad
16 Determination of capacitances windings-to-earth and
between windings
17 Measurement of D.C insulation resistance between each
winding to earth and between windings
18 Measurement of dissipation factor (tan δ) of the insulation
system capacitances
19 Measurement of no-load loss and current at 90 % and 110 %
of rated voltage
21 Measurement of zero-sequence impedance(s) on three-phase
transformers
22 Measurement of frequency response (Frequency Response This test is also to be
Analysis or FRA). repeated at site to
correlate any
transportation
damage.
Bushings
1 Measurement of tan δ and capacitance.
2 Dry lightning impulse voltage withstand test
3 Dry power-frequency voltage withstand test
4 Measurement of Partial Discharge Quantity
5 Tests of Tap Insulation
6 Tightness test on bushings
7 Tightness test at the flange or other fixing device
8 Visual inspection and dimensional check
OLTC
1 Mechanical tests
2 Sequence tests
3 Auxiliary circuits insulation test
4 Overrun test

The contractor shall submit fully filled technical data sheet given in chapter 8B of PS along
with other relevant data during technical approval
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5.3 BOM of sample

The manufacturer shall not change the Bill of Material used in the manufacturing of samples used
for routine testing and Type testing as repeated above and that it intends to supply against the
contract.

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