CSPTCL TR-20/05 220/132/33 KV S/S Daldalseoni & Assoc.

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TECHNICAL SPECIFICATION OF 220/132/33 KV, 160 MVA

POWER TRANSFORMER
3. Scope:
1.1 This specification covers design, engineering, manufacture, assembly, stage testing inspection
and testing before supply and delivery of 160 MVA, 220/132/33 KV 3-phase auto power
transformers complete with all fittings, accessories and associated equipment‘s which are
required for efficient and trouble free operation.
1.2 It is not the intent to specify completely herein all detail of the design and construction of
equipments. However, the equipment shall conform in all respects to standards of
engineering, design and workman ship listed in clause no. 2 and shall be capable of
performing in continuous commercial operation up to the bidder‘s guarantee in a manner
acceptable to the purchaser, who will interpret the meanings of drawing and specification and
shall have the power to eject any work or material which, in his judgment, is not in
accordance therewith. The equipments offered 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 in the commercial order or not.
1.3 The transformers shall conform in all respects to high standards of engineering, design,
workmanship and latest revision of relevant standards at the time of offer and purchaser shall
have the power to reject any work or material which, in his judgment, is not in full accordance
therewith.
1.4 Climatic Conditions:
Peak Ambient Temperature 50 Degree Celsius
Minimum Temperature in Shade 6 Deg. C
Maximum Relative Humidity 95% (sometime approaches saturation)
Average number of thunderstorm 58 days per annum.
Average number of rainy days per annum 90 days.
Average Annual Rainfall 125 cm.
Maximum Wind Pressure 150 kg/meter square.
Altitudes (Not Exceeding) 1000 metres.
Seismic Level Horizontal g.

Standards:
2.1 The transformers and associated accessories shall conform to the latest issues of standards as
given below: -
Internationally
Indian Standard Title
recognised std.
IS-2026 (part I to Power Transformers IEC-76
V)
IS-3639 Fittings & Accessories for power transformers
IS-335 Insulating oils for Transformers. IEC-296, BS-148
IS-2099 Bushings for alternating Voltage above 1000 V IEC-137, BS-223
IS-2705 Current Transformers IEC-185
IS-325 Three phase Induction Motors IEC-34
IS-375 Marking & arrangements for Switchgear, bus bars,
Main Connections and auxiliary Wiring.
IS-3737 Gas operated relays
IS-1886 Code of practice for installation and maintenance
of transformers
IS-2147 Degrees of protection.
IS-5 Colors for ready mix paints
IS-6272 Industrial cooling fans
IS-6600 Guide for loading of oil Immersed transformers BSCP-0160
IS-778 Gun metal gate, globe and check valves for
general purpose
IS-3401 Silica gel.

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IS-4253 Park & Rubber

IS-5561 Electric power connector
IS-5578, IS-11353 Marking & arrangement for switch gear, bus bar,
main connections and auxiliary wiring.
IS-9434 Guide for sampling and analysis of dissolved gas
in oil filled equipments.
IS-12676 Oil impregnated paper insulated condenser
Bushing Dimension and requirements.
Insulation Co-ordination IEC-71
Indian Electricity rule, 1956
CBIP publication no 275 Manual on power
transformers
DOC.ETD 16 Draft standard by BIS for revision of IS-8468 for
(3487) OLTC
DOC.ETD 16 Draft standard by BIS for revision of IS-3639 for
(3574) fitting & accessories for transformers part-I-
standardization of conservator
DOC.ETD 16 --- do --- part 2: dehydrating breather
(3575)
DOC.ETD 16 --- do --- part 3: earthing terminals
(3576)
DOC.ETD 16 --- do --- part 4: temperature indicators
(3577)
DOC.ETD 16 --- do --- part 5: rating & diagram plate
(3578)
Equipment meeting with the requirements of other authoritative International standards which
ensure equal or better performance than the standards mentioned above shall also be
considered. When the equipment offered by the bidder conforms to other standards adopted
and the standards salient points of difference between standards adopted and the standards
specified in this specification shall be clearly brought out in the offer. Two copies of such
standards with authentic translation in English shall be furnished along with the offer.

3. Auxiliary power supply:

Auxiliary electrical equipment shall be suitable for operation on the following supply
system:-
Power Devices Like drive motors 415 V, 3 Phase 4 wire 50 Hz, neutral grounded
AC supply
Lighting, space heaters and fractional 240 V, single phase, 50 Hz neutral grounded AC
kW motors supply.
Alarm, control and protective devices 220 V DC, 2 wire.
Each of the foregoing supplies shall be made available by the bidder at the terminal point for
each transformer for operation as accessories and auxiliary equipment. Bidders scope include
supply of interconnecting cables, terminal boxes etc. the above supply voltage may very as
below and all. Device shall be suitable for continuous operation over entire range of voltages.

i) AC supply: Voltage +10% (-) 20%, frequency + 5%

ii) DC supply: (-) 15% to +10%

4. PRINCIPAL PARAMETERS (128/160 MVA TRANSFORMER):

The transformer shall conform to the following specific parameters: -

SNo Item Specification of160 MVA x-mer

1.1 Rated Voltage Ratio: kV 220/132/33
1.2 Highest system voltage 245/145/36 KV
2. No. of windings Auto transformer with tertiary

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3. Type of cooling ONAN/ ONAF

4. MVA rating corresponding to cooling
system:
a) ONAN Cooling 80% (128/128/402.66MVA)
b) ONAF Cooling 100%(160/160/53.33MVA)
5. Method of connection HV & IV Star
LV Delta
6. Connection Symbol (vector group) YN a0d11
7. System earthing Effectively earthed
8. (a) Percentage impedance‘s, Voltage % Impedance Tolerance
on normal tap and MVA base
corresponding to HV rating and
applicable tolerances:
(i) HV – MV 8.35 +10%
(ii) HV/ LV 30 +15%
(iii) MV / LV 20 +15%
(b) Insulation resistance at an ambient HV-IV/E & LV/E- 3000 M ohm
temp. of 30 deg with 5 KV megger for HV-IV/LV - 4000 M ohm
600 seconds duration

(c) Polarization Index i.e. Ratio of >= 2

megger values of 600 secs to that of 60
secs
(d) DAR (Dielectric Absorption ratio) >= 1.3
i.e. ratio of IR value of 60 sec. to 15
sec.
9. Anticipated continuous loading of
a. HV, IV windings: Not to exceed 110% of its rated capacity
b. Tertiary winding Suitable for no load operation as well as
for loading to its rated capacity with
capacitive or inductive loading or
combination of both (Subject to a
maximum of 33% of the rated capacity of
HV winding
10. Tap changing gear:-
Type OLTC for IV variation.

2) Tap range & steps -10% to + 10%, steps 1.25%

3) Rated for 150 KV & 1000 A (Minimum)
11. Over voltage operating capability and 110% rated voltage Continuous
duration 125% rated voltage for 60 secs.
140% rated voltage for 5 secs.
12. Minimum Air core reactance of HV 20%
windings.
13. The voltage for which star point shall The insulation class of the neutral end of
be insulated to the earth the winding shall be graded to 95 KV.
14. (a) Max. Flux density in any part of 1.6
core and yoke at rated MVA,
frequency and normal voltage (Tesla)
(b) No load current of the transformer
at 105 % of rated voltage 0.5% of rated current (Maximum)
(c) Current density in winding <= 3 Amp/ sq. mm (max.)

15. Insulation levels: For windings HV IV LV

a) 1.2/50 microsecond wave shape 950 650 250
impulse withstand (kVp)

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b) Power frequency voltage withstand 395 230 95

(kV rms.)
c) Tan delta values of winding The measured Tan delta values of winding
shall not exceed 0.45% at 200C
temperature. In case Tan delta of
transformers during testing at works of
manufacturer is measured above maximum
ceiling of 0.45% at 200C temperature, then
CSPTCL reserves right not to accept such
of the transformer. This requirement is to
be confirmed specifically by the Bidders in
their offer.
16 Type of winding insulation:- The HV/IV winding of the transformers
HV/IV winding shall have graded insulation. The
LV winding insulation class of the neutral end of the
winding shall be graded to 95 KV. The
33KV winding shall have full insulation
for 33KV i.e.
250 KVp impulse and 95KVrms power
frequency.
17. System short circuit level and duration If 220 KV side of transformer is connected
for which the transformer shall be on Infinite Bus, the transformer shall be
capable to withstand thermal and capable to withstand terminal short circuit
dynamic stresses (kA rms / sec) on 132 KV for 3 sec. duration.
18. Maximum partial discharge level at 500 pico coulombs
1.5/sq.root 3 of rms. Phase to ground
voltage.
19. Noise level at rated voltage and 81 Db
frequency
20. Permissible temperature rise: Over
ambient temp.
i) Of top oil measured by 400 c
thermometer.
ii) Of winding measured byresistance. 450 c
21. Minimum clearances in air (mm): Phase to phase Phase to ground
(a) HV 2700 2400
(b) IV 1430 1270
(c) LV 700 660
22. Terminals:-
(a) HV Winding Line end (OIP 245 KV
condenser bushing)
(b) IV Winding Line end 145 KV
(OIP condenser bushing)
(c) HV/IV Winding Neutral 72.5 kV OIP condenser bushing
(d) LV Winding 72.5 kV OIP condenser bushing with
center spacing of 1000 mm.
23. Max. Radio Interference voltage level 1000 micro volts
at 1 MHz & 1.5/sq root 3 of rms phase
to ground voltage for HV winding
24. Minimum Visual Corona extinction 320 KV rms
voltage
25. Cooling Equipment‘s: Number of Two Banks each 50%
Banks with Adequate number of Fans.
26. Bushings: HV IV LV/Neutral
(i) Voltage rating Kvrms 245 170 72.5
(ii) Current rating 1250 1250 1250

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(iii) Insulation level:

a.Lightning impulse with stand (kVp) 1050 750 325
b. 1 Minute power frequency 460 275 140
withstand voltage (kV rms)
(iv) Creepage distance (mm) 6125 4250 1815
27. (i) The permissible range of losses at
rated voltage & frequency (without
any positive tolerance)
a) No Load Losses (Iron losses) 31.5 KW - 35 KW
b) Load (Copper Losses) 184.5 KW –205 KW
c) Auxiliary Losses 4.5 KW - 5 KW
(ii) No load losses at 110% of rated Not more than 130% of the losses at rated
voltage & rated frequency voltage & frequency
28. Type of design of the transformer Only Bell type tank construction is
acceptable
29. Tank sheet thickness
(i) Top & bottom Minimum 20 mm
(ii) Sides Minimum 10 mm
30. Conservator tank sheet thickness Minimum 8 mm
31 There shall be two CT cores per HV, Ratio - 800/1-1A KPV- min. 800V
IV and N Bushing CT for REF (1- Accuracy: PS (both cores)
phase ring type turret mounted).
32 There shall be one CT core in middle Ratio to be specified by the Bidder
phase of HV, IV and LV Bushings for
WTI
33 33KV class CT for tertiary winding
(i) Type 1 phase ring type turret mounted
(ii) Ratio 600/1-1
(iii) Accuracy class 5P10/1.0
(iv) Quantity 1 No.
34 Transformer oil:
(a) Appearance The oil shall be clear and transparent and
free from suspended matter or sediment
(b) Density at 27o C max. 0.89g/cm3
(c) Kinematic viscosity max.
(i) At 27 o C 27 cSt.
(ii) Sub-zero temp Under consideration
(d) Interfacial tension @ 27 degree 0.04N/m
min
(e) Flash point Penskymartn (closed) 140 degree centigrade
,min.
(f) Pour point max. - 6oC
(g) Neutralization value (total acidity) 0.01mg. KOH /g
max.
(h) Corrosive sulfur (in terms of Non corrossive
classification of copper strip)
(i) Electric strength(break-down
voltage) 40 kv (RMS) If the value is not attainted
New untreated oil the oil shall be treated.
b) After treatment 60 kv (RMS)
(j) Dielectric dissipation factor (tan 0.002
delta)at 90o C max
(k) Specific resistance (resistivity)
i) At 90 o C min. 35x1012 ohms-cm
ii) At 27 o C min. 1500x1012 ohms-cm

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(l) Oxidation stability

i) Neutralization value after oxidation 0.4 KOH/g
(max) 0.1 % by weight
ii)Total sludge after oxidation(max)
(m) Presence of oxidation inhabitor The oil shall not contain antioxidant
additives
(n) Water content (max) 50 ppm, after treatment should be less than
10

5. GENERAL TECHNICAL REQUIREMENTS

5.1 Duty Requirements:
5.1.1 The interconnecting transformers would be used for Bi directional flow of rated power.
5.1.2 If 220 KV side of transformer is connected on Infinite Bus, the transformer shall be capable to
withstand terminal short circuit on132 KV for 3 sec. duration.The transformers and all the its
accessories like CTs etc. shall be designed to withstand without injury, the thermal and
mechanical effects of any external short circuits at the terminals of any winding for a period
of 3 sec. The short circuit level of the HV system to which the subject transformer will be
connected is 40 KA (Sys, rms, 3 phase fault) for 220 KV and 132KV systems and 31.5KA for
33 KV systems.
5.1.3 The transformer shall be capable of being loaded in accordance with IS:6600. There shall be
no limitation imposed by windings, bushings, tap changer etc. of transformer. Transformer &
all its accessories shall be liberally rated to allow 10% over loading at all taps on continuous
basis without exceeding the temperature limits specified in clause 4.0. The transformer shall
be capable of being operated without danger on each tapping at the rated KVA with specified
voltage variation corresponding to the voltage of that tapping with normal temperature rise.
The design adopted to achieve this shall be indicated in detail in the Bid. Transformer shall be
capable of operating under the natural cooled condition up to the specified load i.e. as ONAN
rating. The forced air cooling equipment shall come into operation by pre-set contacts of
winding temperature indicator and the transformer shall operate as a forced air cooled unit i.e.
as ONAF. Cooling shall be so designed that during total failure of power supply to cooling
fans, the transformer shall be able to operate at full load for Ten (10) minutes without the
calculated winding hot spot temperature exceeding 140 deg.C. Also stopping of two cooling
fans should not have any effect on the cooling system. Transformers fitted with two coolers
(cooling banks) each capable of dissipating 50 per cent of the loss at continuous maximum
rating shall be capable of operating for 20 minutes in the event of failure of the blowers
associated with one cooler, without the calculated winding hot spot temperature exceeding
140oC at continuous maximum rating.
5.1.4 The transformer shall be capable of being operated without danger on any tapping at the rated
KVA with voltage variation of + 10% corresponding to the voltage of that tapping. The
transformers and its accessories shall be liberally rated to allow 10% overloading at all taps
on continuous basis.
5.1.5 Radio interference and Noise Level:
The transformers shall be designed with particular attention to suppression of maximum
harmonic voltage, especially the third and fifth so as to minimize interference with
communication circuits.
The noise level, when energized at normal voltage and frequency with fans and pumps
running shall not exceed, when measured under standard, conditions, the values specified in
NEMA, TR-1.
5.1.6 Transformer shall be capable of operating under the natural cooled condition up-to the
specified load. The forced cooling equipment shall come into operation by preset contacts of
winding temperature indicator and the transformer shall operate as a forced cooled unit, at
specified load. Cooling shall be so designed that during total failure of power supply to
cooling fans, the transformer shall be able to operate at full load for at least ten (10) minutes
without the calculated winding hot spot temperature exceeding 140 deg. C. Also stopping of
one or two cooling fans should not have any effect on the cooling system.
5.1.7 Transformer shall be capable of withstanding thermal and mechanical stress caused by
symmetrical of asymmetrical faults on any winding.

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5.1.8 Transformer shall accept, without injurious heating, combined voltage and frequency
fluctuation of +/-4%, which may produce the following over fluxing condition:
i) 125% for 1 minute) for all transformer where
140% for 5 seconds) base voltage and frequency refers
to rated voltage and frequency
ii) Over fluxing withstand characteristics up to 170% shall be submitted along with the bid.

PERMISSIBLE LOSSES OF 160MVA, 220/132/33 KV POWER TRANSFORMER:-

5.2.1 The losses of 160MVA, 220/132/33 KV Power Transformer should be within the range of
prescribed below for respective losses (without and positive tolerance):
S.No. Particulars Maximum Minimum
1. No load loss in KW 35 31.5
2. Load loss in KW at rated voltage, rated 205 184.5
frequency and rated current at 75°C
3. Auxiliary loss in KW 5 4.5

The bidders shall have to offer no load loss, load loss and auxiliary loss separately.In case any
of the offered losses (i.e. no load loss, load loss or auxiliary loss) quoted by the bidder is
more than the maximum permissible limits, the bid shall be considered as non responsive and
shall be out rightly rejected without and correspondence in the matter.
In case any of the losses are below the minimum range prescribed above, the bid shall be
treated as responsive. However, for price bid evaluation purpose, the minimum range of the
respective loss prescribed above shall be considered.

5.2.2 Guaranteed losses:

The transformer losses at 75oC, rated voltage & frequency should be offered by the bidder in
Schedule-I, Sl. No. 9 (a), (b) & (c). During final testing of each of the transformer, the
measured losses (individually i.e. No load, load & auxiliary losses) should not exceed the
guaranteed losses. In case, any of the losses exceed the guaranteed losses transformer shall not
be accepted. The bidder must clearly specify that the offered losses are ‗FIRM‘ and no
tolerances shall be applicable on the offered values.
Capitalisation of losses:The capitalisation of no load loss, load & auxiliary loss for the bidder
who has quoted above the minimum of the respective range of losses specified in clause 5.2.1
shall be done on the following rates (differential of quoted loss & minimum value of the range
for respective loss).
a) For differential no load loss above min value : Rs. 4,01,840.00 per KW
b) For differential load loss above min value : Rs. 2,13,780.00 per KW
c) For differential auxiliary loss above min value : Rs. 1,60,700.00 per KW
In case a bidder quoted any of the losses below the min value of the range prescribed in clause
5.2.1, the value of loss shall be considered equal to min of the range specified at clause 5.2.1
for respective loss for price bid evaluation purpose. However, it should be clearly noted that
during final testing of each of transformer, the major losses individualy (i.e.no load loss, load
loss, auxiliary loss as applicable) should not exceed the values quoted by the bidder in the bid.
In case any of the loss exceeds the quoted loss, respective transformer shall not be accepted.
The above mentioned rates for capitalization of losses have been worked out as per the formula
prescribed by CBIP in publication No. 317 i.e. manual on transformers.
The contractor must clearly specify that the offered losses are ―FIRM‖ and no tolerances as per
IS shall be applicable on the offered values.

GUARANTEE PERIOD:
The contractor shall ensure that the power transformer supplied shall be guaranteed for a
period of 42 months from the date of satisfactory commissioning of transformer along with all
accessories. Please note that the date of commissioning of last accessory will be treated as date
of commissioning of transformer. The transformer found defective/failed within the above
guarantee period shall be got replaced/repaired by the contractor free of cost, within four

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months from date of issue of intimation letter to the contractor by CSPTCL regarding its
defect/failure.
If the contractor fails to arrange repair/replace the failed/defective transformer within four
months, the contractor shall be liable to pay penalty charges for delayed repairs at the rate of
0.5% of the cost of transformer per week of delay or part thereof, subject to a maximum
ceiling of 10% of the cost of the transformer. This penalty shall be in addition to the liquidated
damages as per clause 14.1 of GCC for delay in completion of the contract.
If the defective/failed transformer is not lifted for replacement/repairing within 2 months from
the date of intimation by CSPTCL regarding defect/ failure OR one month from date of
acceptance of additional Indemnity Bond submitted by the contractor, (in case the transformer
is required to be taken back to the works for repairing) whichever is later.
OR
not repaired within seven months from date of lifting of failed/ defective transformer, penal
action may be taken which will include forfeiture of performance guarantee of transformer
and debarring of the manufacturer from future business with CSPTCL for a period as decided
by CSPTCL in addition to the other applicable penalty.
The above provisions shall be applicable for second time failure also, if any.

2. EXTENDED GUARANTEE PERIOD POST REPAIRS:

Further, the following extended guarantee shall be applicable, in case the transformer fails
within guarantee period.
a) First time failure within guarantee period:
i) If the transformer fails within 12 months from the initial commissioning, the
guarantee period shall get extended to 42 months from the date of satisfactory re-
commissioning of transformer after repairs along with all accessories.
ii) If the transformer fails after 12 months within the original guarantee period, the
original guarantee period shall get extended for a period equal to the time period
lapsed between date of failure to date of re-commissioning after repairs i.e. the
residual guarantee period or 12 months from date of re-commissioning after repairs,
whichever is later.
b) Second time failure of transformer within guarantee period:
If the transformer fails again (second time) within the original/extended guarantee
period, the guarantee shall automatically get extended for further period of two years
from the date of re-commissioning (post repair) or from the end of the original/
previously extended period, whichever is later.
c) Third time failure of transformer within guarantee period:
If the transformer fails within guarantee /extended guarantee period for third time,
this will be treated as adverse performance of contractor as well as manufacturer and
in such case penal action shall be taken which will includes
Forfeiture of 10% BG submitted against performance of transformer.
(ii) Forfeiture of additional 10% performance BG furnished after satisfactory completion
of guarantee period of material/equipments (except power transformer).
(iii) Debarring of the manufacture of the transformer from future business with CSPTCL
for a period as decided by CSPTCL as well as deletion of their name from the vendor
list of CSPTCL for forthcoming turnkey projects.
If, for the purpose of replacement/repairs, the equipment/material is required to be dispatched
to manufacturer‘s works, all charges towards transportation / insurance/ packing / forwarding
will have to be borne by contractor for to and fro dispatches.
In this connection, please note that the following additional conditions will also be applicable
in case any damages/defects are noticed in the equipments or its accessories-
If the material develops defect within guarantee/extended guarantee period after installation at
site or subsequent to installation after repairs (1st or 2nd time), for the purpose of replacement
/ repairs, the same will have to be dismantled and taken out by CSPTCL, in such cases actual
cost of dismantling and replacement of the equipment / material will also be recoverable from
contractor.
In case, transformer fails during guarantee / extended guarantee period, the following terms
shall also be applicable (in first or second time failure both)-

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An additional Indemnity Bond on stamp paper of Rs.250.00 shall be required to be submitted

by the contractor, in case the transformer is required to be taken back to the works for
repairing. The value of this Indemnity Bond shall be equal to the cost of transformer along
with all taxes, duties, freight and testing charges. The transformer shall be handed over for
repairing only after submission and acceptance of additional indemnity bond.
The transformer should be offered for inspection after completion of repairing work. The
repaired Transformer shall be tested for all routine, additional routine, type and special test as
per IS-2026 & as narrated in section-III-B, clause-6 under head ―Tests‖ of technical
specification of transformer.
(iii) The Transformer should be offered for inspection after repairing within four months from
date of intimation of failure by CSPTCL.
(iv) The dispatch instructions shall be issued for repair transformer after its satisfactory
inspection. The transformer should reach the destination (anywhere in C.G. state) within 45
days from date of issue of dispatch instruction failing which actual date of receipt of repaired
transformer at site shall be treated as date of delivery of the repaired transformer for all
contractual purposes.
(v) In case of failure / defect in transformer (first or second time) within guarantee / extended
guarantee period, the validity of performance guarantee for transformer submitted by the
contractor against the contract as per clause 12.1(i) of GCC should be extended up to expiry
of extended guarantee period with additional claim period of six months. In case, contractor
fails to extend the guarantee period of transformer, claim shall lodged with the issuing bank
for encashment of the all performance bank guarantee for transformer.

5.3 Clearances:
The over all dimensions of the transformer shall allow for sufficient clearances for Installation
in:
(a) 220 KV switchyard with bay width of 15000 mm & beam height of 11000 mm.
(b) 132 KV switchyard with bay width of 9600 mm & beam height of 11000 mm.
5.4 Construction Details:
The features and construction details of power transformer shall be in accordance
with the requirements stated hereunder:
5.4.1 Tank and Tank Accessories:
5.4.1.1 Tank:
Tank shall be of welded construction and fabricated from tested quality low carbon steel of
minimum thickness of 20mm. (Base & Tank cover) and 10mm for sides.
All seams and those joints not required to be opened at site shall be factory welded and
whenever possible they shall be double welded. After completion of tank construction and
before painting, dye penetration test shall be carried out on welded parts of jacking bosses,
lifting lugs and all load bearing member. The requirement of post weld heat treatment for
tank/stress relieving parts shall be based on recommendations of BS: 5500 table 4.4.3.1
The Tank stiffeners shall be provided for general rigidity and these shall be designed to
prevent retention of water.
The tanks shall be designed to withstand
(i) Mechanical shocks during transportation
(ii) Vacuum filling of oil at 10 millitorr
Continuous internal pressure of 35 kN/m2 over normal hydrostatic pressure of oil.
Short circuit forces.
Wherever possible the transformer tank and its accessories shall be designed without pockets
wherein gas may collect. Where pockets cannot be avoided, pipes shall be provided to vent
the gas into the main expansion pipes.
Adequate space shall be provided at the bottom of the tank for collection of sediments. The
minimum clearance of outermost winding/connection leads to tank shall not be less than 300
mm on all 4 sides to allow free movement of two persons for inspection. Suitable platforms
may be provided on bottom to facilitate free movement of person all around inside the tank.
The arrangement should be brought out clearly in the drawing.
The base of each tank shall be so designed that it shall be possible to move the complete unit
by skidding in any direction without injury when using plates or rails.

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Tank shields shall be such that no magnetic/fields shall exist outside the tank. If required
impermeable shields shall be provided at the coil ends. Tank shield shall not resonate when
excited at the natural frequency of the equipment. Bidder may confirm use of tank shields in
the schedule of additional information.
Suitable guides shall be provided in the tank for positioning the core and coil assembly.
Each tank shall be provided with
(i) Lifting lugs suitable for lifting the equipment complete with oil
(ii) A minimum of four jacking pads in accessible position at 500 mm height to enable the
transformer complete with oil, to be raised or lowered using hydraulic or screw jacks.
(iii) Suitable haulage holes shall be provided.
The transformer should be of bell tank design only. No other design is acceptable

5.4.1.2 Tank cover:

(a) The tank cover shall be sloped to prevent retention of rainwater and shall not distort when
lifted.
(b) At least two adequately sized inspection openings, one at each end of the tank shall be
provided for easy access to bushings and earth connections. The inspection covers shall not
weigh more than 25 kg. The inspection covers shall be provided with two handles.
(c) The tank covers shall be fitted with pockets at the position of maximum oil temperature of
MCR (Maximum Continuous Rating) for bulbs of oil and winding temperature indicators. It
shall be possible to remove these bulbs without lowering the oil in the tank.
(d) Bushings, turrets, covers of inspection openings, thermometer, pockets etc. shall be designed
to prevent ingress of water into or leakage of oil from the tank.
(e) All bolted connections shall be fitted with weather proof, hot oil resistant gasket in between,
for complete oil tightness. If gasket is compressible metallic stops shall be provided to
prevent over-compression.
5.4.2 Air cell:
The transformers should be supplied with air cell type oil preservation system. It is obligatory
on the part of the bidders to clearly submit complete constructional and technical details of
sealing arrangements duly supported with technical details, pamphlets and dimensional
drawings.
While furnishing details for the above sealing arrangement the bidders must confirm clearly
that the size and capacity of sealing arrangement is adequate for the transformer and for the
quantity of transformer oil required for the transformers.
5.4.3 Axles and Wheels:
(a) The transformers are to be provided with flanged bi-directional wheels and axles. These shall
be so designed as not to deflect excessively to interfere with the movement of the transformer.
Wheels shall be provided with suitable bearings, which shall be rust and corrosion resistant.
Fittings for lubrication shall also be provided.
(b) Suitable locking arrangement along with foundation bolts shall be provided for the wheels to
prevent accidental movement of transformer.
(c) The wheels are required to swivel and they shall be arranged so that they can be turned
through an angle of 90 when the tank is jacked up to clear of rails. Means shall be provided
for locking the swivel movements in positions parallel to and at right angles to the
longitudinal axis of the tank.
(d) The rail track gauge shall be 5‘ – 6‖ (1676 mm) along longer axis as well as along shorter
axis. The arrangement should be such that transformer can be installed in any direction i.e.
along longer axis or along shorter axis on 2 rails with spacing of 1676 mm.
5.4.4 Anti Earthquake Clamping Device:
To prevent transformer movement during earthquake, clamping device shall be provided for
fixing transformer to the foundation. The Bidder shall supply necessary bolts for embedding
in the concrete foundation. The arrangements shall be such that the transformer can be fixed
to or unfastened from these bolts as desired. The fixing of the transformers to the foundations
shall be designed to withstand seismic, events to the extent that a static co-efficient of 0.3g,
applied in the direction of least resistance to that loading will not cause the transformer or
clamping devices as well as bolts to be over stressed.

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The details of the device used and its adequacy shall be brought out in the additional
information schedule.
5.4.5 Conservator Tank
(a) The conservator tank shall be of minimum 8mm thickness and 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 from minimum ambient
temperature to 100oC. Conservator shall be with volumetric capacity at least 7 ½ percent of a
total volume of oil in the main tank of the transformer.
(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 electrically
insulated alarm contact.
(d) Conservator shall be provided in such a position as not to obstruct the electrical connections
to the transformer.
(e) Separate conservator tank/compartment in the main conservator shall be provided for OLTC.
5.4.6 Dehydrating Filter Breather:
Conservator shall be fitted with a dehydrating, filter breather. It shall be so designed that:
(a) Passage of air is through a dust filter and silicagal.
(b) Silicagel is isolated from atmosphere by an oil seal.
(c) Moisture absorption indicated by a change in colour of the tinted crystals can be easily
observed from a distance.
(d) Breather is mounted not more than 1400 mm above rail top level. Minimum quantity of
silicagel to be 1 kG for every 3500 lts of oil in the tank.
5.4.7 Pressure relief device:
Adequate numbers of pressure relief devices (Minimum three no.) should be provided with
each unit. Bidders must submit calculations to prove that the capacity of pressure relief device
and location of the same in the transformer will adequately meet out requirement.
Constructional and design details of pressure relief device must be furnished and it should be
proved by calculation that the size and setting of pressure relief device is adequate,
considering the rating of the transformer and quantity of oil in the transformer. Furnishing of
this information is a must.
Adequate No. of pressure relief devices may be provided at suitable locations which shall be
of sufficient size for rapid release of any pressure that may be generated in the tank and which
may result in damage to 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.
One set of electrically insulated contacts shall be provided for alarm /tripping along with the
recommended settings.
5.4.8 Buccholz Relay:
A double float type Buccholz relay shall be provided. All the gases 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 and taking gas sample. A copper or stainless steel
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
provided with two electrically independent ungrounded contacts, one for alarm on gas
accumulation and the other for tripping on sudden rise of pressure.
5.4.9 Temperature Indicator:
(a) Oil Temperature Indicator (OTI)
All transformers shall be provided with a 150-mm dial type thermometer for top oil
temperature indication. The thermometer shall have adjustable, electrically independent
ungrounded alarm and trip contacts, maximum reading pointer and resetting device mounted
in the cooler control cabinet. A temperature-sensing element suitably located in a pocket on
top oil shall be furnished. This shall be connected to the OTI by means of capillary tubing.
Accuracy class of OTI shall be +1.5% or better.
(b) Winding Temperature Indicator (WTI)
A device for measuring the hot spot temperature of each of the windings shall be provided
(HV, IV & LV). It shall comprise of the following:
(i) Temperature sensing element.

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(ii) Image coil

(iii) Auxiliary CTs,
(iv) 150 mm dia local indicating instrument with maximum reading pointer mounted in Cooler
control cabinet and with two adjustable electrically independent ungrounded contacts (besides
that required for control of cooling equipment), one for high winding temperature alarm and
one for trip.
(v) Calibration device.
(vi) In addition to the above, the following indication equipment shall be provided for each
winding.
(c) Remote winding temperature indicator
It shall be suitable for flush mounting on RTCC panel. The difference between local and
remote WTI indication at any given time shall not exceed 1oC. One RWTI shall be provided
for each winding in the middle phase (HV, IV & LV).
(i) Auxiliary supply if required, at Owner‘s panel, for RWTI, shall be 220 V DC only.
(ii) Accuracy class of WTI shall be + 1.5% or better.
(iii) Any special cables required for shielding purpose for connection between cooler control
cabinet and remote winding Temperature Indicator control circuit shall be in supplier‘s scope
or work.
5.4.10 Earthing Terminals:
(a) Two (2) earthling pads (each complete with two (2) Nos. tapped holes, M 10 bolts, plain and
spring washers) suitable for connection to 110 x 12 mm copper/brass grounding flat shall be
provided each at position close to the two (2) diagonally bottom corners of tank. Earthing
strip shall be connected to grounding mat by the Bidder.
(b) Two earthing terminals suitable for connection to 50 x 6 mm galvanized steel flat shall also
be provided on cooler, marshalling box and any other equipment mounted separately and
shall be connected to grounding mat suitably.
5.4.11 Core:
(a) The core shall be constructed from high grade non aging cold rolled super grain oriented
silicon steel laminations (Hi B). The core material should be of PRIME grade only. Bidder
will offer the core for inspection & approval by the purchaser during manufacturing stage.
Bidder call notice should be accompanied with the following documents as applicable as a
proof towards use of PRIME core material.
(i) Invoice of the supplier
(ii) Mill‘s test certificate
(iii) Packing list
(iv) Bill of lading
(v) Bill of entry certificate by customs
(b) The design of the magnetic circuit shall be such as to avoid static discharges, development of
short circuit paths within itself or to the earthed clamping structure and production of flux
component at right angles to the plane of laminations which may cause local heating.
(c) Core earthing arrangement: The manufacturer should bring out leads from core, end frame
and tank to top of the transformer through insulated bushing. It may be noted that internal
earthing of any nature from core and frame should not be provided. Earthing at site shall be
done by taking connections from the top of the tank and this arrangement will also facilitate
checking of possibility of any multiple core earthing in transformer.
(d) The insulation of core to bolts and core to clamps plates shall be able to withstand a voltage
of 2 kV RMS for one minute.
(e) Core and winding shall be capable of withstanding the shock during transport, installation,
service and adequate provision shall be made to prevent movement of core and winding
relative to tank during these conditions.
(f) All steel sections used for supporting the core shall be thoroughly sand blasted after cutting,
drilling and welding.
(g) As the transformer is of Bell tank design, suitable projecting guides shall be provided on core-
assembly to facilitate removal of tank.
(h) Each core lamination shall be insulated with a material that will not deteriorate due to
pressure and hot oil.

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(i) The supporting frame work of core shall be so designed as to avoid presence of pockets which
would prevent complete emptying of the tank through drain valve or cause trapping of air
during oil filling.
(j) The maximum flux density in any part of the core and yoke at rated MVA, voltage and
frequency at any tap shall not exceed 1.6 tesla.
5.5.1 Winding:
(a) The supplier shall ensure that windings of all EHV class transformers are made in dust proof,
conditioned atmosphere. He shall furnish the facilities available in this regard at his works
along with the Bid.
(b) The conductors shall be of electrolytic grade copper.
(c) The insulation of transformer windings and connections shall be free from insulating
compounds which are liable to soften, ooze out, shrink or collapse or be catalytic and
chemically active in transformer oil during service.
(d) Coil assembly and insulating spacers shall be so arranged as to ensure free circulation of oil
and to reduce the hot spot of the winding.
(e) The stacks of windings shall receive adequate shrinkage treatment before and after final
assembly. Adjustable devices if necessary shall be provided for taking up possible shrinkage
of coils if any, in service. The provision made in this respect shall be clearly brought out in
the Bid.
(f) Tertiary winding:-For 160 MVA transformer, ONAF rating of HV & IV shall be 160 MVA
and that of 33 KV LV (tertiary) rating shall be 53.33MVA .The tertiary of 160 MVA
transformer shall be designed for full rated MVA loading of either capacitive or inductive or
mixed load. The tertiary winding shall not have taps. Tertiary winding shall be without tap
changer. The tertiary winding is intended to be loaded for the specified rating as mentioned
above and accordingly terminals of delta winding needs to be brought out on transformer
through three bushings. One 33 Kv class CT of ratio 600/1-1 Amps having two secondary
cores of rating 1Amp , one of accuracy class 5P10 and other of accuracy class 1 shall be
provided in any one phase of tertiary winding before delta formation for monitoring
circulating current and also to provide protection against circulating current beyond rated
capacity. 1 CT core of suitable ratio shall be provided in the middle phase for monitoring
WTI. For measurement of circulating current of delta winding one Ampere meter of digital
/numeric type suitable for specified CT ratio shall be provided on the RTCC panel. The
tertiary winding shall be designed to carry the fault current under worst fault condition.
5.5.2 Insulating oil:
(a) EHV Grade-I oil shall be used. The quality of the oil supplied with transformer shall conform
to the oil parameters specified in this clause. No inhibitors shall be used in the oil. The oil
samples will be drawn as follows
i) Prior to filling
ii) Before and after heat run test
iii) Before energizing.
All tests as per IS: 335 shall be conducted on all samples.
(b) The insulating oil shall be subjected to testing in the oil manufacturer‘s works before supply
in the presence of the representative of the transformer manufacturer.
(c) Sufficient quantity of oil necessary for first filling of all tanks, coolers and radiator at the
proper level along with 10% extra oil by weight for topping up shall be supplied in on-
returnable containers suitable for outdoor storage.
(d) Power Transformers shall be supplied with oil.
(e) The parameter of the EHV Grade I transformer oil should confirm the values given in
schedule-I Sl. No. 56.
(f) The bidder shall warrant that characteristic of oil furnished shall comply with the
requirements specified in IS-335, 1993 (Fourth Revision) with latest amendment/revision and
shall be suitable for EHV grade transformers.
5.6.1 Oil preservation equipment:
a) For 245 KV class transformers bidder shall offer silica gel breather type oil sealing in
conservator to prevent oxidation and contamination of oil due to contact with water in this
type of oil preservation system conservator shall be fitted with a dehydrating filter breather.
It shall be so designed that:

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CSPTCL TR-20/05 220/132/33 KV S/S Daldalseoni & Assoc.Line

i) Passage of air is through a dust filter and silicagel.

ii) Silicagel is isolated from atmosphere by an oil seal.
iii) Moisture absorption indicated by a change in colour of the tinted crystals can be easily
observed from a distance.
iv) Breather is mounted not more than 1400 mm above rail top level.
b) On line DGA Monitoring device: One Number 5 Gas Online DGA monitoring device +
moisture should be provided on the transformer which should be capable of measuring
following key gases and moisture content individually (Not composite) found in the
transformer oil.
(i) Hydrogen (H2) (iv) Ethylene (C2H4)
(ii) Carbon mono oxide (CO) (v) Methane (CH4)
(iii) Acetylene (C2H2)
The online DGA monitor should be microprocessor based IED alongwith the required
interface software in CD-ROM one with each unit. The device should have capacity to
internally store minimum two years of Data. It should have non volatile memory storage to
prevent loss of data.
The device should have following communication facilities:-
(i) Two separate channels for remote communications plus local USB connection and Ethernet
connections.
Communications protocols supported should include MODBUS, MODBUS/ TCP, DNP3.0,
IEC61850.
Modules available for connection via RS232, RS485, Ethernet, PSTN modern /GSM or
CDMA wireless modems/ IEC61850 compliant latest communication module.
The make and model of on line DGA monitoring device shall be subject to approval of
CSPTCL. The bidder shall submit the details of the device like make, model No., the name of
gases which are detected, the location of fitting in the transformer with the schematic
drawings.
5.7 TERMINAL ARRANGEMENTS:
5.7.1 Bushings:
The bushings of CSPTCL‘s approved make shall be manufactured tested and supplied with
guaranteed particulars generally conforming to the latest issue of the following Standard
Specifications:
i) IS-2099 Bushings for alternating voltage above 1000V
ii) IEC 60137 Bushings for alternating voltage above 1000V
iii) IS 3347 (Part I Dimensions of porcelain transformer bushings for use in lightly
to VIII) polluted atmospheres.
iv) IEC 60233 Tests on hollow insulators
v) IS 2544 Specification for porcelain insulator for voltages above 1000 volts.
vi) IS 5621 Hollow insulators
Oil impregnated paper insulated condenser type bushing shall be provided for 245 KV, 170
KV and 72.5 KV class with the following specifications.
These bushings shall be outdoor immersed self-contained draw-through lead or rod type, with
oil filling. The active part of bushing shall consist of a condenser body built up around a
centre tube using high quality kraft insulating paper. The paper craft shall be wound over the
centre tube with pure aluminium foils inserted at pre designed locations to get optimum
combination of external flashover and internal puncture strength.
The condenser body shall be enclosed in weather resistant housing consisting of a top
expansion chamber, upper porcelain, a welded flange – ground sleeve assembly, lower
porcelain and a bottom cap. The annular space between the condenser body and the housing
shall be filled with Grade-I transformer oil. An assembly located in the top housing hold all
the gasket and O ring between porcelain and metal parts thereby completely sealing the
bushing. An oil site window shall be provided on the expansion chamber for observing the oil
level. The space in the expansion chamber above oil shall be filled with dry Nitrogen gas.
Brown glazed porcelain insulators of high strength are used as air end and oil end insulators.
Air end porcelain shall normally be provided with total nominal creepage length 25 mm/KV
of the rated voltage unless otherwise specified. Oil end porcelain shall be cone shaped without
shed. Air end porcelain shall be provided with long and short sheds(aerodynamic shed
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CSPTCL TR-20/05 220/132/33 KV S/S Daldalseoni & Assoc.Line

profile).Porcelain used in bushing manufacture shall be homogenous, free from lamination,

cavities and other flaws or imperfections that might affect the mechanical or dielectric quality
and shall be thoroughly vitrified, tough and impervious to moisture. Bushings shall be
manufactured from high quality porcelain.
Glazing of the porcelain shall be uniform brown in colour, free from blisters, burrs and
similar other defects.
Bushings hollow column insulators shall be designed to have ample insulation,
mechanical strength and rigidity for the conditions under which they will be used. The hollow
column insulator shall be of reputed make and subject to the approval of CSPTCL. Bushing
porcelain shall be robust and capable of withstanding the internal pressures likely to occur in
service. The design and location of clamps and the shape and the strength of the porcelain
flange securing the bushing to the tank shall be such that there is no risk of fracture. All
portions of the assembled porcelain enclosures and supports other than gaskets, which may in
any way be exposed to the atmosphere shall be composed of completely non hygroscopic
material such as metal or glazed porcelain.
When operating at normal rated voltage there shall be no electric
discharge between the conductors and bushing which would cause corrosion or injury to
conductors, insulators or supports by the formation of substances produced by chemical
action. No radio interference shall be caused by the insulators bushings when operating at the
normal rated voltage.
All iron parts shall be hot dip galvanised and all joints shall be air tight. Galvanized
bolts and nuts shall be used as fasteners. Surface of joints shall be trued up porcelain parts by
grinding and metal parts by machining. Bushing design shall be such as to ensure a uniform
compressive pressure on the joints.
After assembly, the bushings shall be dried out at a very high vacuum pressure. These shall
then be impregnated with transformer oil. Oil impregnation shall be carried out under
pressure. The oil level in bushing shall then be adjusted and the bushings shall be sealed
subsequently.
For the bushings of rated voltage 245 KV, stress relieving shield shall be provided on the
lower cap. The shield shall consist of an aluminium shroud insulated in kraft paper and press
board moulding. The maximum stress in oil and the surface of these shield insulation must be
limited to those values normal for insulated conductors and similar components in the same
transformer.
The draw lead or draw rod connecting the top terminal will be supplied along with bushing.
The complete joint connector shall be provided with the draw lead and the free connector
shall be suitable for brazing the lead from the connecting improvement in the case of draw
rod the free end shall form the connector. For the air side connection, rod type terminal shall
be provided.
The bushing shall be provided with an insulation test tap suitable for measuring bushing
power factor (dissipation factor) and capacitance by ungrounded specimen test method. The
cover of this tap should be removed from the tap attachment only for testing purpose.
Normally the tap shall be grounded through the cover and the bushing shall not be operated
with cover remove.
Tests:
Bushings shall conform to type tests and shall be subjected to routine tests in accordance with
IS: 2099, IEC 60137, IS: 2544 & IS: 5621. The following type test reports of the offered
bushings shall have to be submitted for approval.
Wet power frequency voltage withstand test.
Dry lighting impulse voltage withstand test.
Dry or wet switching impulse voltage withstand test.
Thermal stability test.
Temperature rise test.
Thermal short time current withstand test.
Dynamic current withstand test.
Cantilever load withstand test.
Tightness test on liquid filled and liquid insulated bushings.

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The dielectric tan delta value shall not be more than 0.005.The insulation resistance of the
bushing shall not be less than 20 G ohm. The partial discharge of the bushing shall not be
more than 10 pC.
5.7.2 Terminal connectors:
a) Bushing terminals shall be provided with terminal connectors of approved type and size for
connection to external parts. Terminal connectors must have been successfully type tested
strictly as per IS:5561. The drawing of terminal connector offered shall have to be got
approved by CSPTCL.
b) i) All connections with ACSR zebra conductors shall be bolted type.
ii) Connectors shall consist of two parts. The part connecting bushing stud shall be of
copper and that towards conductor shall be of Aluminium. The copper part shall be
electrolytic grade copper forged and silver plated/ tinned for 10 Microns.
No part of a clamp shall be less than 15 mm thick. Minimum conductor coverage on the
clamp shall be 100mm. Minimum bushing terminal coverage in the clamp shall be 100mm
and minimum pad overlap in the clamp shall be 100*100 mm.
GI nuts, bolts and washers shall be used. Nuts and bolts shall have hexagonal head with
threads as per IS and shall be fully threaded type. Also instead of spring washers check/ lock
nuts shall be provided.
The connectors shall be designed for minimum 120% of the maximum current carrying
capacity of the ACSR zebra conductor and the temperature rise under these conditions shall
not be more than 50% of that of the main conductor. The terminal connector of 132KV side
should be suitable for twin zebra conductor.
Terminal connector shall be suitable for Zebra ACSR conductors. Clamps shall be designed
adequately to take care of any bimetallic effect. The temperature at the clamp shall not exceed
80°C. The bushing side of connector shall be of copper and conductor side shall be of
aluminium.
The terminal connectors shall also meet the following requirements:
Terminal connector shall be tested for short circuit current capability test, temperature rise
test, corona test etc. The drawing of terminal connector offered shall have to be got approved
by CSPTCL
All castings shall be free from blow holes, surface blisters, cracks and cavities. All sharp
edges and corners shall be blurred and rounded off.
The nut, bolts & washers used in current carrying path shall be hot dip galvanized.
For bimetallic connectors, copper alloy liner of minimum thickness of 4 mm shall be integral
with aluminium body.
Flexible connectors shall be made from tinned copper sheets.
All current carrying parts shall be designed and manufactured to have minimum contact
resistance.
5.7.3 Bushing Current Transformer:
Current transformers shall comply with IS: 2705. Bushing current transformers of adequate
ratio are to be provided in HV, IV & neutral bushings for restricted earth fault protection.
Two cores (of PS class) shall be provided for each Bushing CT for REF protection.
One core each shall be provided on middle phase of HV, IV and LV Bushing for WTI.
Further, 33KV CT as per clause 5.5.1(f) shall also be provided in one phase of tertiary.
It shall be possible to remove turret mounted CTs from the transformer tank without
removing the tank cover. Necessary precautions shall be taken to minimize the eddy currents
and local heat generated in the turret.
All secondary leads shall be brought to a terminal box near each bushing. These terminals
shall be wired out to cooler Control Cabinet using separate cables for each core. The terminal
shall be stud type of adequate size.
Bushing CT parameters indicated in the specification are tentative and liable to change within
reasonable limits. The bidder shall obtain Purchaser‘s approval before proceeding with design
of Bushing CTs.
5.7.4 Terminal marking:
The terminal marking and their physical position shall be in accordance with IS:2026 unless
otherwise specified.
5.8 Neutral earthing arrangement:

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CSPTCL TR-20/05 220/132/33 KV S/S Daldalseoni & Assoc.Line

(a) The neutral terminals of the star connected windings shall be brought to the ground level by a
copper grounding bar (of adequate size) which shall be supported from the tank by porcelain
insulators of highest system voltage of 36 kV.
(b) The lend of the copper bar shall be brought to the ground level, at a convenient point, for
connection to ground network through two (2) Zebra conductors. The connection shall be
made by using suitable clamp with necessary accessories.
(c) Suitable flexible copper strip connection of adequate size shall be provided for connecting to
Neutral Bushing terminals to avoid terminal load on the Bushings.
5.9 Auxiliary power supply for OLTC, Cooler control and power circuit:
5.9.1 Auxiliary Power Supplies, shall be as indicated in clause 3.0 provided by CSPTCL at any one
place for OLTC Control and Cooler Control and Cooler Control. The DC operated contactors
coils & push buttons should be suitable for control voltages of 220 volt.
5.9.2 All loads shall be fed by one of the two feeders through an electrically interlocked automatic
transfer switch housed any one of the local control cabinets for tap changer control and cooler
circuits.
5.9.3 Design features of the transfer switch shall include the following:
i) Provision for the selection of one of the feeders as normal source and other as
standby.
ii) Upon failure of the normal source, the loads shall be automatically transferred after
an adjustable time delay to the standby source.
iii) Indication for failure of normal source and for transfer to stand by source and also for
failure to transfer shall be provided locally as well as in remote panel.
iv) Both the transfer and the re-transfer shall be dead transfers and AC feeders shall not
be paralleled at any time.
v) Necessary isolating switches, MCBs and other components for the above power
supply of the bidder.
5.9.4 Tap changing equipment: TAPS IN OLTC:
In 160 MVA 3 phase transformer the OLTC is to be provided on IV winding (i.e. 132 KV)
with tap range of -10% to +10% in steps of 1.25%.
(i) Tap change Switch (General Requirement):
The on load tap changer shall be provided on IV for IV variation as specified at Sr.
No. 10 of clause 4.0.
OLTC gear shall be motor operated for local as well as remote operation. An external hand-
wheel/handle shall be provided for local manual operation.
Arrangement shall be made for securing and padlocking the tap changer wheel in any of the
working positions and it shall not be possible for setting or padlocking the wheel in any
intermediate position. The arrangement shall be such that no padlock key can be inserted
unless all contacts are correctly engaged and switch set in a position where no open or short
circuit is possible. An indicating device shall be provided to show the tap in use.
On Load Tap Changing Gear (OLTC):
The details of the method of diversion of the load current during tap changing; the mechanical
construction of the gear and the control features for OLTC gear shall be submitted with the
bid. Information regarding the service experience on the gear and a list of important users
shall be furnished. The tap changer shall change the effective transformation ratio without
producing phase displacement.
The current diverting contacts shall be housed in a separate oil chamber not communicating
with the oil in main tank of the transformer
The contacts shall be accessible for inspection without lowering oil level in the main tank and
the contact tips shall be replaceable.
The bidder shall indicate the safeguards in order to avoid harmful arcing at the current
diverting contacts in the event of operation of the OLTC gear under over load conditions of
the transformer. Necessary tools and tackles shall be furnished for maintenance of OLTC
gear.
The OLTC oil chamber shall have oil filling and drain plug, oil sampling valve, relief vent
and level glass. It shall also be fitted with surge relay the outlet of which shall be connected to
a separate conservator tank.

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The diverter switch or arcing switch shall be so designed as to ensure that its operation once
commenced shall be completed independently of the control relays or switches, failure of
auxiliary supplies etc.
Drive mechanism chamber shall be mounted on the tank in accessible position. It should be
adequately ventilated and provided with anti-condensation metal clad heaters. All contactors,
relay coils and other parts shall be protected against corrosion, deterioration due to
condensation, fungi etc.
Each transformer unit shall be provided with a local control cabinet and a remote OLTC
control panel. The control feature shall provide following:
Local-remote selector switch mounted in the local control cubicle shall switch control of
OLTC in the following manner: When the selector switch is in LOCAL position, it shall be
possible to operate the RAISE LOWER control switches specified in section (ii) below.
Remote control of RAISE-LOWER functions shall be prevented.
When the selector switch is in REMOTE the local control cubicle mounted RAISE LOWER
Switches specified in Section (ii) shall be inoperative. Remote control of the raise lower
function shall be possible from the remote control panel. The LOCAL-REMOTE selector
switch shall have at least two spare contacts per position which are closed in that position but
open in the other position.
Operating mechanism for on load tap changer shall be designed to go through one step or tap
change per command. Subsequent tap change shall be initiated only by a new or repeat
command.
On load tap changer shall be equipped with a time delay for ―INCOMPLETE STEP‖ in alarm
consisting of a normally open contact which, closes, if the tap changer fails to make a
complete tap change. The alarm shall not operate for momentary loss of auxiliary power.
The selsyn units or approved equivalents shall be installed in the local OLTC control cabinet
to provide tap position indication for the transformer.
The OLTC load tap changer shall be equipped with a fixed resistor network capable of
providing discrete voltage steps for input to the supervisory system.
Limit switches shall be provided to prevent overrunning of the mechanism and shall be
directly connected in the circuit of the operating motor. In addition, a mechanical stop shall be
provided to prevent over-running of the mechanism under any condition. Limit switches may
be connected in the control circuit of the operating motor provided that a mechanical-
declutching mechanism is incorporated.
Thermal device or other means shall be provided to protect the motor and control circuit. All
relays, switches, MCBS etc. shall be mounted in the drive mechanism chamber and shall be
clearly marked for the purpose of identification.
A permanently legible lubrication chart shall be fitted within the driving mechanism chamber.
A five digit counter shall be fitted to the tap changing equipment to indicate the number of
operations completed.
All relays and operating devices shall operate correctly at any voltage between the limits
specified.
It shall not be possible to operate the electric drive when the manual operating gear is in use.
It shall not be possible for any two controls to (i.e. manual, local electrical and remote) be in
operation at the same time.
The equipment shall be suitable for supervisory control and indication with make before
break multi-way switch, having one potential free contact for each tap position. This switch
shall be provided in addition to any other switch/switches which may be required for remote
tap position.
All electrical control switches and the local operating gear shall be clearly labeled in a
suitable manner to indicate the direction of tap changing.
Manual control:
The cranking device for manual operation of the OLTC gear shall be removable and suitable
for operation by a man standing on ground level. The mechanism shall be complete with the
following:
(i) Mechanical tap position indicator which shall be clearly visible from near the transformer.
(ii) A mechanical operation counter.

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(iii) Mechanical stops to prevent over-cranking of the mechanism beyond the extreme tap
positions.
(iv) The manual control considered as back up to the motor operated load tap changer control
shall be interlocked with the motor to block motor-start-up during manual operation. The
manual operating mechanism shall be labeled to show the direction of operation for raising
the primary and vice-versa.
5.9.6 Electrical control:
This includes the following:
(i) Local Electrical control
(ii) Electrical remote control from remote control panel.
(iii) Remote Electrical Group Control
The OLTC control scheme offered shall have provision of remote electrical group control
during parallel operation of transformers. This is in addition to independent control of OLTC.
A four position selector switch having MASTER, FOLLOWER, INDEPENDENT and OFF
position shall be provided in the remote OLTC control panel for each transformer. This shall
be wired to enable operator to select operation of OLTC in either Master, Follower or
Independent mode.
(ii) Out of step relays with timer contacts shall also be provided to give alarm and indication in
case of tap positions in all the transformers under group control being not in identical
position.
(iii) Master Position - If the selector switch is in MASTER position, it shall be possible to control
the OLTC units in the FOLLOWER mode by operating the controls of the MASTER unit
Independent operation of the units under FOLLOWER mode shall have to be prevented.
However, the units under independent mode will be controlled independently.
(iv) Follower position - If the selector switch is in FOLLOWER mode, control of OLTC shall be
possible only from MASTER penal.
(v) Independent Position - In this position of Selector Switch, Control of OLTC of individual unit
only shall be possible.
5.10 Cooling Equipment and its controls
5.10.1 Cooling Equipment
Cooler shall be designed using 2x50 % radiators.
Each radiator bank shall have its own cooling fans, shut off valves, lifting lugs, top and
bottom oil filling valves, air release plug, a drain valve and thermometer pocket fitted with
captive screw cap on the inlet and outlet.
One standby fan for each group shall also be provided and identified with each radiator bank.
Cooling fans shall not be directly mounted on radiator bank which may cause undue
vibration.
The exhaust airflow from cooling fan shall not be directed towards the main tank in any case.
Cooling fans for each radiator bank shall be located so as to prevent ingress of rain water.
Each fan shall be suitably protected by galvanised wire guard.
Cooling fans motors shall be suitable for operation from 415 volts, three phase 50 Hz power
supply and shall conform to IS: 325.
The cooler and its accessories shall be hot painted with corrosion resistant paint.
Each cooling fan motor shall be provided with starter, thermal overload and short circuit
protection.
Each radiator shall be provided with:
One shut off valve at the top (minimum 80 mm size) .
One shut-off valve at the bottom (minimum 80 mm size) .
Air release device at the top.
Main & sampling device at the bottom.
Lifting lugs.
Air release device and oil plug on oil pipe connections.
5.10.2 Cooling Equipment Control (ONAN/ONAF COOLING)
(a) Automatic operation control (switching in and out) of fans shall be provided (with
temperature change) from contacts of winding temperature indicator. The bidder shall
recommend the setting of WTI for automatic change over of cooler control from

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ONAN to ONAF. The setting shall be such that hunting i.e. frequent start stop
operations for small temperature differential do not occur.
(b) Suitable manual control facility for cooler fans with manual/ automatic selector
switches and push buttons shall be provided.
5.10.3 Remote OLTC/Cooler control Panel (RTCC Panel)
The auxiliary devices for remote electrical control of the OLTC and Cooler shall be housed in
a separate panel to be placed in the Control room. The panel shall be made of sheet steel of
not less than 14 SWG and it shall be duly finished with stove enamel paint. The size and of
the control cubicle to be supplied by the bidder shall be 750 mm depth and 2312 mm height
and colour opaline green shade no. 275 of B.S.271-C: 1948, respectively. The width of the
cubicle to be as per bidders‘ practice. Control and signal devices required to be mounted in
the RTCC Panel shall comprise of the following.
1. Local - Remote selector switch for OLTC .
2. Actuating switch/push; button for electrical raise/lower control.
3. Remote tap position indicator with tap number and corresponding; rated voltage marked on
the; instrument. The tap position indicators shall be digital type.
4. A four position selector switch having master follower, independent and off position.
5. Repeater dial of transformer winding temperature indicator.
6. Name plate for each component.
7. Initiating devices and contacts for alarm as well as for indications for discordance in the tap
changer if any of the parallel operating transformer.
8. Cubicle lamp actuated by door, switch, space heater power sockets etc. shall be provided
inside RTCC panel.
9. Annunciator (facia type) Scheme complete with accessories for the following:
(i) Tap changer out of step.
(ii) Tap changer motor trip.
(iii) Failure of AC supply to the OLTC local control Kiosk.
(iv) Fan failure of each group.
(i) Control supplies failure main and standby.
(ii) Cooler supply failure for each supply.
(vii) Two spare windows
(viii) OLTC at extreme positions i.e. lowest or highest tap.
10. Signal lamps for:
(i) Fan ‗ON‘ for each group.
(ii) Standby fan ‗ON‘ for each group.
(iii) Cooling system on manual.
(iv) Cooling system on automatic control.
(v) 415 volts cooler supply auto change over.
(vi) Healthy supply to control gear.
(vii) Tap change in progress.
11. Emergency stop push button will be provided in local control cubicle as well as on remote tap
changer control cubicle panel.
12. 3 No. digital volt meter of 0.5 Accuracy Class (1 for HV , IV& LV) with selector switch
should be provided. HRC cartridge fuse shall be provided for HV , IV& LV PT secondary
voltage.
13. One No. Ammeter of 0.5 accuracy class for delta winding circulating current ( digital).
14. Control & monitoring of RTCC shall be integrated in Sub-station Automation System.
Separate Bay control Unit shall be provided for this.
5.10.4 Cooler control cabinet:
(i) Each transformer unit shall be provided with a cooler control cabinet.
(ii) The cooler control cabinet shall have all necessary devices meant for cooler control
and local temp. indicators. All the contacts of various protective devices mounted on
the transformer shall also be wired up to the terminal board in the cooler control
cabinet. All the secondary terminals of the bushing CT‘s shall also be wired upto the
terminal board at the cooler control cabinet.
(iii) The cooler control cabinet shall have two (2) sections. One section shall have the
control equipment exclusively meant for cooler control. The other section shall house

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the temperature indicators, aux. CT‘s and the terminal boards meant for termination
of various alarm and trip contacts as well as various alarm and trip contacts as well as
various bushing CT secondaries. Alternatively the two sections may be provided as
two separate panels depending on the standard practices of the supplier.
The temperature indicators shall be so mounted that the dials are not more than 1600 mm
from ground level. Glazed door of suitable size shall be provided for convenience of reading.
Control & monitoring of Cooler Control shall be integrated in Sub-station Automation
System. Separate Bay control Unit shall be provided for this.

Nitrogen injection fire prevention system:

Each oil filled transformer shall be provided with a dedicated Nitrogen Injection system for
prevention against the transformer explosion which shall use nitrogen as quenching medium.
The system shall prevent transformer oil tank explosion and possible fire in case of internal /
external cause.
In the event of fire by external causes such as bushing fire, OLTC fires, fire from surrounding
equipment etc., it shall act as a fast and effective fire fighter. It shall accomplish its role as fire
preventer and extinguisher without employing water or carbon dioxide. Fire shall be
extinguished within reasonable with time (not more than 3 minutes so as not to harm the
transformer) of system activation and within 30 seconds (maximum) of commencement of
nitrogen injection.
Activation of the system
Mal-functioning of the Nitrogen injection system could lead to interruption in power supply.
The supplier shall ensure that the probabilities of chances of malfunctioning of the Nitrogen
injection system are practically zero. To achieve this objective, the supplier shall plan out
scheme of activating signals which should not be too complicated to make the system
inoperative in case of actual need. The system shall be provided with automatic controls to
prevent the explosion of transformers. Besides automatic control, remote electrical push
button control at Control box and local manual control in the cubicle shall also be provided.
Simultaneous activation of the following electrical-signals shall be used for initiating the
system under prevention mode/fire extinguishing mode.
Auto Mode
For prevention:
• Differential relay operation.
• Buchholz relay paralleled with pressure relief valve
• Tripping of all circuit breakers (on HV & LV/IV side) associated transformer is the pre-
requisite for activation of system.
For extinguishing
• Fire Detector
• Buchholz relay paralleled with pressure relief valve
Tripping of all circuit breakers (on HV & LV/IV side) associated with transformer is the pre-
requisite for activation of system.
Manual Mode (Local / Remote)
Tripping of all circuit breakers (on HV & LV / IV side) associated with transformer is the pre-
requisite for activation of system.
Manual Mode (Mechanical)
• Tripping of all circuit breakers (on HV & LV / IV side) associated with transformer is the
pre-requisite for activation of system.
The system shall be designed to be operated manually in case of failure of power supply to
the system.
General description
Nitrogen Injection system should be a dedicated system for each oil filled transformer. It
should have a Fire Extinguishing Cubicle (FEC) placed on a plinth at a distance of 5-10 m
away from transformer or placed next to the firewall (if fire fighting wall exists). The FEC
shall be connected to the top of transformer oil tank for depressurization of tank and to the oil
pit (capacity is approximately equal to 10% of total volume of oil in transformer tank / or
existing oil pit) from its bottom through oil pipes.

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The FEC should house a pressurized nitrogen cylinder (s) which is connected to the oil tank
of transformer oil tank at bottom. The Transformer Conservator Isolation Valve (TCIV) is
fitted between the conservator tank and Buchholz relay. Cable connections are to be provided
from signal box to the control box in the control room, from control box to FEC and from
TCIV to signal box. Detectors placed on the top of transformer tank are to be connected in
parallel to the signal box by Fire survival cables. Control box is also to be connected to relay
panel in control room for receiving system activation signals.
Operation
On receipt of all activating signals, the system shall drain - pre-determined volume of hot oil
from the top of tank (i.e. top oil layer), through outlet valve, to reduce tank pressure by
removing top oil and simultaneously injecting nitrogen gas at high pressure for stirring the oil
at pre-fixed rate and thus bringing the temperature of top oil layer down. Transformer
conservator isolation valve blocks the flow of oil from conservator tank in case of tank
rupture / explosion or bushing bursting. Nitrogen occupies the space created by oil drained
out and acts as an insulating layer over oil in the tank and thus preventing aggravation of fire.

System components
Nitrogen Injection system shall broadly consist of the following components. However, all
other components which are necessary for fast reliable and effective working of the system
shall deemed to be included in the scope of supply.

MS Storage tank for storage of extracted oil

The MS storage tank of cylindrical shape should be provided for storage of extracted oil. The
capacity of tank should be minimum 12% of total oil capacity of transformer.
The MS storage tank should have facility of oil filtration in side the tank. For this 2 No.
flanges (one for delivery and the other for suction) should be provided. The suction flange
should be connected to the bottom of the tank. The storage tank should be made of 8 mm
thick plat. The inner side of the tank shall be painted with 2 coats of heat resistant, oil
insoluble, insulating varnish. The outer surface shall be given a primary coat of zinc
chromate, second coat of oil & weather resistant varnish of a colour distinct from primary and
final two coats of glossy oil and weather resisting light grey paint in accordance with shade
No. 631 of IS-5. Adequate size of inspection window should be provided so that tank can be
cleaned by manual labour. A vent pipe of adequate diameter shall be provided a breather
fitted on it in order to allow breathing of air.

CUBICLE (FEC)
The Cubicle Frame shall be made of CRCA sheet of 3 mm (minimum) thick complete with
the base frame, painted inside and outside with post office red colour (shade 538 of IS -5). It
shall have hugged / hinged split doors fitted with high quality tamper proof lock. The doors,
removable covers and panels shall be gasketted all round with neoprene gaskets. The degree
of protection shall be IP55. The following items shall be provided in the Cubicle.
• Nitrogen gas cylinder with regulator and falling pressure electrical contact
manometer.
• Oil drain pipe with mechanical quick drain valve.
• Electro mechanical control equipment for draining of oil of pre-determined volume
and injecting regulated volume of nitrogen gas.
• Pressure monitoring switch for back-up protection for nitrogen release.
• Limit switches for monitoring of the system. Limit switch for pressure switch/sensor
• Butterfly valve with flanges on the top of panel for connecting oil drain pipe and
nitrogen injection pipes for transformer.
• Panel lighting (CFL Type)
• Oil drain pipe extension of suitable sizes for connecting pipes to oil storage tank.
• Space heater.
Control box:
Control box is to be placed in the control room for monitoring system operation, automatic
control and remote operation. The following alarms, indications, switches, push buttons,
audio signal etc. shall be provided.

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• System Oil.
• TCIV open.
• Oil drain valve closed.
• Gas inlet valve closed
• TCIV closed
• Detector trip
• Buchholz relay trip
• Oil drain valve open
• Extinction in progress
• Cylinder pressure low
• Differential relay trip
• PRV trip
• Transformer trip
• System out of service
• Fault in cable connecting fault detector
• Fault in cable connecting differential relay
• Fault in cable connecting Buchholz relay
• Fault in cable connecting PRV
• Fault in cable connecting transformer trip
• Fault in cable connecting TCIV
• Auto / Manual / Off
• Extinction release on / off
• Lamp test
• Visual / Audio alarm for AC supply fail
• Visual / Audio alarm for DC supply fail
• Nitrogen cylinder pressure indication.
• Fire in Transformer.
• Oil drain started.
• Conservator oil isolation valve closed.
• Nitrogen injection started.

As far as possible the control box should be such devised that all the transformers and or
group thereof should be controlled from single spot.
The control box shall have one IEC 61850 compliant IED (BCU) of GE/Alstom/ ABB/
Siemens/SEL make, wherein operation of all the major components of NIFPS shall be logged
in as time tagged events for analysis and evaluation of operation of NIFPS.
This IED shall be a separate state of art Numerical Bay Control Unit dedicated for the
purpose having at least 20 % spare input and 20% spare output contacts over and above the
used contacts. This IED (BCU) shall have freely configurable input and output contacts. The
BCU shall also have Ethernet/RJ ports for achieving redundancy in Ethernet switch
connection. The IED (BCU) shall have self monitoring feature and shall have event logger,
disturbance Recorder and on initiation of event, it shall automatically be downloaded at the
workstation of substation.
The IED (BCU) shall have IRIG –B port for GPS time synchronizing.
Transformer Conservator Isolation Valve:
Transformer conservator isolation valve (TCIV) to be fitted in the conservator pipe line,
between conservator and buchholz relay which shall operate for isolating the conservator
during abnormal flow of oil due to rupture / explosion of tank or bursting of bushing. The
valve shall not isolate conservator during normal flow of oil during filtration or filling or
refilling, locking plates to be provided with handle for pad locking. It shall have proximity
switch for remote alarm, indication with visual position indicator. The TCIV should be of the
best quality as malfunctioning of TCIV could lead to serious consequence. The closing of
TCIV means stoppage of breathing of transformer. Locking plates shall be provided for pad
locking.
Detectors:
The system shall be complete with minimum twenty number of detectors (quartz bulb) fitted
on the top cover of the transformer oil tank. The bulbs should be provided to ensure

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monitoring of all the HV, IV, LV & neutral bushings. Redundancy of detectors should be
ensured & clearly brought in the drawing submitted for approval.

Signal box:
It shall be mounted away from transformer main tank, preferably near the transformer
marshalling box, for terminating cable connections from TCIV & detectors and for further
connection to the control box. The degree of protection shall be IP55.
Cables:
Fire survival cables (capable to withstand 750º C.) of 4 core x 1.5 sq. mm size for connection
of detectors in parallel shall be used. The fire survival cable shall conform to BS 7629-1, BS
8434-1, BS 7629-1 and BS 5839-1, BS EN 50267-2-1 or relevant Indian standards.
Fire Retardant Low Smoke (FRLS) cable of adequate size shall be used for connection of
signal box / marshalling box near transformer and FEC mounted near transformer with
control box mounted in control room. Fire Retardant Low Smoke (FRLS) cable of 4 core x
1.5 sq. mm size shall be used for connection between control box to DC & AC supply source,
FEC to AC supply source, signal box / marshalling box to transformer conservator isolation
valve connection on transformer. Separate cables for AC supply & DC supply shall be used.
Pipes:
Pipes complete with connections, flanges, bends and tees etc. shall be supplied along with the
system.
Other items to be supplied:
(a) Oil drain and nitrogen injection openings with gate valves on transformer tank at suitable
locations.
(b) Flanges between Buchholz relay and conservator tank for fixing TCIV.
(c) Detector brackets on transformer tank top cover.
(d) Spare potential free contacts activating the system i.e. in differential relay, Bucholz relay.
Pressure Relief Device, Circuit breaker of transformer.
(e) Pipe connections between transformer and FEC and between FEC and oil pit required for
collecting top oil.
(f) Cabling for detectors mounted on transformer top cover.
(g) Inter cabling between signal box, control box and FEC.
(h) Butterfly valves / Gate valves on oil drain pipe and nitrogen injection pipe which should be
able to withstand full vacuum.
(i) Supports, signal box etc. which are to be painted with enameled paint.
(j) Any other item required for satisfactory operation of system.

Power supply
For Control Box 220 V DC
For FEC Auxiliary 230 V AC
Spares for three (3) years Operation & Maintenance
The bidder apart from the below mentioned spares shall submit a list of recommendation
spares for three years trouble free operation of the equipments and also furnish unit rates. The
owners will scrutinize the said list and decide on the items on spares to be ordered and the
quantities. These spares shall be supplied by the bidder before end of guarantee period. The
owner reserves right to order the spares with twelve (12) months from the date of order for
main equipments and the rate shall be kept valid till this date. The prices of these spares shall
not be considered for evaluation of the bid.
Mandatory Spares
Cylinder filled with Nitrogen of required Capacity per transformer - 1 No.
Detectors per transformer 3 no.
Regulator assembly per sub-station 1 No.
Modification on the transformer
No modification on the transformer shall be allowed which affects its performance (i.e.
efficiency, losses, heat dissipation ability etc.) safety, life etc. or it‘s any other useful
parameter. This requirement shall be paramount importance and shall form the essence of the
contract. However, in any case, performance of transformer should not be affected in any
manner by having Nitrogen Injection Fire Prevention Cum Extinguishing System (NIFPS)

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and the Bidder / Sub-vendor shall give an undertaking to this effect. All pipes should be
washed / rinsed with transformer oil. If any damage is done to the transformer and / or any
connected equipment during installation & commissioning full recovery therefore shall be
effected from the Bidder /Sub-vendor, of NIFPS system.
It shall be solely the responsibility of bidder / Sub-vendor to install, carry out pre-
commissioning tests & commission NIFPS at the mentioned Sub-Station in this specification,
to the entire satisfaction of the CSPTCL.
Interlocks:
It shall be ensured that once the NIFPES gets activated manually or in automode, all the
connected breakers shall not close until the system is actually put in OFF mode. Also PRV
shall get closed only if all the connected breakers are open.
Tests:
Bidder has to carry out the type test as per relevant IS/IEC. Specifically IP 55 on FEC or have
to produce the report from NABL approved Lab. Reports of all routine test conducted as per
relevant IS/IEC standards in respect of various bought out items including test reports for
degree of protection for FEC / control box / signal box shall be submitted by the supplier.
The supplier shall demonstrate all the functional test associated with the following as Factory
Acceptance Tests:
• FEC, Control Box
• Fire Detector
• Transformer Conservator Isolation Valve
The performance test of the complete system shall be carried out after erection of the system
with transformer at site. Detailed layout drawings, equipment drawing along with 4 sets of
Operation and Maintenance manual along with soft copies (In CDs) shall be submitted by the
supplier along with the consignment. The guaranteed and other technical particulars for the
offered system are indicated in Section - "Guaranteed and Other Technical Particulars". Any
other particulars considered necessary in addition to those listed in that Section may be
furnished by the Bidder.
Terminal Block:
(i) The terminal blocks to be provided shall be fully enclosed with removable covers and made
of moulded, non inflammable plastic material with block and block and barriers moulded
integrally. Such block shall have washer and binding screws for external circuit wire
connections, a white marking strip for circuit identification and molded plastic cove. All
terminals shall be clearly marked with identification numbers or letters to facilitate
connection to external wiring.Stud type terminal connectors shall be provided.
(ii) All internal wiring to be connected to the external equipment shall terminate on terminal
bocks, preferably vertically mounted on the side of each panel. The terminal blocks shall be
1100 V grade and have 10 amps continuous rating, molded piece, complete with insulated
barriers, non-disconnecting stud type terminals, washers, nuts and lock nuts. Terminal block
design shall include a white fiber-marking strip with clear plastic, slip-on / clip-on terminal
cover. Markings on the terminal strips shall correspond to wire number and terminal numbers
on the wiring diagrams.
(iii) Terminal blocks for current transformer secondary leads shall be provided with test links and
isolating facilities Also current transformer secondary leads shall be provided with short-
circuiting and earthing facilities.
(iv) At least 20% spare terminals shall be provided on each panel and these spare terminals shall
be uniformly distributed on all terminal blocks.
(v) Unless otherwise specified, stud type terminal blocks shall be suitable for connecting the
following conductors on each side.
(a) For all circuits except current transformer circuits minimum of two nos. 2.5 mm2
copper.
(b) For all CT circuits minimum of two nos. 4 mm2 copper.
(vi) There shall be a minimum edge to edge clearance of 250 mm between the first row of
terminal block and the associated cable gland plate. Also the clearance between two rows of
terminal blocks shall be minimum of 150 mm.
(vii) Arrangement of the terminal block assemblies and the wiring channel within the enclosure
shall be such that a row of terminal blocks is run parallel and in close proximity along each

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side of the wiring duct to provide for convenient attachment of internal panel wiring. All
adjacent terminal block shall also share this field wiring corridor. A steel strip shall be
connected between adjacent terminal block rows at 450 mm intervals for support of incoming
cable.
5.12 Painting:
The internal and external surfaces including oil filled chamber and structural steel work to be
painted shall be shot or sand blasted to remove all rust and scale or foreign adhering matter or
grease. All steel surfaces in contact with insulating oil shall be painted with two coats of heat
resistant, oil insoluble, insulating varnish. All steel surfaces exposed to weather shall be given
a primary coat of zinc chromate, second coat of oil and weather resistant varnish of a colour
distinct from primary and final two coats of glossy oil and weather resisting Light Gary paint
in accordance with shade no.631of IS-5.
All paints shall be carefully selected to withstand extremes of weather. The paint shall not
scale off or crinkle or be removed by abrasion due to normal handling.
The minimum thickness of outside painting of tank shall be 20 microns and the total thickness
shall be minimum 80 microns.
Bolts and nuts:
All bolts and nuts exposed to weather shall be hot dip galvanized. Bolts and nuts below H12
(1/2 inch) size shall be stainless steel.
5.14 Wiring and cabling.
(a) Cable box/ sealing end shall be suitable for following types of cables:-

i) 415 volt Power 1100 Volt grade PVC insulated aluminum conductor cable
ii) Control 1100 Volt grade PVC insulated 7/0.737 mm stranded
copper conductor cable.

(b) Compression type cable connector shall be provided for termination of power and
control cables.
(c) All controls, alarms, indicating and relaying devices provided with the transformer
shall be wired up to the terminal blocks inside the Local Control Cabinets (both
cooler and OLTC Control Cabinets)
(d) Not more than 2 wires shall be connected to one terminal. Each terminal shall be
suitable for connecting two 7/0. 73 mm stranded copper conductors from each side.
e) All terminal wiring shall be securely supported, neatly arranged, readily accessible
and connected to equipment terminal blocks.
(f) Engraved code identification plastic ferrules marked to correspond with schematic
diagrams shall be fitted at both ends of wires. Ferrules shall fit tightly on wires and
shall not fall off when the wire is disconnected from terminal block.
5.15 Marshalling box:
Some of the manufacturers have a practice to directly install winding temperature indicator
and oil temperature indicator on the body of the transformer in open. It is obligatory on the
part of the bidders to offer a separate marshalling box to enclose such accessories as required
in the Tender specification.
5.16 Fittings:
The following fittings shall be provided with each transformer covered in this specification.
(a) Conservator for main tank, with oil filling hole and cap, isolating valves, drain valve,
magnetic oil level gauge with low level alarm contacts and dehydrating breather.
(b) Conservator for OLTC with drain valve. Buchholz relay, filling hole with cap, prismatic oil
level gauge and dehydrating breather.
(c) Oil preservation equipment.
(d) Pressure relief device alarm contact.
(e) i) Buchholz relay double float type with isolating valves on both sides, bleeding pipe
with pet cock at the end to collect gases and alarm and trip contacts.
ii) Separate surge relay with above features to be provided for OLTC chamber.
(f) Air release plug
(g) Inspection openings and covers.
(h) Bushing with metal parts and gaskets to suit the termination arrangement.

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(i) Winding temperature indicators for local and remote mounting. One RWTI with a four point
selector switch shall be provided for all the winding (HV/LV).
(j) Oil temperature indicators.
(k) Cover lifting eyes, transformer lifting lugs, jacking pads, towing holes and core and winding
lifting lugs.
(l) Protected type mercury or alcohol glass thermometer.
(m) Bottom and top filter valves with threaded male adapters, bottom sampling valve and drain
valve.
(n) Rating and diagram plates on transformers and auxiliary apparatus.
(o) Earthing terminals.
(p) Flanged bi-directional wheels.
(q) Cooler control cabinet.
(r) On load tap changing equipment and OLTC control cabinet.
(s) Drain valves/plugs shall be provided in order that each section of pipe work can be drained
independently.
(t) Bushing CTs for WTI & REF protection & circulating current in tertiary.
(u) Insulating oil.
(v) Cooling fans.
(w) Terminal marking plate.
(x) Jacking pads.
(y) Lifting bollards
(z) Haulage lugs.
(aa) Cover Lifting lugs.
(ab) Valve schedule plate
(ac) RTCC panel
(ad) Bushing terminal clamp & connector
(ae) On line DGA monitor
(af) NIFPS
Note: The fittings listed above are only indicative and any other fittings which generally are
required for satisfactory operation of the transformer are deemed to be included.
5.17 Limits of temperature rise:
The temperature rise on any part of equipment shall not exceed the maximum temperature
rise specified below under the conditions specified in test clauses. The permissible
temperature rise indicated is for a maximum ambient temperature of 50 deg. C. If the
maximum ambient temperature rises, permissible values shall be reduced accordingly. For
actual maximum temperature at the location of installation, refer prefect synopsis.

Maximum Value of
Sl. Temp. rise at a max.
Nature of the part or of the liquid
No. Temp. ambient air temp. not
exceeding 50oC
1. Contacts in air, silver-faced copper, copper 95 40/45
alloy or aluminum alloy [see notes (i) and (ii)]

Bare copper or tinned aluminum alloy. 75 25

2. Contacts in oil: 90 40
Silver-faced copper, copper alloy or aluminum
alloy (see note ii)
Bare copper or tinned aluminum alloy. 80 30
3. Terminals to be connected to external 105 55
conductors by screws or bolts silver faced (see
note iii)
4. Metal parts acting as springs see note iv (see note iv)
5. Metal parts in contract with insulation of the
following classes:
ClassY:(for non-impregnated materials) 90 40

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Class A: (for materials immersed in oil or 100 50

impregnated)
Class E: in air 100 70
in oil 120 50
Class B: in air 130 80
in oil 100 50
Class F: in air 155 105
in oil 100 50
Enamel: oil base 100 50
Synthetic, in air 120 70
Synthetic, in oil 100 50
6. Any part of metal of or insulating material in 100 50
contact with oil, except contacts
7. Oil 90 40

Notes: i) When applying the temperature rise of 40/45 deg.C. care should be taken to ensure
that no damage is caused to the surrounding insulating materials.
ii) The quality of the silver facing shall be such that a layer of silver remains at the
points of contact after the mechanical endurance test. Otherwise, the contacts shall be
regarded as ―bare‖.
iii) The values of temperature and temperature rise and valid whether or not the
conductor connected to the terminals is silver-faced.
iv) The temperature shall not reach a value where the elasticity of the material is
impaired. For pure copper, this implies a temperature limit of 75 deg.C.
5.18 specification for control CABINETS:
Control cabinets shall be of the free standing floor mounting type.
Control cabinet of the operating mechanism shall be made out of 3mm thick sheet or 10mm
thick aluminum plate or casting. Hinged door shall be provided with padlocking arrangement.
Sloping rain hood shall be provided to cover all sides 15mm thick neoprene or better type of
gaskets shall be provided. Colour of paint shall be olive Green in accordance with shade no
220 of IS 5.
Bus bars shall be of tinned copper of adequate cross section to carry the normal current,
without exceeding the permissible temperature rise over an ambient temperature of 50 deg. C
outside the cubicle. The buses shall be designed to withstand forces corresponding to short
circuit current of 25 KA.
Motors rated 1 kw and above being controlled from the control cabinet would be suitable for
operation on a 415 V, 3 phase 50 Hz system. Fractional kw motors would be suitable for
operation on a 240 V, 1-phase, 50 Hz supply system.
Isolating switches shall be group operated units (3 pole for use on 3- phase supply systems
and 2 pole for single phase supply system) quick make quick break type, capable of breaking
safely and without deterioration, the rated current of the associated circuit. Switch handle
shall have provision for locking in both fully open and fully closed positions.
Push button shall be rated for not less than 6 Amps, 415 V A.C or 2 Amps, 220V D.C and
shall be flush mounted on the cabinet door and provided with appropriate name plates. Red,
Green and Amber indicating Lamps shall be flush mounted.
For motors upto 5 KV, contactors shall be direct-on-line, air break, single throw type and
shall be suitable for making and breaking the stalled current of the associated motor which
shall be assumed equal to 6.5 times the full load current of the motor at 0.2 p.f. For motors
above 5 KW, automatic star delta type starters shall be provided. 3 pole contactors shall be
furnished for 3 phase motors and 2-pole contactors for single phase motor. Reversing
contactors shall be provided with electrical interlocks between forward and reverse
contactors. If possible, mechanical interlocks shall also be provided. Contactors shall be
suitable for uninterrupted duty and shall be of duty category class AC4 as defines in IS: 2959.
The main contacts of the contactors shall be silver plated and the insulation class for the coils
shall be class E or better. The dropout voltage of the contactors shall not exceed 70% of the
rated voltage.

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Contactors shall be provided with three elements positive acting, ambient temperature
compensated, time lagged, hand reset type thermal overload relay with adjustable setting.
Hand reset button shall be flush with the front door at the cabinet for resetting with starter
compartment door closed.
Single phasing preventer relay shall be provided for 3 phase motors to provide positive
protections against single phasing.
Mini starters shall be provided with no volt coils whenever required.
Power cables of 1100/650 volts grade stranded aluminum conductor. PVC insulated, PVC
sheathed single steel wire armoured and PVC jacketed shall be used. All necessary cable
terminating accessories such as glands, crimp type tinned copper lugs etc. for power as well
as control cables shall be included in Bidder‘s scope of supply. Suitable brass cable glands
shall be provided for cable entry.
Wiring for all control circuits shall be carried out with 1100/650 volts grade PVC insulated
tinned copper stranded conductors of sizes not smaller than 2.5 mm. Atleast 20% spare
terminal blocks for control wire terminations shall be provided on each connecting stand type.
All terminals shall be provided with ferrules indelibly marked or numbered and these in
identifications shall correspond to the designations on the relevant wiring diagrams. The
terminals shall be rated for adequate capacity which shall not be less than 10 Amps.
Separate terminal blocks shall be provided for terminating circuits of various voltage classes.
CT loads shall be terminated on a separate block and shall have provision for short circuiting
the CT secondary terminals.
Control cabinet shall be provided with 240 V, 1 phase 50 Hz, 20 W fluorescent light fixture
and a suitable rated 240 V, 1 phase, 5 Amps, 3 Pin socket for hand lamps.
Space heaters shall be provided inside each cabinet complete with thermostat (preferably
differential type) to prevent moisture condensation. Heaters shall be controlled by suitably
rated double-pole miniature Circuit Breakers.
Single lamps provided shall be of neon screw type with series resistors, enclosed in bakelite
body. Each single lamp shall be provided with a fuse integrally mounted in the lamp body.
Electric measuring instruments shall be of moving iron type. Ammeters for measuring current
upto 30 Amps shall be directly connected through suitable CTs. Ammeters shall be provided
with selector switches.
Items inside the cabinet of organic material shall be coated with a fungus resistant varnish.
Please note that all DC operated push buttons/ contactors/ coils should be provided with 220
volt DC.
5.19 Motors:
Motors shall be ―Squirrel Cage‖ three phase induction motors of sufficient size capable of
satisfactory operation for the application and duty as required for the driven equipment.
Motors shall conform to IS 325.
6.0 Tests:
The type test reports of the transformer (as per latest version of IS: 2026) of offered
or higher rating conducted at Govt. / Govt. approved laboratory or witnessed by Govt. / Govt.
approved laboratory representative should be submitted along with the bid. The type tests
should not be older than five years.
Copies of all routine test reports as per latest version of IS:2026 on offered or higher rating
transformer conducted within five years on due date of opening should also be submitted with
the bid.
All routine and additional routine tests shall be carried out on each transformer. The type and
special tests mentioned in clause 6.2 shall be carried out on one unit out of the lot. All routine
& type tests shall be witnessed by representative of CSPTCL & ERDA/CPRI or any other
agency authorized by CSPTCL.
The charges for conducting each type test and special tests shall be indicated separately in the
relevant schedule.
6.1 Routine tests:-
All standard routine tests in accordance with IS: 2026 (with latest amendment), with dielectric
tests as per IS:2026 part-III (with latest amendment) shall be carried out on each transformer.
Further some additional routine tests shall also be carried out on each unit.

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The list of routine and additional routine tests shall be carried out on each unit according to
the methods specified in IS:2026 (Part-I):2011 and IS:2026 (Part-III):2009. The details

Sl. Particulars
(A) Routine tests:
1 Measurement of winding resistance
2 Measurement of voltage ratio and check of phase displacement
3 Measurement of Impedance voltage/ short circuit impedance (Principal tap) & load
loss
4 Measurement of no load loss & current
5 Measurement of Insulation resistance
Dielectric routine tests as per IS:2026 (Part-III) i.e. lightning impulse tests on all
phases of HV/IV/LV windings, short duration induced AC withstand voltage tests,
separate source AC withstand voltage tests
7 Tests on load tap changers
(B) Addl. Routine Tests:
1 Dimensional checks as per approved drawing & specification
2 Magnetic circuit test. After assembly ,core shall be tested for 1 minute for 2000 volts
AC between all bolts, side plates & structures steel works
3 Polarisation index – IR value for 15 sec, 60 sec & 600 sec duration shall be recorded
and PI for 600/60 sec and DAR i.e. ratio of IR values of 60/15 seconds shall be
recorded. The PI value (600/60 sec) should be >=2 and DAR value (60/15 sec)
should be >=1.3. These values should be recorded both before and after HV tests.
4 Tank oil leakage test – the complete transformer assly filled with oil shall be
subjected to nitrogen pressure of 0.35 Kg/cm2 above the normal oil head for a
period of 12 Hrs to ensure that there is no oil leakage.
5 Capacitance and tan delta measurement to determine capacitance between winding
and earth. This test should be carried out before and after series of dielectric tests.
6 Tan delta & capacitance Test on bushings (Before and after HV tests)
7 Checking of recording of IR values
(a) Between core & coil frame
(b) Between core & tank
(c) Between coil frame & main tank
The measured IR values should be more than 1000 M Ohms.
8 Magnetic balance test (Before and after HV tests)
Magnetising Current Tests on all three windings with LT voltage (Before and after
HV tests)
9 Tests of PRDs for successful operation
10 Oil BDV test before & after HV tests
11 Sweep Frequency response analysis (SFRA) - SFRA shall be carried out at
manufacturer‘s works with his own SFRA test set. The test shall be repeated at site
with same test set.
12 Measurement of DEW point prior to dispatch of the unit filled with N2 gas prior to
dispatch - This test shall be carried out by manufacturer and results shall be
submitted to CSPTCL for reference.
13 Cooler Control and RTCC Functional checks
14 Functional checks on Air cell
15 Ratio and polarity tests on Bushing Turret CTs
16 Functional checks on Buchholz Relay
Note: All testing equipments viz. CT,PT, ampere-meter, volt-meter, watt meter, frequency
meter, power analyzer, Insulation resistance test kit, winding resistance test kit, winding turns
ratio test kit, tan delta & capacitance measurement test kit, potential divider, temperature
sensors, etc. shall be of appropriate class of accuracy and shall havevalid calibration
certificates from NABL accredited labs.
6.2 Type/ special tests to be carried out on one transformer out of lot:

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Following tests shall be conducted on one transformer of each lot.

6.2.1 Temperature Rise Test:
This test as per cl. 16.8 of IS:2026 (Part-I) and IS:2026 (Part-II) shall be conducted at the
lowest voltage tap having maximum current with 10% over load condition. The supplier
before carrying out such tests, shall submit detailed calculations showing the alternatives
possible, on various taps and for different ratings (ONAN/ONAF), of the transformer and
shall recommend the combination that results in highest temperature rise, for the test. Since
160 MVA transformer is an auto transformer, the temperature rise test shall be conducted for
the condition of simultaneous loading of all three windings for their respective ONAF rating
i.e.220KV and 132 KV winding corresponding to current of 160 MVA, and 33 KV winding
for 53.33 MVA. Loading on two windings for 160 MVA transformer for the measured losses
will not be accepted. Gas chromatographic analysis of oil shall be conducted before and after
heat run test and the values shall be recorded in the test report. The sampling shall be in
accordance with IEC-567. For the evaluation of the gas analysis in temperature rise test, a
method will be proposed which is based on the rate of increase of particular gases and the
permissible limits of minimum detectable value of gases and the maximum limit will be
mutually discussed and agreed upon between the Purchaser and Supplier. This shall be treated
as reference during maintenance of transformer in future.
The calibration of OTI and WTI shall be done by Transformer Manufacturer and these
calibrated OTI, WTI shall be used during testing of transformer. The Sr.No.of WTI,OTI shall
be recorded during testing of transformer and these indicators only shall be supplied with the
transformer. During test the manufacturer selects suitable tap from CT based on gradient
between the reading of WTI & OTI. This tap position is to be clearly recorded on test report
so that selection of correct tap could be done at site to avoid discrepancy in temperature
gradient recorded during factory test and the value recorded at site.
6.2.2 Tank vacuum test as per details given this clause subsequently.
6.2.3 Tank pressure test as per details given in this clause subsequently.
6.2. Pressure Relief Device Test:
The pressure relief device of each size shall be subjected to increase in oil pressure. It shall
operate before reaching the test pressure specified in ‗tank Tests‘ subsequently in this clause
device shall seal off after the excess pressure has been relieved.
6.2.5 Following special tests other than above mentioned tests shall also be carried out as per ―IS:
2026 part-I and part-III (with latest amendment) as applicable on one unit out of the ordered
lot.
(i) Measurement of zero Seq. Reactance.
(ii) Measurement of acoustic noise level.
(iii) Measurement of power taken by fans.
(iv) Measurement of harmonic level in no load current.
(v) Lighting impulse with chop on tail on all 3 phase of HV and LV terminals.
(vi) One cooler cabinet and OLTC cabinet of the transformers (preferably for thefirst unit
of the lot) shall be tested for IP:55 protection in accordance with IS: 2147. In case
facility for this test is not available with the manufacturer or their vendor; the test has
to be carried out at the laboratory of either CPRI or ERDA in presence of CSPTCL‘s
representative and test report should be furnished.
6.2.6 Tests on Assembled Transformer:
a) Check completed transformer against approved out line drawing, provision for all fittings,
finish level etc.
b) Jacking test on the assembled Transformer.
6.3 Tank Tests
6.3.1 Routine Tests: Oil leakage test:
This test will be conducted on each transformer. All tanks and oil filled compartments shall
be tested for oil tightness by completely filling with air or oil of a 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/sq m measured at the base of the tank. The
pressure shall be maintained for a period of not less than 12 hours for oil and one hour or air
during which time no leak shall occur.
6.3.2 Tests to be conducted on one tank out of lot:

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(i) Vacuum Test

One transformer tank out of the whole lot shall be subjected to the specified vacuum. The
tank designed for full vacuum shall be tested at an internal pressure of 3.33 KN/m 2
absolute (25 torr) for one hour. The permanent deflection of flat plate after the vacuum
has been released shall not exceed the values specified below.

orizontal length of flat plate (in mm) Permanent Deflection (in mm)
Up to and including 750 5.0
751 to 1250 6.5
1251 to 1750 8.0
1751 to 2000 9.5
2001 to 2250 11.0
2251 to 2500 12.5
2501 to 3000 16.0
Above 3000 19.0
(ii) Pressure Test
One transformer tank of each size together with its radiator, conservator, vessel and
other fittings shall be subjected to a pressure corresponding to twice the normal head
of oil or to the normal pressure plus 35 KN/m 2 whichever is lower, measured at the
base of the tank and maintained for one hour. The permanent deflection of flat plates
after the excess pressure has been released, should be within the limits specified in
the table given at (i) above.

6.4 TESTS AT SITE: After erection at site, the transformer shall be subject to the following
tests, in presence of manufacturer‘s engineer.
6.4.1 Tests on reaching at site:
(i) Immediately upon receipt of transformer at site and before unloading of transformer
from trailor, core earthing, end frame earthing and tank earthing shall be checked.
Only after satisfactory verification that there is not multiple core earthing in
transformer, unloading of transformer shall be undertaken.
(ii) After receipt of transformer at site physical inspections shall be done for checking
any physical damage to transformer tank and accessories. Further, data of impact
recorder shall be analyzed for any changes before unloading of transformer.
6.4.2 Pre commissioning tests at site:
(i) Insulation resistance test and polarization index.
(ii) Ratio and polarity test
(iii) DGA of oil and di-electric, tan delta and moisture content test of oil.
(iv) OLTC operational test at each tap for lower and raise operation of tap changer.
(v) Magnetic balance tests and measurement of magnetizing current.
(vi) Vector group test
(vii) Short circuit current measurement at low voltage and at all taps
(viii) Measurement of winding resistance at all taps
(ix) Tangent delta and capacitance of Transformer
(x) Tangent delta, capacitance and insulation resistance tests of bushings
(xi) Leakage current between core & tank, core & end frame, end frame and tank and
between short circuited links and neutral in grounded and ungrounded conditions.
(xii) Dew point measurement and recording of pressure of nitrogen gas.
(xiii) SFRA test.
The SFRA test and Dew point measurement shall be carried out in presence of manufacturer‘s
representative. The test kits shall be same as used for carrying out these tests in the factory
and shall be brought by manufacturer‘s representative.
6.4.3 Pre commissioning checks at site:
a) Check the colour of silica gel breather.
b) Check the oil level in the breather housing, conservator tank, cooling system,
condenser housing etc.
c) Check the bushings for conformity of connection to the line etc.
d) Check for correct operation of all protection and alarms.

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i) Buchholz relay
ii) PRV
ii) Excessive winding temperature
iii) Excessive oil temperature
e) Low oil level indication
f) Check for adequate protection on electric circuit supplying the accessories.
g) Check for cleanliness of the Transformer and the surroundings
6.5 Test reports
6.5.1 Copies of certified test reports and oscillograms shall be submitted for approval prior to
dispatch of the equipment. The equipment shall be dispatched only when all the required type
and routine tests have been carried out and test reports have been approved by the purchaser.
6.5.2 Copies of the test reports for the tests carried out on the ancillary apparatus shall be furnished
to the purchaser for approval prior to dispatch.
6.5.3 All auxiliary equipment shall be tested as per the relevant standard. Test certificate shall be
submitted for bought out items.
6.6 Apart from rejection due to failure of the transformer to meet the specified test requirements
the transformer shall be liable for rejection on any one of the following reasons.
No load loss exceeds the values mentioned in schedule-I
Load loss/Auxiliary exceeds the specified values mentioned in schedule-I
Impedance voltage value exceeds the guaranteed value plus tolerance.

7.0 INSPECTION AND TESTING:

7.1 Inspection:
7.1.1 The Purchaser shall have access at all times to the works and all other places of manufacture
where the transformers are being manufactured and the bidder shall provide all facilities for
unrestricted inspection of the bidders works, raw materials, manufacture of all the accessories
and for conducting necessary tests as detailed herein.
7.1.2 The successful bidder shall keep the purchaser informed in advance of the time of starting and
of the progress of manufacture of equipment in its various stages, so that arrangements could
be made for inspection.
7.1.3 No material shall be dispatched from its point of manufacture unless the material has been
satisfactorily inspected and tested.
7.1.4 The acceptance of any quantity of transformer & its accessories shall in no way relieve the
successful bidder of his responsibility for ;meeting all the requirement of this specification
and shall not prevent subsequent rejection if such equipments are later found to be defective.
7.1.5 Acceptance of condition regarding stage inspection at various stages, which will be intimated
to successful bidders, shall be an essence of the contract to be placed against this tender.
7.2 Inspection programme:
7.2.1 The bidder shall chalk out a detailed inspection and testing programme for manufacturing
activities for the various components. An indicative programme of inspection as envisaged
by the CSPTCL is given in Annexure-VII. Stage inspection of core & winding and final
inspection of the transformer shall be carried out at manufacturer‘s works in presence of
CSPTCL‘s representative and representative of a third party i.e. CPRI/ ERDA or any other
agency authorized by CSPTCL. The expenses on witness of tests by third party shall be borne
by CSPTCL.
7.2.2 The routine tests on each transformer is to be carried out free of cost by the bidder. The rates
for type & special tests for one transformer should be separately offered and the same shall be
payable by CSPTCL.
7.3 Stage inspection:
7.3.1 The manufacturer shall indicate the inspections and checks carried out at various stages of the
manufacture of the transformers. A complete record of stage inspection would be kept by the
manufacturer and thus record should be made available for inspection by the representative of
CSPTCL. The manufacturer should indicate the manufacturing programme and CSPTCL will
have a right to depute its inspecting officers during the manufacture. Some of the inspecting
stages are coil winding and core building, assembly of coil on core, the condition of the coil
and core after the treatment in vacuum chamber, assembly within the transformer tank
together with application of tap changer.

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7.3.2 It may be noted that stage inspection for all the units at CSPTCL‘s discretion shall be done at
manufacturer‘s works in presence of CSPTCL‘s representative and representative of third
party authorized by CSPTCL at the following stages.
(a) Fabrication stage of tank: After fabrication, tank shall be inspected for measurement
of its dimensions, thickness of sheets used and leakage test by applying requisite
pressure/ vacuum.
(b) Building up of core: After the core is built but before its clamping, our representative
will inspect the core to take complete weight of the core and also to measure
approximate core loss. If necessary, a small strip of core shall also be taken for
testing at CPRI/ ERDA or at any other testing laboratory of repute.
(c) Preparation of winding: Once the coils are prepared but before the same are fitted on
to the core, stage inspection shall be done to take various measurements and also for
weighment of total weight of coil of each voltage class. Measurement of resistance
shall be taken and for this purpose, a small piece of conductor for each type of
winding shall be made available by the manufacture. The magnetic balance test shall
also be carried out during this stage inspection.
(d) Core Coil Assembly.
Apart from the above, CSPTCL also reserves the right to carry out stage inspections
at other stages also, for which advance intimation shall be given and all necessary
cooperation shall be rendered by the manufacturer.
7.4 Final inspection and testing:
7.4.1 All the routine, additional routine, type and special tests as mentioned in clause 6 shall be
carried out as per IS:2026 (Part-I & III) at manufacturer‘s works in presence of CSPTCL‘s
representative and representative of third party authorized by CSPTCL. In other transformers,
routine & additional routine tests shall be carried out as per clause-6 shall be carried out as
per IS:2026 (Part-I & III) at manufacturer‘s works in presence of CSPTCL‘s representative
and representative of third party authorized by CSPTCL. At the time of final inspection, the
supplier shall identify each and every item/ accessories of the particular transformer under
testing. Unless all the items are identified, the manufacture will not be treated as complete.
Serial number of bushings, serial number of tap changer and other details shall be entered into
the test report to ensure that these items are not being applied to the subsequent transformer
units while testing. Various tests stipulated in IS shall be performed in the presence of our
engineers or when the inspection waiver has been given, in such a case, the testing shall be
done at the manufacturer‘s works as per IS stipulations and same should be confirmed by
documentary evidence by way of Test Certificate which shall be got approved by us.
7.4.2 The WTI & OTI shall be calibrated during testing of transformer and serial Nos. of these
instruments; shall be recorded in test reports. The WTI & OTI used during testing shall be
dispatched with the transformer so that installation of same OTI & WTI on transformer is
done which are utilized during testing of transformer at supplier‘s works. The Bushings and
Radiators on Transformer (if heat run test is conducted) during testing of transformer at
manufacturers works are required to be supplied with the same transformer to avoid any
mismatch / misalignment etc. during assembly of transformer. This should be noted for strict
compliance and confirmed specifically.
7.4.3 Whenever inspection call for a particular transformer is given, the letter of inspection call will
accompany the following:
(a) List of various fittings and accessories, which are ready at the works and will be
offered for inspection. The Inspecting Officer will carry the list and check the items
declared to have been offered for inspection.
(b) It is expected that before a transformer is finally offered for inspection, internal
testing of the transformer for various important parameters like winding resistance,
transformer losses, IR values etc. are already done. CSPTCL may ask for Routine
test report for such tests before conducting the inspection.
(c) List of testing equipments and instruments which will be used during the inspection
of the transformer with their makes, sl. No. and date of calibration, agency who
conducted calibration and validity of calibration certificate should also be furnished
along with the inspection call.
8. Quality Assurance Plan:

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8.1 The Bidder shall invariably furnish following information along with his offer, failing which
the offer shall be liable for rejection.
(i) Statement giving list of important raw materials, names of sub-suppliers for the raw
material, list of standards according to which the raw material are tested, list of tests
normally carried out on raw material in the presence of Bidder‘s representative,
copies of test certificates.
(ii) Information and copies of test certificates as in (i) above in respect of bought out
items.
(iii) List of manufacturing facilities available.
(iv) Level of automation achieved and list of areas where manual processing exists.
(v) List of areas in manufacturing process, where stage inspections are normally carried
out for quality control and details of such tests and inspections.
(vi) Special features provided in the equipment to make it maintenance free.
(vii) List of testing equipment available with the Bidder for final testing of equipment
specified and test. Plant limitation, if any, vis-à-vis the type, special, acceptance and
routine tests specified in the relevant standards. These limitations shall be very
clearly brought out in ―schedule of Deviations‖. The bidder should have power
analyzer for testing & all other routine & acceptance tests facilities as per latest
amendments of IEC.
9. Design control: The supplier shall furnish the checks exercise in design calculations
particularly in respect of short circuit forces and method of clamping end coil to show the
healthiness of the design. The salient features of design together with the certificates of
design engineers will have to be made available to the CSPTCL.
10. Engineering documents: The supplier shall give complete information regarding copper
conductor, insulating paper, core materials, tap changer, gaskets etc. bringing out the detailed
description and specification of these items with explanation as to how our requirements are
being met in this respect.
11. Procurement document control & purchased material & services: The supplier shall indicate
the various sources from whom the items namely copper conductor, insulating paper, core
material, tap changer and other items such as gaskets etc. are being procured. The type of
check, quantum of check and acceptance norms shall be intimated and random test and check
results should be made available for inspection whenever so desired. The vendor list as per
Annexure-VI is only acceptable to us & in case any change in vendor list is required, same
shall be subject to approval of CSPTCL.
12. Documentation:
12.1 All drawings shall confirm to relevant international standards Organization (ISO)
specification. All drawings shall be in ink and suitable for micro filming. All dimensions and
data shall be in S.I. Units.
12.2 The Bidder shall furnish along with the bid dimensional drawings of transformer, and all
other accessories. These drawings shall include the following information.
(i) Dimensions.
(ii) Tolerances on dimensions.
(iii) Material designation used for different components with reference to standards.
(iv) Fabrication details such as welds, finishes and coatings.
(v) Catalogue or part numbers for each component and the total assembly with bill of
materials.
(vi) Identification marking.
(vii) Weight of individual components and total assembled weight.
(viii) Foundation drawing.
(ix) G.A. drawings of cooler control cabinet and RTCC panels.
(x) Schematics drawings of OLTC, RTCC and cooler control.
12.3 The bidder shall also furnish four copies per unit of transformer to the owner bound manuals
covering erection, commissioning, operation and maintenance instructions and all relevant
information and drawings pertaining to the main equipment as well as auxiliary devices.
Marked erection drawings shall identify the component parts of the equipment as shipped to
enable purchaser to carryout erection with his own personnel. Each manual shall also contain

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one set of acceptance reports of the corresponding consignment dispatched. These manuals
shall be invariably furnished to the purchaser before dispatch of transformer.
The manufacturing of the equipment shall be strictly in accordance with approved drawings
and no deviation shall be permitted without the written approval of the purchaser. All
manufacturing and fabrication work in connection with the equipment prior to the approval of
the drawing shall be at the bidder‘s risk.
13. Packing and forwarding:
13.1 The equipment shall be packed in crates suitable for vertical/horizontal transport as the case
may be and suitable to withstand handling during transport and outdoor storage during transit.
The bidder shall be responsible for any damage to the equipment during transit, due to
improper and inadequate packing. The easily damageable material shall be carefully packed
and marked with the appropriate caution symbol. Wherever necessary, proper arrangement
for lifting, such as lifting hooks etc. shall be provided. Any material found short inside the
packing cases shall be supplied by bidder without any extra cost.
13.2 Each consignment shall be accompanied by a detailed packing list containing the following
information:
(i) Name of the purchaser.
(ii) Details of consignment.
(iii) Destination
(iv) Total weight of consignment
(v) Sign showing upper/lower side of the crate.
(vi) Handling and unpacking instructions.
(vii) Bill of material indicating contents of each packing.
The bidder shall ensure that the packing and bill of material are approved by the purchaser
before dispatch.

14. Storage, handling & shipping:

When the transformer is declared ready, the manufacturer has to identify each and every item
associated with this unit and a complete packing list shall be prepared in advance. The
equipments shall be stored and handling properly in shipping depot, while the same is under
process of dispatch. The manufacturer should ensure dispatch of all the related items and
accessories with a particular unit of transformer along with tank.
Tap changer, bushing, radiators and other accessories of the transformer should not be
withheld for use subsequently on; units for testing purposes. If there are any items procured
from sub-vendor which are to be directly installed like instrumentation, panels, control gear
etc. test and inspection report for the same will be kept separately and made available to our
inspecting officers.
It may be noted that ―No change in any accessory or associated equipments after passing all
the test successfully shall be allowed and if this is subsequently defected it shall be binding on
the bidder to replace with the same item with which the initial test were conducted at his part
failing which the entire test shall become null and void. The CSPTCL at its discretion may
consider for rejection of the units thus supplied. The entire cost, for replacement of such
rejected units thus supplied and for repeating acceptance test, shall be borne by the bidder.

Transportation:
The bidder shall include charges for fitting one Electronic impact recorder (on returnable
basis) during transportation of transformers to measure the magnitude and duration of the
impact in all three directions. The acceptance criteria and limits of impact in all three
directions which can be withstood by the equipment during transportation and handling shall
be submitted by the manufacturer during detailed engineering. The recording shall commence
in the factory before dispatch and must continue till the unit is installed in its foundation. The
data of electronic impact recorder(s) shall be down-loaded at site and a soft copy of it shall be
handed over to engineer-in-charge. Further, within three weeks the manufacturer shall
communicate the interpretation of the data. In the unlikely event of impact recorder output
not available at site, the equipment shall be thoroughly internally inspected by the
manufacturer‘s representative before erection at site to ensure healthiness of the equipment.

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(A). In order to conduct low voltage field testing on power transformers before unloading/
commissioning at site to determine the internal condition, the transformer shall be
transported with:
(a) Small bushing (12 KV) may be installed on the bushing cover plate to represent the
actual bushing.
(b) Winding leads may be routed, secured and electrically isolated from the tank walls
and active part.
(c) Temporarily tests leads may be used to connect the winding leads by the small
bushings (which will be removed before erection of the main bushings).
(B). Further, the manufacturer shall mount vehicle tracking system (GPRS/ GPS/ GSM
based) to track the exact position of the vehicle on which the power transformer is
being loaded for transportation and during detailed engineering take approval for the
equipment installed.
The details of arrangement for transport configuration of power transformer (which
shall be adopted by manufacturer) shall be submitted by the manufacturer to CSPTCL
for approval. The price quoted by the bidder should take into account this
requirement.
15. Completeness of equipment and bought out items:
The bidders must furnish the following information‘s along with technical bid.
15.1 A list of all the accessories which will be supplied with the transformer should be furnished.
This should be as per Annexure-II & III. While furnishing the list of accessories in schedule-
VII items, which will be manufactured by the bidder and balance items, which will be
procured from sub-suppliers should be clearly identified and stipulated in the tender.
15.2 It is obligatory on the part of bidder to ensure that supply of all accessories as per Clause
13.1 are made along with Main Tank or prior to delivery of Main Tank so that erection and
commissioning work of Transformer can be completed properly and uninterruptedly. The date
of supply of last accessory will be treated as date of delivery of transformer and penalty shall
be imposed up to a maximum of 10% for delay in supply and supply bills will be processed
accordingly.
15.3 The responsibility for obtaining timely supplies of bought out items will rest on the bidder
and only on this basis, delivery period will be offered in the tender.
15.4 It may be noted that in case of damages/ shortages due to improper packing or any other
negligence, replenishment shall be arranged within one month‘s time. If this is not done, date
of delivery of such accessory will be treated as date of delivery of main equipment and full
penalty shall be recoverable from the bidder on total cost of the equipment. This should be
confirmed.
For bought out items, responsibility for guarantee and obtaining immediate replacement in
case any defects are noticed and in case defective supply of any item is reported, will rest on
the tenderer.
15.5 In case for attending to defect in any accessory or inspection/replacement of the accessory,
which may be bought out item for the tenderers services of engineer of original manufacturer
is required, the same will be organized on immediate basis by the tenderer at his cost.
16. Calculations/ design data required to be submitted with the tender for power transformer:
All the important data of the transformer i.e. net weight of bare copper in each winding,
weight of core without clamping fixtures, weight of core and windings, Cross section of the
core, Flux density calculations, Calculations for short circuit current and its duration, Current
density during short circuit, Calculations showing withstand capability of windings for
thermal & mechanical stresses during short circuit conditions, Mechanical design of
transformer tank etc should be invariably submitted by the Bidder. After placement of
detailed contract the final design calculations shall be submitted for our verification and
records.
16.1 Short circuit withstands capability:
In order to ensure capability of transformer to withstand short circuit forces due to most
severe fault in our inter connected net work the transformer should be designed on the basis
that winding are connected to an infinite bus and fault current is limited by transformer
impedance alone, ignoring system impedance. The calculations to prove dynamic and thermal
short circuit withstand capability of transformer shall be submitted considering the above for

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transformer. The design of winding assembly which is to be furnished in the drawing should
be commensurate with these calculations.
16.2 Design of tank:
Complete mechanical design of transformer tank including details of stiffeners shall be
submitted. The tank shall be designed to withstand the following without permanent
distortion.
(i) Mechanical shocks during transportation.
(ii) Vacuum filling of oil at 10 milli torr in transformer with all fittings.
(iii) Continuous internal pressure of 35 kN/m2 over normal hydrostatic pressure of oil.
(iv) Short circuit forces
(v) Under seismic condition /events both horizontal/vertical .
The calculations for tank stiffeners shall be submitted to prove no. &size of stiffeners are
adequate to withstand full vacuum & pressure. Drawing of tank shall be submitted indicating
stiffeners.
16.3 Design of static end rings (SER) and Magnetic shunts:
Details of Static End Rings (SER) and magnetic shunts, if provided, shall be submitted with
calculations. A drawing indicating locations, size, material of SER and magnetic shunts shall
be submitted.
16.4 Overfluxing capability:
A curve to prove suitability of transformer to withstand various Overfluxing conditions for
the duration indicated in relevant clause without core saturation shall be furnished.
16.5 Cooling calculations:
Calculations of tank surface for heat dissipation, details of radiators, fans for ONAN &
ONAF cooling shall be provided.
16.6 Design Data:
On the basis of offered flux density and current density, the Bidder shall furnish following
design calculations & data. :
16.6.1 Core Data:
Details of core material i.e Name of manufacturer, manufacturer‘s type designation for core ,
thickness of core, curve for Loss Vs Flux density, No of steps of Core & No of limbs, gross
core area, stacking factor, Net core area, height & width of core window, center to center
distance of limb, voltage per turn, wt. of core material, working flux density , core loss in
watts per kg marked on graph for grade of core material & selected flux density, building
factor and calculated no load loss in watts, guaranteed no load loss.
Design data for core shall be submitted. A drawing indicating details of core i.e. limbed
construction, step width & thickness, core belting, top & bottom yoke plate etc shall be
submitted.
16.6.2 Winding Data:
Wt. of copper for windings i.e. for HV, LV, tap, cross sectional area, current density, type of
coil, ID/OD/mean dia of coils, size of winding conductor including parallels, no. of turns per
phase, no of spacers, length of mean turn, weight of copper without paper covering, resistance
per phase of winding at 75oC, I2R loss at 75oC & normal tap, eddy current & stray loss at
75oC, total copper loss at 75oC, guaranteed transformer losses at 75oC. Complete details of
Insulation components i.e. Top & Bottom clamping rings, washers, Pressboard blocks &
cylinders, Pressboard spacers & Phase barriers, Pressboard segments etc shall be submitted
indicating qty , thickness in mm, width & height, wt. Design data for winding as per clause
31.2.2 shall be submitted. Dimensioned drawings indicating details of winding, ducts,
insulation, take off arrangement, clamping ring, pressure points etc shall be submitted.
16.6.3 Quantity of oil:
Complete calculations of oil quantity to be utilized in transformer for first filling shall be
submitted. The calculations shall indicate
(i) Volume of tank including turrets, conservator main & OLTC, volume of headers &
Radiators, oil quantity in OLTC.
(ii) Oil displacement by Active parts i.e. core - coil assembly,
16.7 Capacity of conservator & size of air cell :
While furnishing details of conservator & air cell type sealing arrangement, the Bidder shall
submit details & calculations for adequacy of size and capacity of air cell for the rating of the

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power transformer and also for the quantity of oil required. Catalogue of AIR CELL should
be enclosed clearly marking type designation of selected size of Air cell. A drawing
indicating complete details of conservator with Air cell shall be submitted.
16.8 Capacity of pressure relief device:
Our specification calls for supply of pressure relief device for all power transformers. Bidders
must submit calculation to prove that the capacity/ rating of pressure relief device and
locations of the same for the transformer will adequately meet our requirement.
Constructional and design details of pressure relief device must be furnished and it should be
proved by calculation that the size and setting of pressure relief device is adequate
considering the rating of the transformer and quantity of oil in the transformer.
A drawing indicating complete details of PRDs & their locations on tank shall be submitted.
16.09 Capacity of Silica gel breather:
The Bidder shall submit details & calculations for adequacy of size and capacity of silica gel
breather for the oil quantity in the power transformer.
16.10 Rating of on load tap changer (OLTC):
It has been our experience that due to inadequate rating of OLTC elements, the failure of
OLTC components or pitting of contacts have been observed before the claimed period for
maintenance. To verify the adequacy and suitability of the OLTC components, it is necessary
to furnish the calculations for selecting the proper rating of transition resistance as well as the
normal current rating of OLTC. The calculations shall include the temperature rise of the
OLTC diverter switch and also the short circuit current considered for calculation of
temperature rise.
Calculations shall be submitted to prove that the current rating of OLTC is adequate for the
rating of the transformer winding taking in to account the over loading capability as per IS
6600. The basis for selection of transition resistance and its current carrying capacity shall
also be submitted. In this regard the circulating current in tap winding during tap change
operation through transition resistance shall be taken in to consideration. Adequacy of
insulation provided in the OLTC between various parts needs to be established with specific
reference to the voltage between two taps. Confirmation shall be given that the OLTC is
suitable for bidirectional flow of current. The through current capacity shall be adequate to
handle on continuous basis the winding current including over loading as per IS 6600. The
through current rating and the rating of transition resistance shall take in to account the short
time current rating of the winding. Capability to handle short circuit current to be established
by calculations and also by test reports. The above Calculations for OLTC shall be submitted.
16.11 Capacity of Nitrogen /dry air Cylinder, pressure in Nitrogen / dry air Cylinder to be used
during transportation of transformer shall be submitted.
16.12 The manufacturer shall carry out optimization of Dielectric design of insulation including
electromagnetic design; overload & short circuit withstand capabilities. During design,
transformer modeling shall be done & finite element software (FEM) may be used.
It is assured that these data will be kept strictly confidential by CSPTCL.

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SCHEDULE-I

GUARANTEED TECHNICAL PARTICULARS

01. Name of the Manufacturers

02. Normal continuous rating of (MVA)
(a). With ONAN cooling
(b). With ONAF cooling
03. Normal ratio of transformation
04. Phase connection:
a) HV winding
b) IV winding
c) LV winding
d) Vector group reference no. & symbol
05. Current at rated no load and on principal taps
(Amps) - HV
- IV
- LV
06. Maximum temperature rise:
i) of oil by thermometer
a) at full ONAN rating
b) at full ONAF rating
ii) of winding by resistance
a) at full ONAN rating
b) at full ONAF rating
c) by hot spot temperature indicator
d) Ambient tep. Adopted
07. Temperature gradient between oil and winding
08. Voltage to earth for which the star point will be
insulated
09. LOSSES:
(a) No Load Losses :
i) Guaranteed no load losses at normal ratio, rated
voltage rated out put, rated frequency at 75oC
average winding temp. (KW) (no positive
tolerance is permissible)
ii) No load losses at 110% of rated voltage
(b) Load losses:
Guaranteed load losses at normal ratio, rated
voltage rated out put rated frequency at 75oC
average winding temp. at rated output (KW) (no
positive tolerance is permissible)
(c) Auxiliary losses:
Auxiliary losses at rated output (no positive
tolerance is permissible)
10. Guaranteed total losses at 75oC temp. (i.e. 9 (a)(i)
+ 9 (b)+9(c)
11. Efficiencies at normal ratio, rated voltage, rated At UPF 0.8 PF Lagging
frequency and average winding temp. for 75oC
average winding temp. for outputs of
(i) full load
(ii) ¾ full load
(iii) ½ full load
(iv) ¼ full load
(v) Maximum efficiency with load
12. Resistance per phase at normal tap of

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(a) HV winding
(b) IV winding
(c) LV winding
13. Reactance per phase of (at normal tap of (in
ohms.)
(a) HV winding
(b) IV winding
(c) LV winding
(d) Reactance at rated MVA base
14. Resistance voltage drop at 75 degree centigrade
average winding temp. expressed as percent of
rated voltage
15. Reactance voltage drop expressed as percent of
rated voltage on rated winding MVA
16. Positive sequence Impedance on rated MVA base Normal Highest Lowest
at rated current & freq. At 75 degree centigrade. Tap Tap Tap
Winding temp. between
(a) HV – IV
(b) HV – LV
(c) IV – LV
17. Zero sequence Impedance at 75 degree Centigrade
& at principle tap.
18. Impedence voltage at normal & 75 degree
centigrade average winding temp. expressed as
percentage of rated voltage.
(a) between HV & IV winding
(b) between IV & LV winding
(c) between LV & HV winding
(d) Positive sequence, HV
(e) Positive sequence, IV
(f) Positive sequence, LV
19. Regulation at full load and 75 degree centigrade
Unity power factor
b. 0.8 power factor (lagging)
20. Type of transformer (core or shell)
21. Width of track gauge.
22. Time in minutes for which transformer can be run
at full load without exceeding maximum possible
temp. above ambient temp. when:
(a) Supply to fan group 1 is cutoff
(b) When supply to both groups of fans are cutoff.
23. Permissible over loading
(a) HV winding
(b) IV winding
(c) LV winding
24. Terminal arrangement for
(a) HV winding
(b) IV winding
(c) LV winding
25. Insulation level:
(a). L.I. withstand (Kvp)
(b). P.f. withstand for one minute (dry and wet.)
(c) Switching impulse withstand (KVp)
26. Partial discharge level at 1.5xUm/ square root 3
KV RMS in pico coulomb.

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27. Noise level when energised at normal voltage &

frequency without load (db)
28. External short circuit withstand capacity (KA) and 220KV– KA for ----- - seconds
duration (secs), 132KV – KA for ------ seconds
33 KV – KA for ------ seconds
29. Over fluxing capability of transformer at over
fluxing factor.
(a). 1.7
(b). 1.4
(c). 1.25
(d). 1.10
30. Details of core:
(a) Type of core construction of no. of limbs in
frame.
(b) Type of core joins.
(c) Flux density at rated voltage and frequency and at
principle tap Tesla)
(d) Flux density at principal tap and at 10% over
Voltage (Tesla)
(e) Magnetizing current at normal ratio and
frequency.
(i) 85% of rated voltage
(ii) 100% of rated voltage
(iii) 105% of rated voltage
(f) Power factor of magnetizing current at normal
voltage ratio and frequency.
(g) Core lamination:
(i) Material and grade
(ii) Thickness
(iii) Voltage per turn
(iv) dia of circumscribing circle of core
(v) No. of steps in core
(vi) Dimensions of core
(vii) Net iron area
(viii) Specific Iron Loss in watts/Kg of core
material at working flux density.
(ix) Total Iron loss, KW
(h) Details of core Belting:-
(i) Material, grade, type
(ii) Width
(iii) Thickness
(iv) Fixing method
(i) Core clamping plate (YOKE):-
(i) Material
(ii) Thickness
(iii) Insulation
(iv) Depth & height of Yoke
(v) Net Yoke area
(vi) Flux density in Yoke
(vii) Weight of Yoke
(j) Describe Location/ method of core grounding
(k) Details of oil ducts in core
31. Details of windings:
(a) Type of winding
(b) Material of the winding conductor

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(c) Maximum current density of windings (at rated

current and conductor area)
(i) Conductor Area (sq. cm)
(ii) Current density (A/sq. cm.)
(d) Whether HV windings are interleaved
(e) Whether winding are preshrunk
(f) Whether adjustable coil clamps are provided for
HV, IV and LV windings
(g) Whether steel rings used for the windings, If so,
whether they are split.
(h) Whether electro-static shields are provided to
obtain uniform voltage. Distribution in the HV
windings
(i) Insulating material used for:
(a) HV winding
(b) IV winding
(c) LV winding
(j) Insulating material used between
(a) HV and IV winding
(b) IV and LV winding
(c) LV winding and core
(d) Regulating winding and earth
(k) Type of axial coil supports
(a) HV winding
(b) IV winding
(c) LV winding
(l) Type of Radial coil supports
(a) HV winding
(b) IV winding
(c) LV winding
(m) (i) Maximum allowable torque on coil clamping
bolts:-
(ii) clamping ring details
- Thickness of ring
- Dia of ring
- No.& size of pressure screw
(n) Power frequency Test voltage for 1 minute
withstand test on
(a) HV winding
(b) IV winding
(c) LV winding
(o) Impulse test on windings 1.2/50 micro sec. Full
wave withstand.
(a) HV
(b) IV
(c) LV
(p) Switching surge test
(a) HV
(b) IV
(c) LV
32 BUSHINGS
(a) Type & make
(b) Rated voltage class & rated current
(c) Dry & Wet flashover voltage
(d) Power frequency withstand test voltage for 1

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minute for wet & Dry (KV rms)

(e) Visible corona discharge voltage (KV rms)
(f) Partial discharge level
(g) Under oil flashover of puncture withstand test
voltage (1.2/50 micro sec. Wave.)
(h) Full wave impulse withstand test voltage (1.2/50
micro sec.wave.)
(i) Positive
(ii) Negative
(i) Switching withstand test voltage (KV peal)
(j) Creepage distance in air (mm)
(k) Protected Creepage distance (mm)
(l) Recommended gap setting.
(m) Weight of assembled bushing, kg.
(n) Qty.of oil in ltrs.
(o) Whether test tap is provided.
(p) Cantilever & Torsional force withstand values.
(q) Type of connection lead arrangement & length of
condenser portion.
(r) Bottom PCD & Details of bolts.
(s) Details of bushing current transformers:
(i) Quantity
(ii) No. of cores
(iii) Ratio
(iv) V.A. burden
(v) Accuracy
(vi) Knee point voltage
(vii) Magnetizing current at Knee point voltage
(viii) Secondary resistance.
(ix) Free space required at top for removal of
bushing (mm)
33. Minimum clearance (mm)
(a) HV
(b) IV
(c) LV
34. Approx. weight of following :
(a) Core excluding clamping
(b) Core with clamping
(c) Coil with insulation
(d) Wt. of steel
(e) Core and winding
(f) Fittings and parts
(g) Oil required for first filling including 10% extra.
(h) (i) Transportation wt. excluding accessories.
(ii) Shipping details:
- Approx. wt. Of heaviest package
- Approx. dimension of largest package
(i) Un-tanking weight
(j) Total weight of transformer with oil and fittings
35. Details of Tank
(a) Type of tank
(b) Approx. thickness of sheet
(i) Sides
(ii) Bottom
(iii) Cover

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(iv) Details of stiffener & under carriage

(c) Vacuum recommended for hot oil circulation
(torr.)
(d) Vacuum to be maintained during oil filling in
transformer tank (torr.)
(e) Vacuum to which the tank can be subjected
without distortion (torr.)
(f) No. of bi-directional wheels provided
(g) Please note that only bell tank design is
acceptable. Please confirm that offered
transformers are of bell tank design.
36. Conservator:
(a) Thickness of sheet
(b) Size
(c) Total volume (Liters)
(d) Volume between the highest and lowest
visible oil levels (Ltrs)
(e) Power required by heaters (if provided) (KW)
37. Details of oil preserving equipment offered (Air
Cell) please indicate type, make & size.
38. Radiator:
(a) overall dimensions, 1xbxh (mm)
(b) Total weight with oil (Kg)
(c) Total weight without oil (Kg)
(d) Thickness of Radiator tube (mm)
(e) Types of mounting
(f) Vacuum withstand capability
39. Cooling System
(a) Make and type
(b) No. of connected units
(c) No. of standby units
(d) Rated power input
(e) Capacity (cu. M/min or litres/min
(f) Rated voltage (volts)
(g) Locked motor current
(h) Efficiency of motor at full load (percent)
(i) Temperature rise of motor at full load
(degree centigrade)
(j) BHP of driven equipment
(k) Temperature range over which control is
adjustable
(l) Whether the fan suitable for continuous
operation at 85% of their rated voltage
(m) Estimated time constant in hours for
i) Natural cooling
ii) Forced air cooling
(n) Period of continuous working at full load with
out fans (in min.)
(o) Continuous MVA rating without fans, MVA
40. Gas and oil operated relay (make, type, rang of
setting etc.)
41. Temperature indicator
(a) Make and type
(b) Permissible setting rang for alarm & trip
(c) Number of contacts

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(d) Current rating of each contact

(e) Whether remote indicators provided. If so
whether equipment required at purchaser‘s control
room‘s included
42. Approximate over all dimension of transformer in
mm.
(i) Length
(ii) Breadth
(iii) Height
43. Minimum clearance height for lifting core and
winding from tank
44. Minimum clearance height for lifting core and
winding from tank
45. Please confirm transformer will be transported
with oil/nitrogen gas
46. Lifting jacks
(i) Governing standard
(ii) No. of jacks on one set
(iii) Type and make
(iv) Capacity (tonnes)
(v) Pitch (mm)
(vi) Lift (mm)
(vii) Height in closed position (mm)
(viii) Mean diameter of thread (mm)
47. Marshalling kiosk
(i) Make and type
(ii) Details of apparatus proposed to be housed
in the kiosk
48. Details of anti earthquake device provided, if any
49. Tap changing equipment (these details refer to the
basic rating of OLTC. As guaranteed by
manufacturer)
(i) Make
(ii) Type
(iii) Power flow direction /bi-directional /
restricted bi- directional
(iv) Rated voltage to earth (kv)
(v) Rated current (amps.)
(vi) Step voltage (volt)
(vii) Number of steps
(viii) Control manual /Local electrical /remote
electrical
(ix) Voltage control automatic /non automatic
(x) Line drop compensation provided /not
provided
(xi) Parallel operation
(xii) Protective devices
(xiii) Auxiliary supply detail
(xiv) Time for complete tap change (one step) in
sec.
(xv) Divertor selector switch transient time
(cycles)
(xvi) Value of maximum short circuit current
(amps)
(xvii) Maximum impulse withstand test voltage

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with 1.2/50 micro-seconds full wave between

switch assembly and ground (kv peak)
(xviii) Maximum impulse frequency test voltage
between switch assembly land earth (kv rms)
(xix) Maximum impulse withstand test voltage
with 1.2/50 microseconds across the tapping range
(kv peak)
(xx) Approximate overall dimensions of tap
changer (hxwxd)
(xxi) Approx. overall weight (kg)
(xxii) Approx. mass of oil (kg)
(xxiii) Particulars of the O.L.T.C. control cubicle
50. Driving mechanism box
(a) Make and type
(b) Details of apparatus proposed to be housed
in the box.
51. Please enclose list of accessories and fittings
being provided on transformer. Please confirm
these are as stipulated in tender.
52. Whether the transformer covered have been fully
type tested and if so, whether copies of type test
certificates enclosed with tender.
53. Valves: indicate details of valves, their type, sizes
and no. required/ fitted
54. a) type and make of pressure relief devices
(b) No. of each type pf devices per transformer
(c) Minimum pressure at which device operates.
55. Please give details of PRV like make, rating etc.
56. Characteristics of Insulating oil to be used
(a) Density in gms/cu. Cm
(b) Kinetic viscosity in cst
(c) Interfacial Tension at 27oC in N/M
(d) Flash point in oC
(e) Pour point in oC
(f) Acidity (Neutralization/Value)
(g) Corrosive Sulphur in %
(h) Electric strength Breakdown
a) As received Voltage (KV rms)
b) After treatment (KV rms)
(i) Dielectric dissipation factor
(tan delta) at 90 oC
(j) Saponification value in mg of KOH/gm
(k) Water content in ppm
(l) Specific resistance
(i) at 90 oC ohm/cm
(ii) at 27 oC ohm/cm
(m) N-dm Analysis CA % CM % CP %
(n) Oxidation stability
(i) Neutralization value after oxidation
(ii) Total sludge after oxidation.
(o) Aging characteristic as per Border 140 h/110 oC
(p) Saponification value in mg of KOH/gm
(q) Dielectric loss after 90 oC
(r) Aging characteristics as per
NEMA 164 H/110 oC

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(s) Neutralization value in mg of KOH/gm

(t) Sludge content weight %
(u) Pemitivity at 60 oC
(v) Specific heat at 60 oC
(w) Thermal conductivity at 60 oC
(x) Mean coefficient of expansion
57. Details of online DGA monitoring device:
(i) Make
(ii) Name of gases which will be monitored
(iii) Please confirm that necessary soft wares has
been provided
58. Details of nitrogen injection fire protection system
device
(a) Make & model
(b) Auxiliary supply required
(c) size & capacity of storage tank proposed to
be provided

SIGNATURE OF BIDDER
Date
Place NAME
DESIGNATION
(SEAL)

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ANNEXURE-II

LIST OF FITTINGS AND ACCESSORIES TO BE PROVIDED WITH POWER

TRANSFORMER.

Each transformer shall be provided with the following accessories.

(i) Dial type Thermometers for oil: - A dial type indicating thermometer with repeater of robust
pattern mounted on the side of the transformer at a convenient height to read the temperature
in the hottest part of the oil and fitted with alarm and trip contacts. Remote oil temperature
indicator shall also be mounted on RTCC panel.
(ii) 3 no. Winding temperature indicator for HV , IV& LV winding:- It shall be indicating type
with repeater responsible to the combination of top oil temperature and winding current,
calibrated to follow the hottest spot temperature of the transformer winding,. The winding
temperature indicator shall operate a remote alarm before the hottest spot temperature
approaches a dangerous value and it shall automatically actuate the cooling fan Motors.
(iii) a) Remote winding temperature indicator is to be installed in the indoor control panel
i.e. fan control cubicle with its repeater on remote tap charger control cubicle.
b) In addition to the winding temperature indication device another device for
measurement of hot spot in transformer winding using fibre optic sensors should also
be provided. The probes shall be directly installed in each phase of power transformer
to measure the winding hot spot temperature. The fibre optic cables should be
brought out of the main tank to tank wall penetrator feed through a plate. The feed
through plate should be welded on the tank. The external fibre optic extension cable
shall then be run to the control cabinet. Separate temperature indicator should be
provided for hot spot measurement through this device. The fibre optic sensor
display shall be brought to the RTCC panel also.
(iv) a. One magnetic type oil level gauge with low level alarm contacts and dial showing
minimum, maximum and normal oil levels. The gauge shall be readable from the
gauge transformer base level.
b. One plain oil level gauge of over lapped type on other side of conservator.
(v) Minimum 3 no. pressure relief valves : The quantity of these valves should commensurate
with the quantity of oil in the transformer and also location of valves should be properly
designed to adequately release the excessive pressure.
(vi) A set of air release valves on the top and on the radiators and also at appropriate place
(vii) A safety valve of the chimney type with an equalizer pipe interconnecting the top of the
conservator and upper most part of the safety valve should be provided to prevent rise of oil
in the safety valve pipe. Any other substitute arrangement shall also be acceptable.
(viii) One thermometer pocket for mercury in glass type thermometer.
(ix) The safety valve pipe shall preferably take off from the side of the transformer tank near to
the tank cover and not from the top of the tank cover. The requirements shall be met as
specified in ‗CBIP‘ specification.
(x) One double float gas detector relay (Buchholz relay) with alarm and tripping contacts to
detect accumulation of gas and sudden changes of oil pressure, complete with shutoff valves
and flanges couplings to permit easy removal without lowering oil level in the main tank, a
blend valve for gas venting, and test valve. Make of buchholz relay shall be as per our
approved list of vendors.
(xi) Heat exchangers or radiators complete with shut of valves and with facility for oil draining
arrangement.
(xii)a/ Two oil conservator, with required accessories, one for main tankand other for OLTC.
b/ Air cell type breathing arrangement with oil preserving equipment complete in all respects.
(xiii) Eye bolts and lugs on all parts for easy handling.
(xiv) Two grounding earth terminals at diagonally opposite corner of tank.
(xv) One rating and diagram plate.
(xvi) A set of minimum 4 nos. flanged bi-directional wheels for rail mounting (for 1676mm rail
gauge).
(xvii) A set of fans required for ONAF cooling of the transformer with following information.
a. Number of Radiator Banks.

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b. No. of cooling fans of adequate voltage & rpm) provided in each bank to ensure 100% ONAF
rating of the transformer. As per our specification, for each bank one additional cooling fan is
to be included which will be duly wired-up.
(xviii) Suitable jacking lugs and haulage holes.
(xix) Thermosyphone filter assembly with complete details.
(xx) Inspection window & main holes with bolted cover as per Annexure-IV.
(xxi) Lifting arrangement for the complete transformer, core coil assembly and also tank.
(xxii) One foldable ladder on main tank.
(xxiii) For the purpose of taking earthing connection from the neutral bushing, adequate number of
brackets with small support insulators shall be provided on the body of the tank so that
earthing could be arranged by us near the earthing pit of transformer itself.
(xxiv) A separate weather proof FCC (Fan/Cooler control) cubicle shall be mounted on the
transformer containing dial type thermometer and winding temperature indicator and
terminals of dial, type thermometer, winding temperature indicator, buchholz relay, MDG,
control of fans etc.
Please note provision of separate Fan Control Cubicle (FCC) is a must. FCC shall be suitably
dimensioned to accommodate following:-
(a) The wiring from RTCC shall be brought to marshalling box and for terminating the
same adequate number of suitably rated terminal connectors shall be provided.
(b) Necessary cable glands shall be included in the scope of supply.
(c) Arrangement for terminating the connecting leads of OTI, WTI, buchholz, magnetic
oil level gauge etc. shall be made in the marshalling box. It should be possible to
read OTI and ETI readings without opening the box through suitable glass window.
All trip alarm and repeater signals will be transferred to control room for which
arrangement will have to be made.
(d) Starters for cooling fans shall be housed in marshalling box and necessary switches
for local operation of fans shall be provided.
(e) Local remote control switch for OLTC shall be provided.
(f) Space heater with switch, cubicle illumination lamp, fuses, links overload protection
arrangement for motors and other accessories shall be included in the scope of supply.
(xxv) One set of indoor RTCC (Remote tap changer control) cubicle complete with provision for
remote operation of OLTC, as independent or master/follower scheme, with oil and winding
temperature repeater, tap position indicator with annunciation for fan group ON/OFF and
cooler supply fail indicator and Tap changer in progress.
(xxvi) One set of erection manual/relevant drawing/leaflets should be secured permanently inside the
RTCC cubicle as a guideline for site erection and commissioning.
(xxvii) Three separate connection i.e. connection from core, connection from end frame and
connection from tank shall be brought out on to a terminal box with cover. Arrangement for
inter connecting these terminals in the terminal box shall also be provided. This arrangement
shall facilitate verification of core, end frame and tank insulation.
(xxviii) Mounting of radiators on the IV bushing should be avoided. In no case, the radiators should
be projected above the main tank height.
(xxix) All transformers shall be supplied with a full outfit of tools, spanners, jacks, special tools for
assembly and all spanners shall be single ended and of very good quality of ―Gedore‖ or
―Ttaparia‖ make.
2. The equipments and accessories furnished with the transformer shall be suitably mounted on
the transformer for ease of operation, inspection and maintenance and the mounting details
shall be subject to the approval of the purchaser. All valves shall be provided either with
blind companion flanges or with pipe plugs for protection.
3. Indication, alarm and relay equipment shall have contacts suitable for operation with
220V/110V DC supply. Any other accessories or appliances recommended by the
manufacturer for the satisfactory operation of the transformer shall also have 110 DC as input.
4. (a) OLTC and its controls shall be as per Clause 5.10 Section-II of specification.
(b) All cabinets & panels shall be conforming to stipulations under Clause-5.18 of
specifications.
(c) All 220/132KV and neutral bushings shall be of OIP condenser type and as per
Clause 5.7.1 Section-II of specifications.

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5. NIFP system as per clause 5.10.5.

6. On line DGA Monitoring device as per clause 5.6.1(b).
Accessories, which are not included in the above schedule but details of which are given in
tender specification and which are necessary for satisfactory operation of Transformer shall
be deemed to have been included in the accepted price without any extra cost to the CSPTCL.

*****

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ANNEXURE-III

LIST OF TRANSFORMER ACCESSORIES AND TEST CERTIFICATES

REQUIRED FOR THEM
S.No Accessory Test-certificates required
Condenser Appearance, construction and dimensional check.
Bushing Test for leakage of internal filling at a pressure of 1.0 Kg/cm for 12
hours.
Insulation resistance measurement with 2000V megger.
Dry/wet power frequency voltage withstand test.
Dry/wet power frequency voltage withstand test for test tap
insulation
Partial discharge measurement upto 1.5 UN 3Kv.
Measurement of tangent delta and capacitance.
Pressure Gauges/ Appearance, construction and dimensional check.
Differential Pressure Calibration test.
Gauges Alarm contact setting test.
OLTC. Oil tightness test for the diverter switch oil chamber at an oil
pressure of 0.5 Kg/cm2 at 100 degree centigrade for 1 hour.
Mechanical operation test.
Operation sequence measurement
Insulation resistance measurement using 2000V megger.
Power frequency voltage withstand test on diverter switch to earth
and between even and odd contacts.
Power frequency voltage withstand test on tap selector- between
stationary contacts, between max. and min. taps, between phases and
supporting frames, between phases.
Operation test of complete tap changer.
Operation and dielectric test of driving mechanism.
Winding & Oil Calibration test.
Temperature Dielectric test at 2 KV for one minute.
Indicator Accuracy test for indication and switch setting scales.
Test for adjustability of switch setting.
Test for switch rating.
Measurement of temperature rise with respect to the heater coil
current.
PRV Functional test with Compressed air to check bursting pressure,
indicating flag operation and switch operation.
Dielectric test at 2 Kv for one minute.
Switch contact test at 5A, 240 Volt AC.
Cooling fans Insulation resistance measurement.
Dielectric test at 2 KV between winding and body for one minute.
Operation check.
Appearance, construction and dimensional check.
Buchholz relay Leak test with transformer oil at a pressure of 3 Kg/cm2 for 30
minutes at ambient temperature for relay casing.
Insulation resistance measurement with 500V megger.
Dielectric test at 2KV for 1 minute.
Elements test at 1.75 Kg/cm2 for 15 minutes using transformer oil at
ambient temperature.
Loss of oil and surge test.
Gas volume test.
Mechanical strength test.
Velocity calibration test.
Appearance construction and dimensional check.

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Oil level indictor Test for oil levels.

Switch operation for low level alarm.
Switch contact test at 5A 240V AC.
Dielectric test at 2 KV for 1 minute.
Appearance, construction and dimensional check.
Pressed steel Air pressure test at 2 kg/cm2 under water for 15 minutes.
radiators Appearance, construction and dimensional check.
OLTC control Appearance, construction and dimensional check.
cubicle/ cooler Electric operation.
control cabinet Insulation resistance measurement using 500V megger at ambient
temperature.
Dielectric test at 2 KV for 1 minute.

Bushing current Appearance, construction and dimensional check.

transformer Polarity check.
Measurement of insulation resistance.
High voltage power frequency test.
Determination of ratio error and phase angle of measuring and
protection BCTs.
Determination of Turns ratio error for PS class BCT.
Determination of composite error for protective class BCT.
Interturn insulation withstand test.
Exciting current characteristic test.
Secondary winding resistance measurement.
Knee-Point voltage, measurement for PS class BCT.

Date SIGNATURE OF BIDDER

Place NAME
DESIGNATION
(SEAL)

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LIST OF VENDERS FOR MAJOR ITEMS OF TRANSFORMER

S. Name of Item Supplier/manufacturer

No.
1. CRGO M/s. Nippon steel corporation, Japan
M/s. Kawasaki Corp., Japan (M/s JFE, Japan)
M/s. Armco, USA,
M/s. Covefi, France
M/s. Salzgittar, Germany
M/s. S Usinor, France
M/s Transfer, France
M/s Mitsubishi, Japan.
M/s AST Terni, Italy
M/s. EBG India Pvt Limited, (Indian Agent) for
M/s GELSE NKIRCHEN, Germany
M/s British Steel Corporation , UK
M/s Thyseen Krupp Group of Companies
M/s. POSCO, Korea
M/s A.K.Steel USA

2. Winding conductor M/s Invex Filli Isolati Speciali s.p.a. Italy

(a) M/s. Asta
M/s. Smit Draad, Holland
M/s. Incab Industries, Jamshedpur
M/s. Sterlite Industries, Mumbai
M/s. Bhandari Conductor, Mumbai/ Mandideep.
M/s. Shakti Insulated Wires, Mumbai
M/s KSH International Pvt Limited, Taloja
M/s Delta-Trans Conductor, Mumbai
M/s Vijay Electricals, Hyderabad
M/s RIMA Transformers & Conductors (P) Ltd, Bangalore.
M/s Lacroix and Kress (GMBH) Germany
M/s Pirellicavi Italy
M/s Shree Cable & Conductors
M/s. Hindalco
M/s. Chandra Metals
M/s. BCPL Conductors

(b) CTC Conductor M/s Sam Dong Korea

M/s Invex Filli Isolati Speciali s.p.a. Italy
M/s Loc Roix AND KRESS – Germany
M/s. KSH International (P) Ltd.
M/s. Chandra Metals

3. Precompressed press M/s. H. Weidmann, Switzerland

Board & press Board M/s. Fige Holms Brruk, Swedan
components M/s. Senapathy Whiteley, Banglore
M/s. Raman Board, Mysore

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4. Insulating Material M/s. Dupont, USA

M/s. Senapathy Whiteley, Banglore
M/s. H. Weidmann, Switzerland
M/s. Munksio
M/s Amotfors, Sweden
M/s Krammerer
5. Air Cell M/s PRONL, France,
M/s. Swastik
M/s. Unirub
M/s. Rubber Products
M/s Sukrut Udyog
M/s Nu-cork Products (P) Ltd., Bhiwadi (Raj.)
6. Gaskets M/s. Talbros, Faridabad
M/s. Cortica, Chennai
M/s. Packing & Jointing, Chennai
M/s Indian Rubber Products, Haridwar
M/s Bombay Oil Seal Mfg. Mumbai
M/s MGM Rubber Kolkata
M/s Bharat Corrub Industries, Vadodara.
M/s Indian work Industries
M/s Works Product Pvt Ltd
M/s Nu-cork Products (P) Ltd., Bhiwadi (Raj.)
7. OIP Condensor bushing M/s. BHEL
M/s. CGL
M/s. TELK
M/s ASEA-MICAFIL
M/s. Trench
M/s. Alstom (earlier M/s. Areva)
M/s. Vijai Electricals Ltd.
M/s ABB
8. Terminal Connector M/s. Best & Crompton, Chennai
M/s. PeeVee Engg., Bangalore
M/s. Milind Engg., Mumbai
M/s. Nootan, Baroda
M/s Utsav, Baroda
M/s Vinayak and Co., Mumbai
M/s Megha Engg. Enterprises, Chennai
M/s Klemmen Engg. Corporation , Chennai
9. OTI/WTI with repeater M/s. Accurate Control,UK
M/s. AKM, Swedan
M/s. Perfect Control, Chennai, India
M/s. Preci Measure, Banglore
M/s Radix Electrosystems Pvt. Ltd/ Radix Pyrotech India
10. Magnetic oil gauge M/s. Sukrut Udyog, Pune
M/s. Yogya, Jhansi
11. Buchholz Relay M/s. Fukuda Instrument, Japan
M/s. Atvus,Calcutta
M/s. English Electric, Chennai
M/s. Prayog; M/s BHEL
M/s Instrument and Control, Vadodara
12. Pressure Relief Device M/s. Qualtrol, USA
M/s. GE, USA;
M/s. Sukrut Udyog, Pune
13. Fan & Motor M/s. Alstom (earlier Areva)
M/s. CGL, Mumbai
M/s. Khaitan, Calcutta.

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M/s EPC, Calcutta

M/s Marathan
14. Un-impregnated M/s. Permali Wallace Bhopal
Densified laminated M/s. Kit ply Assam
wood M/s. Mysore Polymers Banglore
M/s Narmada Forest Ind. Pvt. Ltd. Bhopal.
M/s Western India Plywood , Kerala
M/s Rochling Detonite
15. Valves M/s. Leader
M/s. Bombay Metal & Alloys
M/s. Audco
M/s. Petson
M/s. Manixon
M/s. Creseant
M/s Precision Engg. Kottayam,
M/s Eapen Joseph, Kottayam
M/s Apex Piping Systems, Jalandhar
M/s Liberty Engg., Mumbai
M/s Niton Valves, Mumbai
M/s Eapen Joseph & Co., Coimbatore
M/s Oswal Agra
M/s Neo Engg. Ahamedabad
M/s CG Valve Udaipur
16. MCB M/s. Sieman
M/s. MDS
M/s. S&S
M/s. Havell's
17. Fuse M/s. Siemens/ S&S / Areva / Havell's
18. Tank Steel M/s. SAIL/Jindal/Essar steel
19. OLTC Complete M/s. BHEL
M/s. CTR
M/s. TELK
M/s Easun, Madras
20. Terminal Blocks M/s. ELMEX
M/s. Technoplast,
M/s. Tosha
21. Silica gel Breather M/s. Yogya Enterprises, Jhansi.
M/s. Anusen Industries, Pune.
M/s Instruments & Controls , Vadodara, India
22. Transformer oil M/s Apar Limited, Mumbai
M/s Savita Oil Technologies
M/s. Raj Petrochemicals
23. Radiator M/s CTR Manufacturing Industries, Pune
M/s Thermal Transformer Product, Bangalore
M/s Exotherm, Bangalore.
M/s P.E. Engg. Hyderanad.
M/s Hitech Switchgear, Mumbai
M/s Mahindra Electrical works
M/s Triveni Electroplast
24. On line DGA monitor M/s. GE Kelman- Transfix DGA500
M/s. Morgan Schaffer Calisto-5
M/s. A-EBerley Hydrocol-1005
25. NIFP System M/s. CTR
M/s Easun Reyrolle

Note: The contractor should submit their offer considering the above mentioned vendors.

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DRAWINGS AND DATA TO BE FURNISHED BY THE CONTRACTOR.

The following drawings and data are to be submitted by the contractor for approval:

(a) Outline dimensional drawings of transformer and its accessories including conservator
complete with Bill of material and details of all parts, their quantity, rating & name of
Vendors indicating clearances of transformer body from live terminals i.e. HV, IV, LV.
(b) Drawing of transformer tank with location of inspection windows, thickness of side/bottom/top
of tank, details of stiffener.
(c) Drawing indicating limbed core construction with complete details of no., width and wt. of
core laminations with size of steps; thickness of core laminations ; dimension of window; size of
limbs; Gross and net core ; wt. of complete core.
(d) Drawing indicating core belting arrangement with details of belting, belting material etc.
(e) Large scale dimensioned drawings for HV , IV& LV windings of the transformer; size and no.
of parallel of HV, LV and IV of cooling ducts, coil clamping arrangement, no./size & location
of pressure screws, clamping ring; top yoke arrangement etc. The details should commensurate
with the short circuit calculations submitted by you for each rating of transformer
(f) Detailed drawing of transformer tank with complete core and winding indicating clearances
inside transformer tank as also passage and space for free movement of at least two persons
for inspection of active parts etc .
(g) Schematic diagram showing the flow of oil in the cooling system as well as each limb and
winding. Longitudinal and cross-sectional views showing the duct sizes, cooling pipes etc. for
the transformers/radiators drawn to scale .
(h) Drawings giving the weights for foundations.
(i) Combined Rating and diagram plate including tap changing, which should also include details of
guaranteed and measured no load and load losses as also winding resistances and percentage
impedances at all taps.
(j) Schematic control and wiring diagram for all auxiliary equipment and control cubicle.
(k) Drawing showing constructional details, dimensions, mechanical & technical particulars of
bushings. Arrangement of terminals and details of connection of bushing shall also be indicated
in drawing with their technical particulars.
(l) Transportation drawing of transformer.
(m) Details of fittings and cable box.
(n) Drawing showing arrangement and details of tap changing gear including selector switch,
diverter switch and drive mechanism.
(o) Valve Schedule plate.
(p) Oil filling instruction plate for conservator fitted with Air cell breather arrangement
including equalizing arrangement if any required at the time of taking full Vacuum at site.
(q) Drawing and instruction for fitting ofAir Cell.
(r) Drawing of conservator indicating internal details of air cell MOG, oil level gauge and silica gel
breather pipe fitting arrangement.
(s) Drawings of all HV IV & LV bushings with complete details meeting TS requirement.
(t) Drawings of HV,IV,LV& neutral terminal connectors indicating plate thickness, no. of nut
bolts with size and other details.
(u) Drawing of foldable& detachable ladder with its complete details and fitting arrangement on
transformer/ conservator tank.
(v) Drawing for HV/IV/LV neutral earthing arrangement indicating voltage rating of insulators and
its fitting arrangements, size of copper strips, terminal connectors etc.
(w) Detailed drawing indicating two views of all valves provided in the transformer tank.
(x) Detailed internal drawing of transformer indicating transportation locking arrangement provided
to avoid shifting of core assembly.
(y) Drawing showing weights of transformers, cooling fan structures, FCC structures with distance
from central line of transformer for casting of civil foundation for transformer and associated
equipments.
(aa) Drawing of Earthing terminal box showing earthing arrangement for core, end frame, tank
giving details of voltage class and current rating of terminal bushings.
(ab) Drawing indicating insulation thickness details and other arrangement provided between core
assembly and bottom yoke and base of bottom of tank.

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(ac) Drawing indicating details of ‗O‘ ring gasketting arrangement provided in transformer tank
covers.
(ad) Detailed Drawing of jacks.
(ae) Drawing of stiffeners provided on top, each faces/sides of tank with their number and size.
(af) Drawing indicating number, location, size of shields/ magnetic shunts and its material provided
inside the tank as per clause 11.1 (g).
(ag) Drawing indicating internal details of transformer giving complete details of clearances from live
parts.
(ah) Drawing of internal LV winding termination arrangement indicating minimum clearance
between core and LV take off lead.
(ai) Drawing for Lead termination to bottom of HV IV& LV Neutral Bushings
(aj) Drawing for Lead termination to bottom of HV IV& LV bushings.
(ak) Internal drawing & design of Core & Winding indicating all attachment with identification
numbers, description including take-off arrangement of lead connection for Core & End frame
and related Bill of Material
(al) Locking arrangement drawing for tank top cover, core & winding with complete dimension &
details.
(am) Plan view of the bottom of Bell Tank for complete details of core coil resting arrangement,
indicating clearly dimensional details, material of insulation, clamping arrangement with details
of nuts/ bolts,clearance from all sides provided at bottom.
(an) Drawing indicating complete details, dimension & mounting arrangement of OLTC inside the
tank with respect to End frame.
(ao) Drawing indicating complete details, dimensions & fixing arrangement of static end rings if
used.
(ap) Other relevant drawings.

The manufacturer shall supply four (4) copies of the drawings as listed out above, which
will describe the equipment in details for approval.Three sets of instruction books, operation and
maintenance manuals and spare part bulletin, shall be supplied. In addition to above two sets of
manuals and drawings with test certificates for each unit to be despatched as per despatch instructions.

It will be obligatory on the part of the manufacturer to ensure that the weight of core
lamination, weight of copper ,weight of steel , weight of transformer tank along with fitting and
accessories, quantity of oil for first filling including wastage and 10 % extra of that quantity, total
weight of core plus winding after assembly, total weight of transformer and other dimension of
transformer are worked out carefully. It may be noted that at the time of submission of final drawings,
variation in these weights beyond the limits of (+) 5% shall not be permitted.

DETAILS OF INSPECTION PROGRAMME

(A). Inspections to be performed at manufacturer‘s works in presence of CSPTCL‘s representative
and/ or a representative of NABL accredited third party.

1.0 Stage Inspection:

It may be noted that stage inspection for all the units at CSPTCL‘s discretion shall be done at
manufacturer‘s works in presence of CSPTCL‘s representative and representative of third
party authorized by CSPTCL at the following stages.

After the core is built but before its clamping, CSPTCL‘s representative will inspect the core
to take complete weight of the core and also to measure approximate core loss. If necessary, a
small strip of core shall also be taken for testing at ERDA/ CPRI at our discretion.

Once the coils are prepared and are fitted on to the core, stage inspection of the core coil
assembly shall be done to take measurements of HV/ LV windings. A small piece of
conductor for each type of winding shall be made available by the manufacture. The magnetic
balance test shall also be carried out during this stage inspection.

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Apart from the above, the CSPTCL also reserves the right to carry out stage inspections at
other stages also, for which advance intimation shall be given and all necessary cooperation
shall be rendered by the manufacturer.

2.0 Final inspection:

After satisfactory stage inspections, ovening of core coil assembly and tanking thereafter shall
be carried out by the manufacturer. Call for final inspection of the transformer shall be given
after readiness of transformer in all respects. During the final inspection, all routine and
additional routine tests shall be carried out on each unit according to the methods specified in
IS:2026 (Part-I):2011 and IS:2026 (Part-III):2009. These tests shall be witnessed by
CSPTCL‘s representative and representative of third party authorized by CSPTCL The details
of the tests to be carried out are as given here under:

Sl. Particulars
(A) Routine tests:
1 Measurement of winding resistance
2 Measurement of voltage ratio and check of phase displacement
3 Measurement of Impedance voltage/ short circuit impedance (Principal tap) & load
loss
4 Measurement of no load loss at 90%, 100% & 110% of rated voltage and no load
current
5 Measurement of Insulation resistance
6 Dielectric routine tests as per IS:2026 (Part-III) i.e. lightning impulse tests on all
phases of HV/LV windings, short duration induced AC withstand voltage tests,
separate source AC withstand voltage tests
7 Tests on load tap changers
(B) Addl. Routine Tests:
1 Dimensional checks as per approved drawing & specification
2 Magnetic circuit test. After assembly ,core shall be tested for 1 minute for 2000 volts
AC between all bolts, side plates & structures steel works
3 Polarisation index – IR value for 15 sec, 60 sec & 600 sec duration shall be recorded
and PI for 600/60 sec and DAR i.e. ratio of IR values of 60/15 seconds shall be
recorded. The PI value (600/60 sec) should be ≥2 and DAR value (60/15 sec) should
be ≥1.3. These values should be recorded both before and after HV tests.
4 Tank oil leakage test – the complete transformer assly filled with oil shall be subjected
to nitrogen pressure of 0.35 Kg/cm2 above the normal oil head for a period of 12 Hrs
to ensure that there is no oil leakage.
5 Capacitance and tan delta measurement to determine capacitance between wingding
and earth. This test should be carried out before and after series of dielectric tests by
ANSI II method.
6 Test on bushings and tan delta capacitance and IR values
7 Checking of recording of IR values
(a) Between core & coil frame
(b) Between core & tank
(c) Between coil frame & main tank
The measured IR values should be more than 1000 M Ohms.
8 Magnetic balance and magnetizing current (3 phase & 1 phase at normal tape) test
9 Tests of PRDs for successful operation
10 Oil BDV test before & after HV tests
11 Sweep Frequency response analysis (FRA)- SFRA shall be carried out at
manufacturer‘s works with his own SFRA test set. The test shall be repeated at site
with same test set.

Further, following type & special tests as per clause 6.2, Section-II of tender specifications shall be
carried out on one unit out of the lot.

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Temperature rise test as per IS:2026 (part-I) & clause 4 of IS:2026 (part-II) on both ONAN/ONAF
ratings.
Tank vacuum test and tank pressure test
Test on pressure relief devices
i) Measurement of zero Seq. Reactance.
ii) Measurement of acoustic noise level.
iii) Measurement of power taken by fans.
iv) Measurement of harmonic level in no load current.
v) Lighting impulse with chop on tail on all 3 phase of HV and LV terminals.
vi) One cooler cabinet and OLTC cabinet of the transformers (preferably for the first unit of the
lot) shall be tested for IP:55 protection in accordance with IS: 2147. In case facility for this
test is not available with the manufacturer, the test has to be carried out at the laboratory of
either CPRI or ERDA in presence of CSPTCL‘s representative and test report should be
furnished.
Tests on Assembled Transformer:
a) Check completed transformer against approved out line drawing, provision for all
fittings, finish level etc.
b) Jacking test on the assembled Transformer.

3.0 Tests to be conducted at destination site of CSPTCL:

On delivery / receipt, after erection at site, the transformer shall be subject to the following
tests, in presence of supplier‘s engineer.

3.1 Tests on reaching at site:

(i) Immediately upon receipt of transformer at site and before unloading of transformer from
trailor, core earthing, end frame earthing and tank earthing shall be checked. Only after
satisfactory verification that there is not multiple core earthing in transformer, unloading of
transformer shall be undertaken.
(ii) After receipt of transformer at site physical inspections shall be done for checking any
physical damage to transformer tank and accessories. Further, data of impact recorder shall
be analyzed for any changes before unloading of transformer.

3.2 Pre commissioning tests:

(i) Insulation resistance test and polarization index.
(ii) Ratio and polarity test
(iii) DGA of oil and di-electric, tan delta, resistivity & moisture content test of oil.
(iv) OLTC operational test at each tap for lower and raise operation of tap changer.
(v) Magnetic balance tests and measurement of magnetizing current.
(vi) Vector group test
(vii) Percentage impedance test at all taps
(viii) Short circuit current measurement at low voltage and at all taps
(ix) Measurement of winding resistance at all taps
(x) Tangent delta, capacitance and insulation resistance tests of bushings
(xi) Measurement of IR values between core & coil frame, core & tank end coil frame and tank.
(xii) Dew point measurement and recording of pressure of nitrogen gas.
(xiii) SFRA test.

The SFRA test and Dew point measurement shall be carried out in presence of manufacturer‘s
representative. The test kits shall be same as used for carrying out these tests in the factory
and shall be brought by manufacturer‘s representative.
(B). Checks to be performed by the manufacturer during various stages of manufacturer of
transformer. The in house test reports may be reviewed by CSPTCL‘s representative during
stage / final inspection.
Tank and conservator:
Certification of chemical analysis and material tests of plates.
Welder‘s qualification and weld procedure.
Testing of electrodes for quality of base materials and coatings.

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Inspection of major weld preparation and joint.

Crack detection of major strength weld seams by ‗dye penetration test‘.
Measurement of film thickness of:
Oil insoluble varnish.
Zinc chromate paint.
Finished coat.
Check correct dimensions between wheels, demonstrate turning of wheels through 90 degrees
and further dimensional check.
Check for physical properties of materials for lifting lugs, jacking pads etc. All load bearing
welds including lifting lug welds shall be subjected to NDT.
Tank vacuum & Tank pressure tests as per CBIP manual on transformer & as per this
specification.
Leakage test of the conservator and tank.
Measurement of thickness of tank plates i.e. top, Bottom & Sides.
All double welds shall be tested for leaks with dry nitrogen, at the pressure not less than 7
kg/sq.cms. (atm)
All tanks, single welds, cooling coils, radiators valve and other parts necessary for complete
transformer shall be tested for leaks and strength by applying pressure not less than 0.7 atm
for a period of 24 hrs or not less than 1 atm for a period of 06 hours. If leaks occur, the tests
shall be conducted after all leaks have been stopped.
Certification of all test results.
2. Core:
Sample testing of core material for checking thickness of lamination, special loss, bend
properties, magnetization characteristics (B-H Curve) and Epstein curve.
Check on the quality of varnish, if used on the stampings.
Measurement of thickness and hardness of varnish on stampings.
Solvent resistance test to check that varnish does not react in hot oil.
Check overall quality of varnish by sampling to ensure uniform shining colour, no bare spot,
no over burnt varnish layer and not bubbles on varnished surface.
Check on the amount of burrs.
Bow check on stampings.
Check for the over lapping of stampings, Corners of the sheets are to be apart.
Visual and dimensional check during assembly stage.
Check on completed core for measurement of iron loss characteristic and check for any hot
spot by exciting the core so as to induce the designed value of flux density in the core.
Visual and dimensional checks for straightness and roundness of core, thickness of limbs and
suitability of clamps. Weightment of core with belting after building up.
High voltage test of 2KV for one minute between core and clamps.
Certification of all test results.

3. Insulating material:
Sample check for physical properties of materials.
Check for dielectric strength, .
Visual and dimensional checks.
Check for the reaction of hot oil on insulating materials.
Dimensional stability test at high temperature for insulating material.
Tracking resistance test on insulating material.
Certification of all test results.

4. Winding:
Sample check on winding conductor for mechanical properties and electrical conductivity.
Check insulating distance between high voltage/low voltage connection, cable and earth and
other live parts.
Check for proper cleanliness and absence of dust.
Visual dimensional checks on conductor for scratches, dent marks etc.
Sample check on insulating paper for PH values bursting strength and electric strength.

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Check for bonding of insulating paper on conductor and absence of short circuit between
parallel strands.
Check for brazed joints wherever applicable.
Measurement of voltage, when yoke/core is completely restocked and all connection are
ready.
Measurement of no. of turns in each winding and cross sectional area of windings.
Weightment of windings.
Certification of all test results.
5. Checks before drying process:
Weight of complete core, winding and insulation.
Check condition of insulation of the conductor and between windings, Insulation gap between
HV connection, cables, earth and other live parts. Similarly check for HV/LV connections.
Insulation of core shall be tested at 2KV /min between core to bolts and core to clamp plates.
Check for proper cleanliness and absence of dust etc.
Certification of all test results.

6. Checks after drying process:

Record measurement of temperature, vacuum and drying time during vacuum treatment.
Check for completeness of drying by measuring IR values and Tan Delta.
DP test shall be carried out after jacking test.

7. Pre shipment check at manufacturer‘s works:

Check for inter changeability of components of similar transformers for mounting
dimensions.
Check for proper packing and preservation of accessories like radiators, bushings, explosion
vent, dehydrating breather, rollers, buchholz relay, fans, control cubicle, connecting pipes,
conservator etc.
Check for proper provision of bracing to arrest the movement of core and winding assembly
inside the tank.
Gas tightness test to conform tightness.
Derivation of leakage rate and ensure adequate reserve gas capacity.
Note:
(i). Further tests:
The Purchaser reserves the right to having other reasonable, tests carried out at his
own expenses either before shipment or at site to ensure that the transformer complies
with the requirements of this specifications.
(ii). Test reports:
After all tests have been completed seven certified copies of each test report shall be
furnished. Each report shall supply the following information:

(i) Complete identification data including serial number of the transformer.

(ii) Method application, where applied duration and interpretation of results for
each test.
(iii) Temperature data corrected to 75 degree centigrade including ambient
temperature.

LIST OF HAND TOOLS & JACKS TO BE SUPPLIED ALONG WITH THE POWER
TRANSFORMER

One tool box consisting of the following hand tools of reputed make shall be supplied.

No. Spanners of different sizes

1 a) Open jaw double ended 08 No.
b) Cranked ring double ended 03 No.
c) Tubular Box double ended 01 No.

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2 Tommy Bar (for Tabular Box spanner)

3 Adjustable wrenches 02 No.

4 Pipe wrench 01 No.
5 Screw Drivers of different sizes 05 No.
6 Flat Nose, Round Nose, Side Cutting Pliers 03 No.
7 Gasket punches 10 No.
8 Filkeswith Handles 02 No.
9 Hammers with Handles 02 No.
10 Knife with Handles 02 No.
11 Adjustable Hacksaw 01 No.
12 Cold Chisel 01 No

ROUTINE AND ADDITIONAL ROUTINE TESTS

Remarks (mention specific
Sl. comments regarding tests
Particulars
No. results as per standards or
not)
(A) Routine tests:
1 Measurement of winding resistance – The resistance of HV,
IV & LV windings should be carried out at different taps and
values at the ambient temperature & converted values at 75
deg C should be recorded in a separate sheet.
2 Measurement of voltage ratio and check of voltage vector
relationship – The measurement of HV to LV ratio at all taps
should be recorded and ratio error should be mentioned in a
separate sheet. The voltage vector relationship should also be
recorded to ensure the vector group of the transformer.
3 Measurement of Impedance voltage/ short circuit impedance
(Principal tap) & load loss – Tests to be carried out at normal,
highest & lowest tap
4 Measurement of no load loss & current – The values of no
load loss and no load current at normal tap at 90%, 100% &
110% of rated voltage should be recorded before and after
dielectric test.
5 Measurement of Insulation resistance – The insulation
resistance between HV/tank, LV/tank & HV/LV should be
recorded with 5KV megger for 15 seconds, 60 seconds & 600
seconds. The values and PI of 60th / 15th& 600th / 60th
should be mentioned in a separate sheet. The values should be
recorded before & after HV tests.
6 Dielectric tests – Separate sources voltage withstand tests,
induced over voltage withstand test and lighting impulse
withstand tests on all phases of HV & LV as per IS: 2026
should be carried out in following sequence: (i) One reduced
full wave impulse
(ii) Three 100% full impulse
(iii) 650KV p for HV and 170KV p for LV winding. Results
should be indicated in separate sheet with Oscillograms output
should be enclosed.
7 Tests on load tap changers - The testing of OLTC should be

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done as per clause 16.9.1 of IS:2026 part-I. After the tap

changer is assembled on the transformer, the following tests
should be performed at 100% of rated auxiliary supply
voltage.
(i) Eight complete operating cycles with transformer not
energized. (ii) One complete operating cycle with
transformer not energized with 85% of rated auxiliary supply
voltage. (iii) One complete operating cycle with the
transformer energized at rated voltage and frequency at no
load loss. (iv) Ten tap change operations with +/- two steps on
either side of the normal tap with as far as possible rated
current of the transformer with one winding short circuited.
(B) Addl Routine Tests:
1 Dimensional checks as per approved drawings &
specifications – All dimensions as per approved drawing
should be checked.
2 Magnetic circuit test. After assembly ,core shall be tested for
1 minute for 2000 volts AC between all bolts, side plates &
structures steel works
3 Tank oil leakage test – the complete transformer assly filled
with oil shall be subjected to nitrogen pressure of 0.35
Kg/cm2 above the normal oil head for a period of 12 Hrs to
ensure that there is no oil leakage.
4 Capacitance and tan delta measurement to determine
capacitance between wingding and earth. This test should be
carried out before and after series of dielectric tests.
5 Test on bushings: All tests on bushings including capacitance,
creepage distance & tan delta measurement as per IS
6 Checking of recording of
(A) IR values
(a) Between core & coil frame
(b) Between core & tank
(c) Between coil frame & main tank
The measured IR values should be more than 1000 M
Ohms.
(B) Measurement & recording of currents with application of
400V 3 phase AC supply on HV side & LV side shorted
(a) Between core & coil frame
(b) Between core & tank
(c) Between coil frame & main tank
7 Magnetizing current measured with LT supply (before and
after HV tests)
Particulars With three/single phase supply
Volts Amp
8 Magnetic balance test (before and after HV tests)
9 Tests of PRDs for successful operation
10 Oil BDV test before & after HV tests
11 Frequency Response Analysis (FRA)

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TYPE AND SPECIAL TESTS

The following type tests shall be performed:
(i) Temperature rise tests as per clause 4 of IS: 2026 part-II. – The temperature rise of oil &
winding should not be more than the limits specified in the tender specifications.
(ii) Tank vacuum tests:
One transformer tank out of the whole lot shall be subjected to the specified vacuum. The
tank designed for full vacuum shall be tested at an internal pressure of 3.33 KN/m 2 absolute
(25 torr) for one hour. The permanent deflection of flat plate after the vacuum has been
releases shall not exceed the values specified below.

Horizontal length of flat plate (in mm) Permanent Deflection (in mm)
Up to and including 750 5.0
751 to 1250 6.5
1251 to 1750 8.0
1751 to 2000 9.5
2001 to 2250 11.0
2251 to 2500 12.5
2501 to 3000 16.0
Above 3000 19.0

(iii) Tank Pressure Test

Transformer tank together with its radiator, conservator, vessel and other fittings shall be
subjected to a pressure corresponding to twice the normal head of oil or to the normal
pressure plus 35 KN/m 2 whichever is lower, measured at the base of the tank and maintained
for one hour. The permanent deflection of flat plates after the excess pressure has been
released after conducting vacuum test should not be more than the values specified above.
(iv) Measurement of zero sequence reactance as per clause 16.10 of IS:2026 part-I.
(v) Measurement of acoustic noise level as per clause 16.12 of IS:2026 part-I.
(v) Measurement of harmonics of the no load current as per clause 16.13 IS:2026 part-I.
(v) Measurement of power taken by the fans as per clause 16.14 of IS:2026 part-I.
(vii) Lightning impulse tests with chop on tail as per clause 14 of the IE:60076. The sequence to be
followed for routine lightning impulse tests and chopped lightning impulse tests for this
particular unit shall be as mentioned here under:
One reduced level full impulse;
One full level full impulse;
One or more reduced level chopped impulse(s);
Two full level chopped impulses;
Two full level full impulses.
(viii) One cooler cabinet and one OLTC cabinet of the transformer shall be tested for IP:55
protection in accordance with IS:2147. This test may be conducted either at manufacturer‘s
works or any other Govt. approved laboratory.

Sequence of tests
The sequence of routine tests, type tests, special tests (whenever applicable) and routine tests required
to be conducted on the transformer is as mentioned hereunder:

Sl.No. DESCRIPTION
1 Dimensional checks as per approved drawings & specifications
2 Pressure relief device test.
3 Degree of protection IP 55 for OLTC & cooling control cabinets.
4 Magnetic circuit insulation test 2 KV- 1 Min. core to Yoke clamp, core to fixing
plate, core bolt to Yoke.

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Sl.No. DESCRIPTION
5 Checking of IR values
(a) Between core & coil frame
(b) Between core & tank
(c) Between coil frame & main tank
The measured IR values should be more than 1000 M Ohms.
6 Magnetic balance test at normal and extreme taps.
7 Magnetizing current measured with LT supply (both single phase and three phase)
8 Voltage ratio at all taps & polarity/phase displacement at normal tap.
9 IR value at 15, 60, 600 sec (before & after HV & Heat Run tests). PI value should
not be less than 2
10 Capacitance and tan delta (before & after HV & TR tests) at 5 KV & 10 KV, LV +
TANK, HV + LV to TANK under grounded, ungrounded and guarded specimen
modes.
11 Winding resistance measurement at all taps.
12 Oil DGA test (before and after HV & TR tests)
13 Oil BDV test (before and after HV & TR tests)
14 No load loss and current (before & after HV & TR Routine Tests) at 90%, 100%
and 110% of rated voltage with 3Watt meter, 3A and 3V meters methods.
15 Separate source voltage withstand test
16 Induced over voltage withstand test
17 Harmonic analysis of no load current at 90%, 100%, 110% of rated voltage
18 Zero sequence impedance test at 10%, 20%, 60%, 80%, 100% of test current at
extreme taps and normal taps.
19 Impulse test as per specifications on all phases.
20 Load loss at extreme taps & normal tap & impedance all taps by digital power
analyser.
21 Temperature rise test at ONAN & ONAF ratings & quoted max. losses.
22 Measurement of power consumption by fans
23 Max. static head of oil measured at the base for 12 hrs.
24 Tests on OLTC: Circuit insulation test 2 KV- 1Min.
25 Operations tests: 8 Cy, 1 Cy at 85% V 1 Cy at no-load and Rated V, 10 Cy + / - 2
steps from normal tap and rated current.
26 Cooler control test: Circuit insulation test 2 KV- 1 Min.
Operation test.
27 Bushing current transformer ratio & polarity tests.
28 Acoustic noise level test.
29 Frequency Response Analysis (FRA)
30 Tests of PRDs for successful operation

***

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4. TECHNICAL SPECIFICATION OF 132/33 KV, 63 MVA POWER

TRANSFORMER

Scope:
1.1 This specification covers design, engineering, manufacture, assembly, stage testing inspection
and testing before supply and delivery of 02 (Two) No. 63 MVA, 132/33 KV 3-phase two
winding transformers complete with all fittings, accessories and associated equipment‘s
which are required for efficient and trouble free operation.
1.2 It is not the intent to specify completely herein all detail of the design and construction of
equipments. However, the equipment shall conform in all respects to standards of
engineering, design and workman ship listed in clause no. 2 and shall be capable of
performing in continuous commercial operation up to the contractor‘s guarantee in a manner
acceptable to the purchaser, who will interpret the meanings of drawing and specification and
shall have the power to eject any work or material which, in his judgment, is not in
accordance therewith. The equipments offered 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 contractor‘s supply, irrespective of whether those are specifically
brought out in this specification and / or in the work order or not.
1.3 The transformers shall conform in all respects to high standards of engineering, design,
workmanship and latest revision of relevant standards at the time of offer and purchaser shall
have the power to reject any work or material which, in his judgment, is not in full accordance
therewith.
1.4 Climatic Conditions:
Peak Ambient Temperature 50 Degree Celsius
Minimum Temperature in Shade 6 Deg. C
Maximum Relative Humidity 95% (sometime approaches saturation)
Average number of thunderstorm 58 days per annum.
Average number of rainy days per annum 90 days.
Average Annual Rainfall 125 cm.
Maximum Wind Pressure 150 kg/meter square.
Altitudes (Not Exceeding) 1000 metres.
Seismic Level Horizontal g.

Standards:
2.1 The transformers and associated accessories shall conform to the latest issues of standards as
given below:
Indian Internationally
Title
Standard recognised std.
IS-2026 (part Power Transformers IEC-76
I to V)
IS-3639 Fittings & Accessories for power transformers
IS-335 Insulating oils for Transformers. IEC-296, BS-148
IS-2099 Bushings for alternating Voltage above 1000 V IEC-137, BS-223
IS-2705 Current Transformers IEC-185
IS-325 Three phase Induction Motors IEC-34
IS-375 Marking & arrangements for Switchgear, bus bars, Main
Connections and auxiliary Wiring.
IS-3737 Gas operated relays
IS-1886 Code of practice for installation and maintenance of
transformers
IS-2147 Degrees of protection.
IS-5 Colors for ready mix paints
IS-6272 Industrial cooling fans
IS-6600 Guide for loading of oil Immersed transformers BSCP-0160
IS-778 Gun metal gate, globe and check valves for general

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purpose
IS-3401 Silica gel.
IS-4253 Park & Rubber
IS-5561 Electric power connector
IS-5578, IS- Marking & arrangement for switch gear, bus bar, main
11353 connections and auxiliary wiring.
IS-9434 Guide for sampling and analysis of dissolved gas in oil
filled equipments.
IS-12676 Oil impregnated paper insulated condenser Bushing
Dimension and requirements.
Insulation Co-ordination IEC-71
Indian Electricity rule, 1956
CBIP publication No. 275 Manual on power
transformers
DOC.ETD Draft standard by BIS for revision of IS-8468 for OLTC
16 (3487)
DOC.ETD Draft standard by BIS for revision of IS-3639 for fitting
16 (3574) & accessories for transformers part-I-standardization of
conservator
DOC.ETD --- do --- part 2: dehydrating breather
16 (3575)
DOC.ETD --- do --- part 3: earthing terminals
16 (3576)
DOC.ETD --- do --- part 4: temperature indicators
16 (3577)
DOC.ETD --- do --- part 5: rating & diagram plate
16 (3578)

Equipment meeting with the requirements of other authoritative International standards which
ensure equal or better performance than the standards mentioned above shall also be
considered. When the equipment offered by the bidder conforms to other standards adopted
and the standards salient points of difference between standards adopted and the standards
specified in this specification shall be clearly brought out in the offer. Two copies of such
standards with authentic translation in English shall be furnished along with the offer.

3. Auxiliary power supply:

Auxiliary electrical equipment shall be suitable for operation on the following supply
system:-
Power Devices Like drive motors 415 V, 3 Phase 4 wire 50 Hz, neutral grounded
AC supply
Lighting, space heaters and fractional 240 V, single phase, 50 Hz neutral grounded AC
kW motors supply.
Alarm, control and protective devices 220 V/110 V DC, 2 wire with facility for selection
of either 220 volt or 110 volt.
Each of the foregoing supplies shall be made available by the bidder at the terminal point for
each transformer for operation as accessories and auxiliary equipment. Bidders scope include
supply of interconnecting cables, terminal boxes etc. the above supply voltage may very as
below and all. Device shall be suitable for continuous operation over entire range of voltages.

i) AC supply: Voltage +10% (-) 20%, frequency + 5%

ii) DC supply: (-) 15% to +10%

4. PRINCIPAL PARAMETERS (63 MVA TRANSFORMERS):

The transformer shall conform to the following specific parameters: -

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Sl.
Item Specification of 63 MVA x-mer
No.
1.1 Rated Voltage Ratio: kV 132/33
1.2 Highest system voltage 145/36 KV
2.0 No. of windings Two winding transformer
3.0 Type of cooling ONAN/ ONAF
4.0 MVA rating corresponding to cooling
system:
a) ONAN Cooling 80% (50 MVA)
b) ONAF Cooling 100%(63 MVA)
5.0 Method of connection HV & LV Star
LV delta
6.0 Connection Symbol (vector group) YN yn0
7.0 System earthing Solidly/ Effectively earthed
8.0 (a) Percentage Impedance‘s (HV-LV), % Impedance Tolerance
Voltage on normal tap and MVA base 10 +-10%
Corresponding to HV rating and applicable
tolerances:
(b) Insulation resistance at an ambient temp. HV/LV- Min. 4000 M.Ohms,
of 30 deg with 5 KV megger for 600 HV/E, LV/E- Min 3000 M. Ohms
seconds duration

(c) Polarisation Index i.e. Ratio of megger >= 2

values of 600 secs to that of 60 secs
(d) DAR (Dielectric Absorption ratio) i.e. >= 1.3
ratio of IR value of 60 sec. to 15 sec.
9.0 Anticipated continuous loading of windings:
a) HV and LV 110% of its rated capacity.
10.0 Tap changing gear:-
Type OLTC for HV neutral end.
2) Tap range & steps -15% to + 5%, steps 1.25%
3) Rated for 132 KV (neutral end) & 500 A (Min.)
11.0 Over voltage operating capability and 110% rated voltage Continuous
duration 125% rated voltage for 60 secs.
140% rated voltage for 5 secs.
12.0 Minimum Air core reactance of HV 20%
windings.
13.0 The voltage for which star point shall be The insulation class of the neutral end of
insulated to the earth the winding shall be graded to 95 KV.
14.0 (a) Max. Flux density in any part of core 1.6
and yoke at rated MVA, frequency and
normal voltage (Tesla)
(b) No load current of the transformer at 0.5% of rated current (Maximum)
105 % of rated voltage
(c) Current density in winding <= 3 Amp/ sq. mm (max.)
15.0 Insulation levels: For windings HV LV
15.1 1.2/50 microsecond wave shape impulse 650 170
withstand (kVp)
15.2 Power frequency voltage withstand (kV 230 95
rms.)

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15.3 Tan delta values of winding The measured Tan delta values of
winding shall not exceed 0.45% at 200C
temperature. In case Tan delta of
transformers during testing at works of
manufacturer is measured above
maximum ceiling of 0.45% at 200C
temperature, then CSPTCL reserves right
not to accept such of the transformer. This
requirement is to be confirmed
specifically by the Bidders in their offer.
16.0 Type of winding insulation:-
HV/IV winding graded
LV winding full
17.0 System short circuit level and duration for 132KV side of transformer shall be
which the transformer shall be capable to connected on a infinite bus & 33KV shall
withstand thermal and dynamic stresses (kA be capable to withstand terminal short
rms / sec) circuit for 3 sec. duration.
18.0 Maximum partial discharge level at 500 pico coulombs
1.5/sq.root 3 of rms. Phase to ground
voltage.
19.0 Noise level at rated voltage and frequency 81 Db

20.0 Permissible temperature rise: Over ambient

temp.
20.1 Of top oil measured by thermometer. 400 c
20.2 Of winding measured byresistance. 450 c
20.3 Gradient between oil & winding temp 160 c (max)
21.0 Minimum clearances in air (mm): Phase to phase Phase to ground
21.1 HV 1430 1270
21.2 LV 700 660
22.0 Terminals:-
22.1 HV Winding Line end (OIP condenser 170 KV
bushing)
22.2 HV/LV Winding Neutral 72.5 kV OIP condenser bushing
22.3 LV Winding 72.5 kV OIP condenser bushing with
center spacing of 1000 mm.
23.0 Max. Radio Interference voltage level at 1 1000 micro volts
MHz & 1.5/sq root 3 of rms phase to ground
voltage for HV winding
24.0 Minimum Visual Corona extinction voltage 320 KV rms
25.0 Cooling Equipment‘s: Number of Banks Two Banks each 50%
with Adequate number of Fans.
26.0 Bushings: HV LV
26.1 Voltage rating Kvrms 170 72.5
26.2 Current rating 1250 1250
26.3 Insulation level:
a.Lightning impulse with stand (kVp) 750 250
b. 1 Minute power frequency 275 140
withstand voltage (kV rms)
26.4 Creepage distance (mm) 3625(132 KV) 1813(33 KV)
27.1 Maximum permissible losses at rated
voltage & frequency (without any positive
tolerance)
a) No Load Losses (Iron losses) 22.5 - 25 KW
b) Load (Copper Losses) +Aux. Losses 133– 147.5 KW
c) Auxiliary losses 2.3 – 2.5 KW

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27.2 No load losses at 110% of rated voltage & Not more than 130% of the losses at rated
rated frequency voltage & frequency
28. Type of design of the transformer Only Bell type tank construction is
acceptable
29. Tank sheet thickness
(i) Top & bottom Minimum 20 mm
(ii) Sides Minimum 10 mm
30. Conservator tank sheet thickness Minimum 8 mm
31. There shall be two CT cores per HV, LV Ratio for HV & HVN bushings - 400/1-
and HVN/LVN Bushing CT for REF (1- 1A KPV- min. 800V Accuracy: PS (both
phase ring type turret mounted). cores)
Ratio for LV & LVN bushings - 1200/1-
1A KPV- min. 1200V Accuracy: PS
(both cores)
32. There shall be one CT core in middle phase Ratio to be specified by the Bidder
of HV and LV Bushings for WTI
33. Transformer oil:
(a) Appearance The oil shall be clear and transparent and
free from suspended matter or sediment
(b) Density at 27o C max. 0.89g/cm3
(c) Kinematic viscosity max.
(i) At 27 o C 27 cSt.
(ii) Sub-zero temp Under consideration
(d) Interfacial tension @ 27 deg min 0.04N/m
(e) Flash point Penskymartn (closed) min. 140 degree centigrade
(f) Pour point max. - 6oC
(g) Neutralization value (total acidity) max. 0.01mg. KOH /g
(h) Corrosive sulfur (in terms of Non corrossive
classification of copper strip)
(i) Electric strength(break-down voltage)
New untreated oil 40 kv (RMS) If the value is not attainted
b) After treatment the oil shall be treated.
70 kv (RMS)
(j) Dielectric dissipation factor (tan delta)at 0.002
90o C max
(k) Specific resistance (resistivity)
i) At 90 o C min. 35x1012 ohms-cm
ii) At 27 o C min. 1500x1012 ohms-cm
(l) Oxidation stability
i) Neutralization value after oxidation (max) 0.4 KOH/g
ii)Total sludge after oxidation (max) 0.1 % by weight
(m) Presence of oxidation inhabitor The oil shall not contain antioxidant
additives
(n) Water content (max) 50 ppm, after treatment should be less
than 10
34. Oil sample taken from the transformer after
the completion of site processing and tested
in approved manner shall have the
following values before commissioning of
the transformer.
Break down strength Minimum 70 KV withstand
Moisture content Maximum of 10 ppm
Resistivity at 90oc minimum 35x1012 ohm.cm (min)
Interfacial Tension at 27oc 0.04 N/M (min)
v. Dielectric dissipation factor at 90 oC 0.002 (max.)

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5. GENERAL TECHNICAL REQUIREMENTS

5.1 Duty Requirements:
5.1.1 The interconnecting transformers would be used for Bi directional flow of rated power.
5.1.2 The transformers and all the its accessories like CTs etc. shall be designed to withstand
without injury, the thermal and mechanical effects of any external short circuits at the
terminals of any winding for a period of 3 sec. If 132KV side of transformer is connected on a
infinite bus, 33KV shall be capable to withstand terminal short circuit for 3 sec. duration.

5.1.3 The transformer shall be capable of being loaded in accordance with IS:6600. There shall be
no limitation imposed by windings, bushings, tap changer etc. of transformer. Transformer &
all its accessories shall be liberally rated to allow 10% over loading at all taps on continuous
basis without exceeding the temperature limits specified in clause 4.0. The transformer shall
be capable of being operated without danger on each tapping at the rated KVA with specified
voltage variation corresponding to the voltage of that tapping with normal temperature rise.
The design adopted to achieve this shall be indicated in detail in the Bid. Transformer shall be
capable of operating under the natural cooled condition up to the specified load i.e. as ONAN
rating. The forced air cooling equipment shall come into operation by pre-set contacts of
winding temperature indicator and the transformer shall operate as a forced air cooled unit i.e.
as ONAF. Cooling shall be so designed that during total failure of power supply to cooling
fans, the transformer shall be able to operate at full load for Ten (10) minutes without the
calculated winding hot spot temperature exceeding 140 deg.C. Also stopping of two cooling
fans should not have any effect on the cooling system. Transformers fitted with two coolers
(cooling banks) each capable of dissipating 50 per cent of the loss at continuous maximum
rating shall be capable of operating for 20 minutes in the event of failure of the blowers
associated with one cooler, without the calculated winding hot spot temperature exceeding
140 deg C at continuous maximum rating.
5.1.4 The transformer shall be capable of being operated without danger on any tapping at the rated
KVA with voltage variation of + 10% corresponding to the voltage of that tapping. The
transformers and its accessories shall be liberally rated to allow 10% overloading at all taps
on continuous basis.
5.1.5 Radio interference and Noise Level:
The transformers shall be designed with particular attention to suppression of maximum
harmonic voltage, especially the third and fifth so as to minimize interference with
communication circuits.
The noise level, when energized at normal voltage and frequency with fans and pumps
running shall not exceed, when measured under standard, conditions, the values specified in
NEMA, TR-1
5.1.6 Transformer shall be capable of operating under the natural cooled condition up-to the
specified load. The forced cooling equipment shall come into operation by preset contacts of
winding temperature indicator and the transformer shall operate as a forced cooled unit, at
specified load. Cooling shall be so designed that during total failure of power supply to
cooling fans, the transformer shall be able to operate at full load for at least ten (10) minutes
without the calculated winding hot spot temperature exceeding 140 deg. C. Also stopping of
one or two cooling fans should not have any effect on the cooling system.
5.1.7 Transformer shall be capable of withstanding thermal and mechanical stress caused by
symmetrical of asymmetrical faults on any winding.
5.1.8 Transformer shall accept, without injurious heating, combined voltage and frequency
fluctuation of +/-4%, which may produce the following over fluxing condition:
(i) 125% for 1 minute for all transformer where base voltage and
140% for 5 seconds frequency refers to rated voltage and frequency
(ii) Over fluxing withstand characteristics up to 170% shall be submitted along with the
bid.

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GUARANTEED LOSSES AND MAXIMUM PERMISSIBLE LOSSES:-

Maximum permissible losses:
While the contrsctor may offer their own design, it may be noted that the transformer losses at 75oC
rated voltage and rated frequency should not exceed the following maximum limits (Without any
positive tolerance):
Maximu Minimu
Sl. No. Particulars
m m
1 No Load losses in KW 25 22.5
2 Load loss in KW at rated voltage, rated frequency and 147.5 133
rated current at 75oC in KW
3 Auxiliary Loss in KW 2.5 2.3

The bidders shall have to offer no load loss, load loss and auxiliary loss separately. In case
any of the offered losses (i.e. no load loss, load loss and auxiliary loss) quoted by the bidder is
more than the maximum permissible limits , the bid shall be considered as non responsive and
shall be out rightly rejected without any correspondence in the matter.
In case any of these losses are below the minimum range prescribed above, the bid shall be
treated as responsive. However, for price bid evaluation purpose, the minimum range of the
respective loss prescribed above shall be considered.
5.2.2 Guaranteed losses:
The transformer losses at 75oC, rated voltage & frequency should be offered by the
contractor. During final testing of each of the transformer, the measured losses (individually
i.e. No load, load & auxiliary losses) should not exceed the guaranteed losses. In case, any of
the losses exceed the guaranteed losses transformer shall not be accepted. The contractor must
clearly specify that the offered losses are ‗FIRM‘ and no tolerances shall be applicable on the
offered values.

5.2.3 Capitalisation of losses:

The capitalisation of no load loss, load loss and auxiliary loss for the bidder who has quoted
above the minimum of the respective range of losses specified in pre clause-5.2.1 shall be
done on following rates (differential of quoted loss and minimum value of the range for
respective loss).
For differential no load loss above Min value: Rs.4,01,840.00 per KW
For differential load loss above Min value : Rs.2,13,780.00 per KW
For differential auxiliary loss above Min value Rs.1,60,700.00 Per KW

In case a bidder quotes any of the losses below the minimum value of the range prescribed in
pre clause-5.2.1, the value of loss shall be considered equal to minimum of the range
specified at clause-5.2.1 for respective loss for price bid evaluation purpose. However, it
should be clearly noted that during final testing of each of transformer, the measured losses
individually (i.e. no load loss, load loss & auxiliary loss as applicable) should not exceed the
values quoted by the bidder in the bid. In case any of the loss exceeds the quoted loss,
respective transformer shall not be accepted.
The above mentioned rates for capitalization of losses have been worked out as per the
formula prescribed by CBIP publication No. 317 i.e. manual on Transformers.

5.2.4 GUARANTEE PERIOD:

The contractor shall ensure that the power transformer supplied shall be guaranteed for a
period of 42 months from the date of satisfactory commissioning of transformer along with all
accessories. Please note that the date of commissioning of last accessory will be treated as
date of commissioning of transformer. The transformer found defective/ failed within the
above guarantee period shall be got replaced/ repaired by the contractor free of cost, within
four months from date of issue of intimation letter to the contractor by CSPTCL regarding its
defect/failure.

If the contractor fails to arrange repair/replace the failed/defective transformer within four
months, the contractor shall be liable to pay penalty charges for delayed repairs at the rate of

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0.5% of the cost of transformer per week of delay or part thereof, subject to a maximum
ceiling of 10% of the cost of the transformer. This penalty shall be in addition to the
liquidated damages as per clause 14.1 of GCC for delay in completion of the contract.

If the defective/failed transformer is not lifted for replacement/repairing within 2 months from
the date of intimation by CSPTCL regarding defect/ failure OR one month from date of
acceptance of additional Indemnity Bond submitted by the contractor, (in case the transformer
is required to be taken back to the works for repairing) whichever is later.
OR
not repaired within seven months from date of lifting of failed/ defective transformer, penal
action may be taken which will include forfeiture of performance guarantee of transformer
and debarring of the turnkey contractor in addition to the other applicable penalty.

The above provisions shall be applicable for second time failure also, if any.

EXTENDED GUARANTEE PERIOD POST REPAIRS:

Further, the following extended guarantee shall be applicable, in case the transformer fails within
guarantee period.

a) First time failure within guarantee period:

i) If the transformer fails within 12 months from the initial commissioning, the
guarantee period shall get extended to 42 months from the date of satisfactory re-
commissioning of transformer after repairs along with all accessories.
ii) If the transformer fails after 12 months within the original guarantee period, the
original guarantee period shall get extended for a period equal to the time period
lapsed between date of failure to date of re-commissioning after repairs i.e. the
residual guarantee period or 12 months from date of re-commissioning after repairs,
whichever is later.

b) Second time failure of transformer within guarantee period:

If the transformer fails again (second time) within the original/extended guarantee period, the
guarantee shall automatically get extended for further period of two years from the date of re-
commissioning (post repair) or from the end of the original/ previously extended period,
whichever is later. Further the contractor shall be required to submit an additional
performance bank Guarantee equivalent to 10 % of the FOR destination price of Power
Transformer with validity up to expiry of extended guaranteed period plus six months
additional claim period. This performance bank Guarantee shall be in addition to 10%
performance guarantee submitted as per clause No. 12.1 (i).

c) Third time failure of transformer within guarantee period:

If the transformer fails within guarantee /extended guarantee period for third time, this will be
treated as adverse performance of contractor as well as manufacturer and in such case penal
action shall be taken which will includes
Forfeiture of 10% BG submitted against Performance of transformer.
Forfeiture of additional 10% performance BG of transformer furnished subsequent to second
time failure.
The contractor shall be debarred from future business with CSPTCL and other Chhatishgarh
state power companies for a period as decided by management.
The name of the transformer manufacture shall be deleted from the vendor list of CSPTCL for
power transformer of the capacity supplied for the instant case and higher capacities for
forthcoming turnkey project and shall not be considered for procurement cases of CSPTCL as
well as other Chhattisgarh state power companies for a period as decided by management.

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If, for the purpose of replacement/repairs, the equipment/material is required to be dispatched

to manufacturer‘s works, all charges towards transportation / insurance/ packing / forwarding
will have to be borne by contractor for to and fro dispatches.

In this connection, please note that the following additional conditions will also be applicable
in case any damages/defects are noticed in the equipments or its accessories-

If the material develops defect within guarantee/extended guarantee period after installation at
site or subsequent to installation after repairs (1st or 2nd time), for the purpose of replacement
/ repairs, the same will have to be dismantled and taken out by CSPTCL, in such cases actual
cost of dismantling and replacement of the equipment / material will also be recoverable from
contractor.

In case, transformer fails during guarantee / extended guarantee period, the following terms
shall also be applicable (in first or second time failure both)-

An additional Indemnity Bond on stamp paper of Rs.250.00 shall be required to be submitted

by the contractor, in case the transformer is required to be taken back to the works for
repairing. The value of this Indemnity Bond shall be equal to the cost of transformer along
with all taxes, duties, freight and testing charges. The transformer shall be handed over for
repairing only after submission and acceptance of additional indemnity bond.

The transformer should be offered for inspection after completion of repairing work. The
repaired Transformer shall be tested for all routine, additional routine, type and special test as
per IS-2026 & as narrated in section-III-B, clause-6 under head ―Tests‖ of technical
specification of transformer.

(iii) The Transformer should be offered for inspection after repairing within four months from
date of intimation of failure by CSPTCL.

(iv) The dispatch instructions shall be issued for repair transformer after its satisfactory
inspection. The transformer should reach the destination (anywhere in C.G. state) within 45
days from date of issue of dispatch instruction failing which actual date of receipt of repaired
transformer at site shall be treated as date of delivery of the repaired transformer for all
contractual purposes.

(v) In case of failure / defect in transformer (first or second time) within guarantee / extended
guarantee period, the validity of performance guarantee for transformer submitted by the
contractor against the contract as per clause 12.1(i) of GCC should be extended up to expiry
of extended guarantee period with additional claim period of six months. In case, contractor
fails to extend the guarantee period of transformer, claim shall lodged with the issuing bank
for encashment of the all performance bank guarantee for transformer.

5.3 CLEARANCES
The over all dimensions of the transformer shall allow for sufficient clearances for installation
in:-

132KV switchyard with bay width of 9600 mm and beam height of 11000 mm.

5.4 CONSTRUCTION DETAILS

The features and construction details of power transformer shall be in accordance with the
requirements stated hereunder:

5.4.1 Tank and Tank Accessories:

5.4.1.1 Tank:

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Tank shall be of welded construction and fabricated from tested quality low carbon steel of
minimum thickness of 20 mm. (Base & Tank cover) and 10mm for sides.
All seams and those joints not required to be opened at site shall be factory welded and
whenever possible they shall be double welded. After completion of tank construction and
before painting, dye penetration test shall be carried out on welded parts of jacking bosses,
lifting lugs and all load bearing member. The requirement of post weld heat treatment for
tank/ stress relieving parts shall be based on recommendations of BS: 5500 table 4.4.3.1.
The Tank stiffeners shall be provided for general rigidity and these shall be designed to
prevent retention of water.
The tanks shall be designed to withstand
(i) Mechanical shocks during transportation
(ii) Vacuum filling of oil at 10 milli torr
(iii) Continuous internal pressure of 35 kN/m2 over normal hydrostatic pressure of oil.
Short circuit forces.
Wherever possible the transformer tank and its accessories shall be designed without pockets
wherein gas may collect. Where pockets cannot be avoided, pipes shall be provided to vent
the gas into the main expansion pipes.
Adequate space shall be provided at the bottom of the tank for collection of sediments. The
minimum clearance of outermost winding/connection leads to tank shall not be less than 300
mm on all 4 sides to allow free movement of two persons for inspection. Suitable platforms
may be provided on bottom to facilitate free movement of person all around inside the tank.
The arrangement should be brought out clearly in the drawing.
The base of each tank shall be so designed that it shall be possible to move the complete unit
by skidding in any direction without injury when using plates or rails.
Tank shields shall be such that no magnetic/fields shall exist outside the tank. If required
impermeable shields shall be provided at the coil ends. Tank shield shall not resonate when
excited at the natural frequency of the equipment.Manufacturer may confirm use of tank
shields in the schedule of additional information.
Suitable guides shall be provided in the tank for positioning the core and coil assembly.
Each tank shall be provided with
(i) Lifting lugs suitable for lifting the equipment complete with oil
(ii) A minimum of four jacking pads in accessible position at 500 mm height to enable
the transformer complete with oil, to be raised or lowered using hydraulic or screw
jacks.
(iii) Suitable haulage holes shall be provided.
One detachable bolted type mild steel (MS) ladder with anti-climbing arrangement shall be
provided. Ladder for climbing up to & over top cover of power transformer shall be
mechanically sturdy enough to bear the load of healthy maintenance staff without any
shake/jerks. The arrangement shall not be detached after erection and commissioning of the
unit, hence shall be provided with padlock locking arrangement for anti-climbing device. On
the upper top of the ladder, provision for support shall be provided. However, the
arrangement of the ladder shall be approved by CSPTCL. Collapsible ladder shall not be
acceptable.
The transformer should be of bell tank design only. No other design is acceptable.

5.4.1.2 Tank cover:

(a) The tank cover shall be sloped to prevent retention of rainwater and shall not distort
when lifted.
(b) At least two adequately sized inspection openings, one at each end of the tank shall
be provided for easy access to bushings and earth connections. The inspection covers
shall not weigh more than 25 kg. The inspection covers shall be provided with two
handles.
(c) The tank covers shall be fitted with pockets at the position of maximum oil
temperature of MCR (Maximum Continuous Rating) for bulbs of oil and winding
temperature indicators. It shall be possible to remove these bulbs without lowering
the oil in the tank.

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(d) Bushings, turrets, covers of inspection openings, thermometer, pockets etc. shall be
designed to prevent ingress of water into or leakage of oil from the tank.
(e) All bolted connections shall be fitted with weather proof, hot oil resistant gasket in
between, for complete oil tightness. If gasket is compressible metallic stops shall be
provided to prevent over-compression.

5.4.2 Air cell:

The transformers should be supplied with air cell type oil preservation system. It is obligatory
on the part of the bidders to clearly submit complete constructional and technical details of
sealing arrangements duly supported with technical details, pamphlets and dimensional
drawings.
While furnishing details for the above sealing arrangement the bidders must confirm clearly
that the size and capacity of sealing arrangement is adequate for the transformer and for the
quantity of transformer oil required for the transformers.
5.4.3 Axles and Wheels:
(a) The transformers are to be provided with flanged bi-directional wheels and axles. These
shall be so designed as not to deflect excessively to interfere with the movement of the
transformer. Wheels shall be provided with suitable bearings, which shall be rust and
corrosion resistant. Fittings for lubrication shall also be provided.
(b) Suitable locking arrangement along with foundation bolts shall be provided for the wheels
to prevent accidental movement of transformer.
(c) The wheels are required to swivel and they shall be arranged so that they can be turned
through an angle of 90 when the tank is jacked up to clear of rails. Means shall be
provided for locking the swivel movements in positions parallel to and at right angles to
the longitudinal axis of the tank.
(d) The rail track gauge shall be 5‘ – 6‖ (1676 mm) along longer axis as well as along shorter
axis. The arrangement should be such that transformer can be installed in any direction i.e.
along longer axis or along shorter axis on 2 rails with spacing of 1676 mm.
(e) Pulling eyes shall be provided to facilitate movement/ pulling of transformers and these
shall be suitably braced in a vertical direction so that bending does not occur when the pull
has in vertical component.

5.4.4 Anti Earthquake Clamping Device:

To prevent transformer movement during earthquake, clamping device shall be provided for
fixing transformer to the foundation. The Bidder shall supply necessary bolts for embedding
in the concrete foundation. The arrangements shall be such that the transformer can be fixed
to or unfastened from these bolts as desired. The fixing of the transformers to the foundations
shall be designed to withstand seismic, events to the extent that a static co-efficient of 0.3g,
applied in the direction of least resistance to that loading will not cause the transformer or
clamping devices as well as bolts to be over stressed.
The details of the device used and its adequacy shall be brought out in the additional
information schedule.
5.4.5 Conservator Tank
(a) The conservator tank shall be of minimum 8 mm thickness and 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 from
minimum ambient temperature to 100oC. Conservator shall be with volumetric
capacity at least 7 ½ percent of a total volume of oil in the main tank of the
transformer.
(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
electrically insulated alarm contact.
(d) Conservator shall be provided in such a position as not to obstruct the electrical
connections to the transformer.
(e) Separate conservator tank/compartment in the main conservator shall be provided for
OLTC.

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(f) Conservator shall be provided with air cell to avoid direct contact of atmospheric air
with transformer oil.

5.4.6 Dehydrating Filter Breather:

Conservator shall be fitted with a dehydrating, filter breather. It shall be so designed that:
(a) Passage of air is through a dust filter and silicagal.
(b) Silicagel is isolated from atmosphere by an oil seal.
(c) Moisture absorption indicated by a change in colour of the tinted crystals can be
easily observed from a distance.
(d) Breather is mounted not more than 1400 mm above rail top level. Minimum quantity
of silicagel to be 1 kG for every 3500 lts of oil in the tank.
(e ) Minimum quantity of silicagel to be 1 Kg for every 3500 lts of oil in the tank.

5.4.7 Pressure relief device:

Adequate numbers of pressure relief devices (Minimum three no.) should be provided with
each unit. Bidders must submit calculations to prove that the capacity of pressure relief device
and location of the same in the transformer will adequately meet out requirement.
Constructional and design details of pressure relief device must be furnished and it should be
proved by calculation that the size and setting of pressure relief device is adequate,
considering the rating of the transformer and quantity of oil in the transformer. Furnishing of
this information is a must.Adequate No. of pressure relief devices may be provided at suitable
locations which shall be of sufficient size for rapid release of any pressure that may be
generated in the tank and which may result in damage to 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. One set of electrically insulated contacts shall be provided for
alarm /tripping along with the recommended settings.
5.4.8 Buccholz Relay:
A double float type Buccholz relay shall be provided. All the gases 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 and taking gas sample. A copper or stainless steel
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
provided with two electrically independent ungrounded contacts, one for alarm on gas
accumulation and the other for tripping on sudden rise of pressure.
Note: The manufacturer shall ensure that the compartments housing of relay contacts of
Pressure Relief Valve and Buchholz Relay are made water and vermin proof. The
compartment housing contacts of PRV and Buchholz Relay shall be tested for water proofing
at the time of inspection and effectiveness of water proofing shall be demonstrated at the time
of inspection.

5.4.9 Temperature Indicator:

(a) Oil Temperature Indicator (OTI)
All transformers shall be provided with a 150-mm dial type thermometer for top oil
temperature indication. The thermometer shall have adjustable, electrically
independent ungrounded alarm and trip contacts, maximum reading pointer and
resetting device mounted in the cooler control cabinet. A temperature-sensing
element suitably located in a pocket on top oil shall be furnished. This shall be
connected to the OTI by means of capillary tubing. Accuracy class of OTI shall be
+1.5% or better.
(b) Winding Temperature Indicator (WTI)
A device for measuring the hot spot temperature of each of the HV &LV windings
shall be provided. It shall comprise of the following:
Temperature sensing element.
(ii) Image coil
(iii) Auxiliary CTs,
(iv) 150 mm dia local indicating instrument with maximum reading pointer mounted in
Cooler control cabinet and with two adjustable electrically independent ungrounded

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contacts (besides that required for control of cooling equipment), one for high
winding temperature alarm and one for trip.
(v) Calibration device.
(vi) In addition to the above, the following indication equipment shall be provided for
each winding.
(c) Remote winding temperature indicator
It shall be suitable for flush mounting on RTCC panel. The difference between local
and remote WTI indication at any given time shall not exceed 1deg C. One RWTI
shall be provided for each winding in the middle phase (HV & LV).
(i) Auxiliary supply if required, at Owner‘s panel, for RWTI, shall be 110/220 V
DC only.
(ii) Accuracy class of WTI shall be + 1.5% or better.
(iii) Any special cables required for shielding purpose for connection between cooler
control cabinet and remote winding Temperature Indicator control circuit shall
be in supplier‘s scope or work.
5.4.10 Earthing Terminals:
(a) Two (2) earthling pads (each complete with two (2) Nos. tapped holes, M 10 bolts,
plain and spring washers) suitable for connection to 110 x 12 mm copper/brass
grounding flat shall be provided each at position close to the two (2) diagonally
bottom corners of tank. Earthing strip shall be connected to grounding mat by the
Bidder.
(b) Two earthing terminals suitable for connection to 50 x 6 mm galvanized steel flat
shall also be provided on cooler, marshalling box and any other equipment mounted
separately and shall be connected to grounding mat suitably.

5.4.11 Core:
(a) The core shall be constructed from high grade non aging cold rolled super grain
oriented silicon steel laminations (Hi B). The core material should be of PRIME
grade only. Bidder will offer the core for inspection & approval by the purchaser
during manufacturing stage. Bidder call notice should be accompanied with the
following documents as applicable as a proof towards use of PRIME core material.
(i) Invoice of the supplier
(ii) Mill‘s test certificate
(iii) Packing list
(iv) Bill of lading
(v) Bill of entry certificate by customs

(b) The design of the magnetic circuit shall be such as to avoid static discharges,
development of short circuit paths within itself or to the earthed clamping structure
and production of flux component at right angles to the plane of laminations which
may cause local heating.
(c) Core earthing arrangement: The manufacturer should bring out leads from core, end
frame and tank to top of the transformer through insulated bushing. It may be noted
that internal earthing of any nature from core and frame should not be provided.
Earthing at site shall be done by taking connections from the top of the tank and this
arrangement will also facilitate checking of possibility of any multiple core earthing
in transformer.
(d) The insulation of core to bolts and core to clamps plates shall be able to withstand a
voltage of 2 kV RMS for one minute.
(e) Core and winding shall be capable of withstanding the shock during transport,
installation, service and adequate provision shall be made to prevent movement of
core and winding relative to tank during these conditions.
(f) All steel sections used for supporting the core shall be thoroughly sand blasted after
cutting, drilling and welding.
(g) As the transformer is of Bell tank design, suitable projecting guides shall be provided
on core-assembly to facilitate removal of tank.

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(h) Each core lamination shall be insulated with a material that will not deteriorate due to
pressure and hot oil.
(i) The supporting frame work of core shall be so designed as to avoid presence of
pockets which would prevent complete emptying of the tank through drain valve or
cause trapping of air during oil filling.
(j) The maximum flux density in any part of the core and yoke at rated MVA, voltage
and frequency at any tap shall not exceed 1.6 tesla.
5.5.1 Winding:
(a) The supplier shall ensure that windings of all EHV class transformers are made in dust
proof, conditioned atmosphere. He shall furnish the facilities available in this regard at
his works along with the Bid.
(b) The conductors shall be of electrolytic grade copper.
(c) The insulation of transformer windings and connections shall be free from insulating
compounds which are liable to soften, ooze out, shrink or collapse or be catalytic and
chemically active in transformer oil during service.
(d) Coil assembly and insulating spacers shall be so arranged as to ensure free circulation of
oil and to reduce the hot spot of the winding.
(e) The stacks of windings shall receive adequate shrinkage treatment before and after final
assembly. Adjustable devices if necessary shall be provided for taking up possible
shrinkage of coils if any, in service. The provision made in this respect shall be clearly
brought out in the Bid.
5.5.2 Insulating oil:
(a) EHV Grade-I oil shall be used. The quality of the oil supplied with transformer shall
conform to the oil parameters specified in this clause. No inhibitors shall be used in
the oil. The oil samples will be drawn as follows
i) Prior to filling
ii) Before and after heat run test
iii) Before energizing.
All tests as per IS: 335 shall be conducted on all samples.
(b) The insulating oil shall be subjected to testing in the oil manufacturer‘s works before
supply in the presence of the representative of the transformer manufacturer.
(c) Sufficient quantity of oil necessary for first filling of all tanks, coolers and radiator at
the proper level along with 10% extra oil by weight for topping up shall be supplied
in on-returnable containers suitable for outdoor storage.
(d) Power Transformers shall be supplied with oil.
(e) The parameter of the EHV Grade I transformer oil should confirm the values given in
schedule-I Sl. No. 28.
(f) The bidder shall warrant that characteristic of oil furnished shall comply with the
requirements specified in IS-335, 1993 (Fourth Revision) with latest
amendment/revision and shall be suitable for EHV grade transformers.
5.6.1 Oil preservation equipment:
a) The manufacturer shall offer silica gel breather type oil sealing in conservator to
prevent oxidation and contamination of oil due to contact with water in this type of
oil preservation system conservator shall be fitted with a dehydrating filter breather.
It shall be so designed that:
i) Passage of air is through a dust filter and silica gel.
ii) Silica gel is isolated from atmosphere by an oil seal.
iii) Moisture absorption indicated by a change in colour of the tinted crystals can be
easily observed from a distance.
iv) Breather is mounted not more than 1400 mm above rail top level.

b) On line DGA Monitoring device:

One Number 5 Gas Online DGA monitoring device + moisture should be provided on
the transformer which should be capable of measuring following key gases and
moisture content individually (Not composite) found in the transformer oil.

(i) Hydrogen (H2) (iv) Ethylene (C2H4)

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(ii) Carbon mono oxide (CO) (v) Methane (CH4)

(iii) Acetylene (C2H2)

The online DGA monitor should be microprocessor based IED alongwith the required
interface software in CD-ROM one with each unit. The device should have capacity to
internally store minimum two years of Data. It should have non volatile memory storage to
prevent loss of data.

The device should have following communication facilities:-

Two separate channels for remote communications plus local USB connection and Ethernet
connections.
Communications protocols supported should include MODBUS, MODBUS/ TCP, DNP3.0,
IEC61850.
Modules available for connection via RS232, RS485, Ethernet, PSTN modern /GSM or
CDMA wireless modems/ IEC61850 compliant latest communication module.
The make and model of on line DGA monitoring device shall be subject to approval of
CSPTCL. The contractor shall submit the details of the manufacturer‘s device like make,
model No., the name of gases which are detected, the location of fitting in the transformer
with the schematic drawings. The on line DGA monitor of only approved vendors as per the
vendor list given in ―List of Vendors for Major items of Transformer‖ shall only be
acceptable.
5.7 TERMINAL ARRANGEMENTS:
5.7.1 Bushings:
The bushings of CSPTCL‘s approved make shall be manufactured tested and supplied with
guaranteed particulars generally conforming to the latest issue of the following Standard
Specifications:

i) IS-2099 Bushings for alternating voltage above 1000V

ii) IEC 60137 Bushings for alternating voltage above 1000V
iii) IS 3347 Dimensions of porcelain transformer bushings for use in lightly
(Part I to VIII) polluted atmospheres.
iv) IEC 60233 Tests on hollow insulators
v) IS 2544 Specification for porcelain insulator for voltages above 1000 volts.
vi) IS 5621 Hollow insulators

Oil impregnated paper insulated condenser type bushing shall be provided for 170 KV, 72.5
KV class with the following specifications.
These bushings shall be outdoor immersed self-contained draw-through lead or rod type, with
oil filling. The active part of bushing shall consist of a condenser body built up around a
centre tube using high quality kraft insulating paper. The paper craft shall be wound over the
centre tube with pure aluminium foils inserted at pre designed locations to get optimum
combination of external flashover and internal puncture strength.
The condenser body shall be enclosed in weather resistant housing consisting of a top
expansion chamber, upper porcelain, a welded flange – ground sleeve assembly, lower
porcelain and a bottom cap. The annular space between the condenser body and the housing
shall be filled with Grade-I transformer oil. An assembly located in the top housing hold all
the gasket and O ring between porcelain and metal parts thereby completely sealing the
bushing. An oil site window shall be provided on the expansion chamber for observing the oil
level. The space in the expansion chamber above oil shall be filled with dry Nitrogen gas.
Brown glazed porcelain insulators of high strength are used as air end and oil end insulators.
Air end porcelain shall normally be provided with total nominal creepage length 25 mm/KV
of the rated voltage unless otherwise specified. Oil end porcelain shall be cone shaped without
shed. Air end porcelain shall be provided with long and short sheds(aerodynamic shed
profile).Porcelain used in bushing manufacture shall be homogenous, free from lamination,
cavities and other flaws or imperfections that might affect the mechanical or dielectric quality
and shall be thoroughly vitrified, tough and impervious to moisture. Bushings shall be

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manufactured from high quality porcelain. Glazing of the porcelain shall be uniform brown in
colour, free from blisters, burrs and similar other defects.
Bushings hollow column insulators shall be designed to have ample insulation,
mechanical strength and rigidity for the conditions under which they will be used. The hollow
column insulator shall be of reputed make and subject to the approval of CSPTCL. Bushing
porcelain shall be robust and capable of withstanding the internal pressures likely to occur in
service. The design and location of clamps and the shape and the strength of the porcelain
flange securing the bushing to the tank shall be such that there is no risk of fracture. All
portions of the assembled porcelain enclosures and supports other than gaskets, which may in
any way be exposed to the atmosphere shall be composed of completely non hygroscopic
material such as metal or glazed porcelain.
When operating at normal rated voltage there shall be no electric
discharge between the conductors and bushing which would cause corrosion or injury to
conductors, insulators or supports by the formation of substances produced by chemical
action. No radio interference shall be caused by the insulators bushings when operating at the
normal rated voltage.
All iron parts shall be hot dip galvanised and all joints shall be air tight. Galvanized
bolts and nuts shall be used as fasteners. Surface of joints shall be trued up porcelain parts by
grinding and metal parts by machining. Bushing design shall be such as to ensure a uniform
compressive pressure on the joints.
After assembly, the bushings shall be dried out at a very high vacuum pressure. These shall
then be impregnated with transformer oil. Oil impregnation shall be carried out under
pressure. The oil level in bushing shall then be adjusted and the bushings shall be sealed
subsequently.
For the bushings of rated voltage 170 KV, stress relieving shield shall be provided on the
lower cap. The shield shall consist of an aluminium shroud insulated in kraft paper and press
board moulding. The maximum stress in oil and the surface of these shield insulation must be
limited to those values normal for insulated conductors and similar components in the same
transformer.
The draw lead or draw rod connecting the top terminal will be supplied along with
bushing. The complete joint connector shall be provided with the draw lead and the free
connector shall be suitable for brazing the lead from the connecting improvement in the case
of draw rod the free end shall form the connector. For the air side connection, rod type
terminal shall be provided.
The bushing shall be provided with an insulation test tap suitable for measuring
bushing power factor (dissipation factor) and capacitance by ungrounded specimen test
method. The cover of this tap should be removed from the tap attachment only for testing
purpose. Normally the tap shall be grounded through the cover and the bushing shall not be
operated with cover remove.
Tests:
Bushings shall conform to type tests and shall be subjected to routine tests in accordance with
IS: 2099, IEC 60137, IS: 2544 & IS: 5621. The following type test reports of the offered
bushings shall have to be submitted for approval.
Wet power frequency voltage withstand test.
Dry lighting impulse voltage withstand test.
Dry or wet switching impulse voltage withstand test.
Thermal stability test.
Temperature rise test.
Thermal short time current withstand test.
Dynamic current withstand test.
Cantilever load withstand test.
Tightness test on liquid filled and liquid insulated bushings.

The dielectric tan delta value shall not be more than 0.005.The insulation resistance of the
bushing shall not be less than 20 G ohm. The partial discharge of the bushing shall not be
more than 10 pC.
5.7.2 Terminal connectors:

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a) Bushing terminals shall be provided with terminal connectors of approved type and
size for connection to external parts. Terminal connectors must have been
successfully type tested strictly as per IS:5561. The drawing of terminal connector
offered shall have to be got approved by CSPTCL.
b) i) All connections with ACSR zebra conductors shall be bolted type.
ii) Connectors shall be electrolytic grade copper forged and silver plated/ tinned
for 10 Microns.
No part of a clamp shall be less than 15 mm thick. Minimum conductor coverage on the
clamp shall be 100mm. Minimum bushing terminal coverage in the clamp shall be 100mm
and minimum pad overlap in the clamp shall be 100*100 mm.

GI nuts, bolts and washers shall be used. Nuts and bolts shall have hexagonal head with
threads as per IS and shall be fully threaded type. Also instead of spring washers check/ lock
nuts shall be provided.
The connectors shall be designed for minimum 120% of the maximum current carrying
capacity of the ACSR zebra conductor and the temperature rise under these conditions shall
not be more than 50% of that of the main conductor. The terminal connector of 33KV side
should be suitable for twin zebra conductor.
Terminal connector shall be suitable for Zebra ACSR conductors. Clamps shall be designed
adequately to take care of any bimetallic effect. The temperature at the clamp shall not exceed
80°C. The bushing side of connector shall be of copper and conductor side shall be of
aluminium.
The terminal connectors shall also meet the following requirements:
Terminal connector shall be tested for short circuit current capability test, temperature rise
test, corona test etc. The drawing of terminal connector offered shall have to be got approved
by CSPTCL
All castings shall be free from blow holes, surface blisters, cracks and cavities. All sharp
edges and corners shall be blurred and rounded off.
Minimum conductor coverage on the clamp shall be 100mm. Minimum bushing terminal
coverage in the clamp shall be 100mm and minimum pad overlap in the clamp shall be
100*100 mm.
The nut, bolts & washers used in current carrying path shall be hot dip galvanized.
For bimetallic connectors, copper alloy liner of minimum thickness of 4 mm shall be integral
with aluminium body.
Flexible connectors shall be made from tinned copper sheets.

All current carrying parts shall be designed and manufactured to have minimum contact
resistance.
5.7.3 Bushing Current Transformer:
Current transformers shall comply with IS: 2705. Bushing current transformers of adequate
ratio are to be provided in HV, LV & HV/LV neutral bushings for restricted earth fault
protection. Two cores (of PS class) shall be provided for each Bushing CT for REF
protection.
One core each shall be provided on middle phase of HV, LV and neutral Bushing for WTI.
It shall be possible to remove turret mounted CTs from the transformer tank without
removing the tank cover. Necessary precautions shall be taken to minimize the eddy currents
and local heat generated in the turret.
All secondary leads shall be brought to a terminal box near each bushing. These terminals
shall be wired out to cooler Control Cabinet using separate cables for each core. The terminal
shall be stud type of adequate size.
Bushing CT parameters indicated in the specification are tentative and liable to change within
reasonable limits. The bidder shall obtain Purchaser‘s approval before proceeding with design
of Bushing CTs.
5.7.4 Terminal marking:
The terminal marking and their physical position shall be in accordance with IS:2026 unless
otherwise specified.
5.8 Neutral earthing arrangement:

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(a) The neutral terminals of the star connected windings shall be brought to the ground
level by a copper grounding bar (of adequate size) which shall be supported from the
tank by porcelain insulators of highest system voltage of 36 kV.
(b) The end of the copper bar shall be brought to the ground level, at a convenient point,
for connection to ground network through two (2) Zebra conductors. The connection
shall be made by using suitable clamp with necessary accessories.
(c) Suitable flexible copper strip connection of adequate size shall be provided for
connecting to Neutral Bushing terminals to avoid terminal load on the Bushings.
5.9 Auxiliary power supply for OLTC, Cooler control and power circuit:
5.9.1 Auxiliary Power Supplies, shall be as indicated in clause 3.0 provided by CSPTCL at any one
place for OLTC Control and Cooler Control and Cooler Control. The DC operated contactors
coils & push buttons should be suitable for control voltages of either 220 volt or 110 volt.
5.9.2 All loads shall be fed by one of the two feeders through an electrically interlocked automatic
transfer switch housed any one of the local control cabinets for tap changer control and cooler
circuits.
5.9.3 Design features of the transfer switch shall include the following:
i) Provision for the selection of one of the feeders as normal source and other as
standby.
ii) Upon failure of the normal source, the loads shall be automatically transferred after
an adjustable time delay to the standby source.
iii) Indication for failure of normal source and for transfer to stand by source and also for
failure to transfer shall be provided locally as well as in remote panel.
iv) Both the transfer and the re-transfer shall be dead transfers and AC feeders shall not
be paralleled at any time.
v) Necessary isolating switches, MCBs and other components for the above power
supply of the bidder.
5.9.4 Tap changing equipment: TAPS IN OLTC:
with tap range of -15% to +5% in steps of 1.25 %.
(i) Tap changer Switch (General Requirement):
The on load tap changer shall be provided on HV for HV variation as specified at Sr.
No. 10 of clause 4.0.
OLTC gear shall be motor operated for local as well as remote operation. An external hand-
wheel/handle shall be provided for local manual operation.
Arrangement shall be made for securing and padlocking the tap changer wheel in any of the
working positions and it shall not be possible for setting or padlocking the wheel in any
intermediate position. The arrangement shall be such that no padlock key can be inserted
unless all contacts are correctly engaged and switch set in a position where no open or short
circuit is possible. An indicating device shall be provided to show the tap in use.
On Load Tap Changing Gear (OLTC):
The details of the method of diversion of the load current during tap changing; the
mechanical construction of the gear and the control features for OLTC gear shall be submitted
with the bid. Information regarding the service experience on the gear and a list of important
users shall be furnished. The tap changer shall change the effective transformation ratio
without producing phase displacement.
The current diverting contacts shall be housed in a separate oil chamber not communicating
with the oil in main tank of the transformer
The contacts shall be accessible for inspection without lowering oil level in the main tank and
the contact tips shall be replaceable.
The bidder shall indicate the safeguards in order to avoid harmful arcing at the current
diverting contacts in the event of operation of the OLTC gear under over load conditions of
the transformer. Necessary tools and tackles shall be furnished for maintenance of OLTC
gear.
The OLTC oil chamber shall have oil filling and drain plug, oil sampling valve, relief vent
and level glass. It shall also be fitted with surge relay the outlet of which shall be connected to
a separate conservator tank.

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The diverter switch or arcing switch shall be so designed as to ensure that its operation once
commenced shall be completed independently of the control relays or switches, failure of
auxiliary supplies etc.
Drive mechanism chamber shall be mounted on the tank in accessible position. It should be
adequately ventilated and provided with anti-condensation metal clad heaters. All contactors,
relay coils and other parts shall be protected against corrosion, deterioration due to
condensation, fungi etc.
Each transformer unit shall be provided with a local control cabinet and a remote OLTC
control panel. The control feature shall provide following:
Local-remote selector switch mounted in the local control cubicle shall switch control of
OLTC in the following manner: When the selector switch is in LOCAL position, it shall be
possible to operate the RAISE LOWER control switches specified in section (ii) below.
Remote control of RAISE-LOWER functions shall be prevented.
When the selector switch is in REMOTE the local control cubicle mounted RAISE LOWER
Switches specified in Section (ii) shall be inoperative. Remote control of the raise lower
function shall be possible from the remote control panel. The LOCAL-REMOTE selector
switch shall have at least two spare contacts per position which are closed in that position but
open in the other position.
Operating mechanism for on load tap changer shall be designed to go through one step or tap
change per command. Subsequent tap change shall be initiated only by a new or repeat
command.
On load tap changer shall be equipped with a time delay for ―INCOMPLETE STEP‖ in
alarm consisting of a normally open contact which, closes, if the tap changer fails to make a
complete tap change. The alarm shall not operate for momentary loss of auxiliary power.
The selsyn units or approved equivalents shall be installed in the local OLTC control cabinet
to provide tap position indication for the transformer.
The OLTC load tap changer shall be equipped with a fixed resistor network capable of
providing discrete voltage steps for input to the supervisory system.
Limit switches shall be provided to prevent overrunning of the mechanism and shall be
directly connected in the circuit of the operating motor. In addition, a mechanical stop shall be
provided to prevent over-running of the mechanism under any condition. Limit switches may
be connected in the control circuit of the operating motor provided that a mechanical-
declutching mechanism is incorporated.
Thermal device or other means shall be provided to protect the motor and control circuit. All
relays, switches, MCBS etc. shall be mounted in the drive mechanism chamber and shall be
clearly marked for the purpose of identification.
A permanently legible lubrication chart shall be fitted within the driving mechanism chamber.
A five digit counter shall be fitted to the tap changing equipment to indicate the number of
operations completed.
All relays and operating devices shall operate correctly at any voltage between the limits
specified.
It shall not be possible to operate the electric drive when the manual operating gear is in use.
It shall not be possible for any two controls to (i.e. manual, local electrical and remote) be in
operation at the same time.
The equipment shall be suitable for supervisory control and indication with make before
break multi-way switch, having one potential free contact for each tap position. This switch
shall be provided in addition to any other switch/switches which may be required for remote
tap position.
All electrical control switches and the local operating gear shall be clearly labeled in a
suitable manner to indicate the direction of tap changing.
Manual control:
The cranking device for manual operation of the OLTC gear shall be removable and suitable
for operation by a man standing on ground level. The mechanism shall be complete with the
following:
(i) Mechanical tap position indicator which shall be clearly visible from near the
transformer.
(ii) A mechanical operation counter.

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(iii) Mechanical stops to prevent over-cranking of the mechanism beyond the extreme tap
positions.
(iv) The manual control considered as back up to the motor operated load tap changer
control shall be interlocked with the motor to block motor-start-up during manual
operation. The manual operating mechanism shall be labeled to show the direction of
operation for raising the primary and vice-versa.

Electrical control:
This includes the following:
Local Electrical control
Electrical remote control from remote control panel.
(v) Remote Electrical Group Control

The OLTC control scheme offered shall have provision of remote electrical group
control during parallel operation of transformers. This is in addition to independent
control of OLTC.
A four position selector switch having MASTER, FOLLOWER, INDEPENDENT
and OFF position shall be provided in the remote OLTC control panel for each
transformer. This shall be wired to enable operator to select operation of OLTC in
either Master, Follower or Independent mode.
(vi) Out of step relays with timer contacts shall also be provided to give alarm and
indication in case of tap positions in all the transformers under group control being
not in identical position.
(vii) Master Position: If the selector switch is in MASTER position, it shall be possible to
control the OLTC units in the FOLLOWER mode by operating the controls of the
MASTER unit Independent operation of the units under FOLLOWER mode shall
have to be prevented. However, the units under independent mode will be controlled
independently.
(viii) Follower position: If the selector switch is in FOLLOWER mode, control of OLTC
shall be possible only from MASTER penal.
(ix) Independent Position: In this position of Selector Switch, Control of OLTC of
individual unit only shall be possible.
5.10 Cooling Equipment and its controls:
5.10.1 Cooling Equipment
Cooler shall be designed using 2x50 % radiators.
Each radiator bank shall have its own cooling fans, shut off valves, lifting lugs, top and
bottom oil filling valves, air release plug, a drain valve and thermometer pocket fitted with
captive screw cap on the inlet and outlet.
One standby fan for each group shall also be provided and identified with each radiator bank.
Cooling fans shall not be directly mounted on radiator bank which may cause undue
vibration.
The exhaust airflow from cooling fan shall not be directed towards the main tank in any case.
Cooling fans for each radiator bank shall be located so as to prevent ingress of rain water.
Each fan shall be suitably protected by galvanised wire guard.
Cooling fans motors shall be suitable for operation from 415 volts, three phase 50 Hz power
supply and shall conform to IS: 325.
The cooler and its accessories shall be hot painted with corrosion resistant paint.
Each cooling fan motor shall be provided with starter, thermal overload and short circuit
protection.
Each radiator shall be provided with:
One shut off valve at the top (minimum 80 mm size).
One shut-off valve at the bottom (minimum 80 mm size).
Air release device at the top.
Main & sampling device at the bottom.
Lifting lugs.
Air release device and oil plug on oil pipe connections.

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5.10.2 Cooling Equipment Control (ONAN/ONAF COOLING)

(a) Automatic operation control (switching in and out) of fans shall be provided (with
temperature change) from contacts of winding temperature indicator. The bidder shall
recommend the setting of WTI for automatic change over of cooler control from
ONAN to ONAF. The setting shall be such that hunting i.e. frequent start stop
operations for small temperature differential do not occur.
(b) Suitable manual control facility for cooler fans with manual/ automatic selector
switches and push buttons shall be provided.
5.10.3 Remote OLTC/Cooler control Panel (RTCC Panel)
The auxiliary devices for remote electrical control of the OLTC and Cooler shall be housed in
a separate panel to be placed in the Control room. The panel shall be made of sheet
steel of not less than 14 SWG and it shall be duly finished with stove enamel paint. The
size and of the control cubicle to be supplied by the bidder shall be 750 mm depth and
2312 mm height and colour opaline green shade no. 275 of B.S.271-C: 1948,
respectively. The width of the cubicle to be as per bidders‘ practice. Control and signal
devices required to be mounted in the RTCC Panel shall comprise of the following.
1. Local - Remote selector switch for OLTC .
2. Actuating switch/push; button for electrical raise/lower control.
3. Remote tap position indicator with tap number and corresponding; rated voltage marked
on the; instrument. The tap position indicators shall be digital type.
4. A four position selector switch having master follower, independent and off position.
5. Repeater dial of transformer winding temperature indicator.
6. Name plate for each component.
7. Initiating devices and contacts for alarm as well as for indications for discordance in the
tap changer if any of the parallel operating transformer.
8. Cubicle lamp actuated by door, switch, space heater power sockets etc. shall be
provided inside RTCC panel.
9. Annunciator (facia type) Scheme complete with accessories for the following:
(i) Tap changer out of step.
(ii) Tap changer motor trip.
(iii) Failure of AC supply to the OLTC local control Kiosk.
(iv) Fan failure of each group.
(v) Control supplies failure main and standby.
(vi) Cooler supply failure for each supply.
(vii) Two spare windows
(viii) OLTC at extreme positions i.e. lowest or highest tap.
10. Signal lamps for:
(i) Fan ‗ON‘ for each group.
(ii) Standby fan ‗ON‘ for each group.
(iii) Cooling system on manual.
(iv) Cooling system on automatic control.
(v) 415 volts cooler supply auto change over.
(vi) Healthy supply to control gear.
(vii) Tap change in progress.

11. Emergency stop push button will be provided in local control cubicle as well as on
remote tap changer control cubicle panel.

12. 2 No. digital volt meter of 0.5 Accuracy Class (1 for HV & other for LV) with selector
switch should be provided. HRC cartridge fuse shall be provided for HV and LV PT
secondary voltage.
5.10.4 Cooler control cabinet:
(i) Each transformer unit shall be provided with a cooler control cabinet.
(ii) The cooler control cabinet shall have all necessary devices meant for cooler
control and local temp. indicators. All the contacts of various protective devices
mounted on the transformer shall also be wired up to the terminal board in the

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cooler control cabinet. All the secondary terminals of the bushing CT‘s shall
also be wired upto the terminal board at the cooler control cabinet.
(iii) The cooler control cabinet shall have two (2) sections. One section shall have
the control equipment exclusively meant for cooler control. The other section
shall house the temperature indicators, aux. CT‘s and the terminal boards meant
for termination of various alarm and trip contacts as well as various alarm and
trip contacts as well as various bushing CT secondaries. Alternatively the two
sections may be provided as two separate panels depending on the standard
practices of the supplier.
The temperature indicators shall be so mounted that the dials are not more than
1600 mm from ground level. Glazed door of suitable size shall be provided for
convenience of reading.

Nitrogen injection fire prevention system:

Each oil filled transformer shall be provided with a dedicated Nitrogen Injection system
for prevention against the transformer explosion which shall use nitrogen as quenching
medium. The system shall prevent transformer oil tank explosion and possible fire in
case of internal / external cause.
In the event of fire by external causes such as bushing fire, OLTC fires, fire from
surrounding equipment etc., it shall act as a fast and effective fire fighter. It shall
accomplish its role as fire preventer and extinguisher without employing water or
carbon dioxide. Fire shall be extinguished within reasonable with time (not more than 3
minutes so as not to harm the transformer) of system activation and within 30 seconds
(maximum) of commencement of nitrogen injection.
Activation of the system
Mal-functioning of the Nitrogen injection system could lead to interruption in power
supply. The supplier shall ensure that the probabilities of chances of malfunctioning of
the Nitrogen injection system are practically zero. To achieve this objective, the
supplier shall plan out scheme of activating signals which should not be too
complicated to make the system inoperative in case of actual need. The system shall be
provided with automatic controls to prevent the explosion of transformers. Besides
automatic control, remote electrical push button control at Control box and local
manual control in the cubicle shall also be provided. Simultaneous activation of the
following electrical-signals shall be used for initiating the system under prevention
mode/fire extinguishing mode.
Auto Mode
For prevention:
• Differential relay operation.
• Buchholz relay paralleled with pressure relief valve
• Tripping of all circuit breakers (on HV & LV side) associated transformer is the pre-
requisite for activation of system.
For extinguishing
• Fire Detector
• Buchholz relay paralleled with pressure relief valve
Tripping of all circuit breakers (on HV & LV side) associated with transformer is the
pre-requisite for activation of system.
Manual Mode (Local / Remote)
Tripping of all circuit breakers (on HV & LV side) associated with transformer is the
pre-requisite for activation of system.
Manual Mode (Mechanical)
• Tripping of all circuit breakers (on HV & LV side) associated with transformer is
the pre-requisite for activation of system.
The system shall be designed to be operated manually in case of failure of power
supply to the system.
General description
Nitrogen Injection system should be a dedicated system for each oil filled transformer.
It should have a Fire Extinguishing Cubicle (FEC) placed on a plinth at a distance of 5-

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10 m away from transformer or placed next to the firewall (if fire fighting wall exists).
The FEC shall be connected to the top of transformer oil tank for depressurization of
tank and to the oil pit (capacity is approximately equal to 10% of total volume of oil in
transformer tank / or existing oil pit) from its bottom through oil pipes.
The FEC should house a pressurized nitrogen cylinder (s) which is connected to the oil
tank of transformer oil tank at bottom. The Transformer Conservator Isolation Valve
(TCIV) is fitted between the conservator tank and Buchholz relay. Cable connections
are to be provided from signal box to the control box in the control room, from control
box to FEC and from TCIV to signal box. Detectors placed on the top of transformer
tank are to be connected in parallel to the signal box by Fire survival cables. Control
box is also to be connected to relay panel in control room for receiving system
activation signals.
Operation
On receipt of all activating signals, the system shall drain - pre-determined volume of
hot oil from the top of tank (i.e. top oil layer), through outlet valve, to reduce tank
pressure by removing top oil and simultaneously injecting nitrogen gas at high pressure
for stirring the oil at pre-fixed rate and thus bringing the temperature of top oil layer
down. Transformer conservator isolation valve blocks the flow of oil from conservator
tank in case of tank rupture / explosion or bushing bursting. Nitrogen occupies the
space created by oil drained out and acts as an insulating layer over oil in the tank and
thus preventing aggravation of fire.
System components
Nitrogen Injection system shall broadly consist of the following components. However,
all other components which are necessary for fast reliable and effective working of the
system shall deemed to be included in the scope of supply.
MS Storage tank for storage of extracted oil
The MS storage tank of cylindrical shape should be provided for storage of extracted
oil. The capacity of tank should be minimum 12% of total oil capacity of transformer.
The MS storage tank should have facility of oil filtration in side the tank. For this 2 No.
flanges (one for delivery and the other for suction) should be provided. The suction
flange should be connected to the bottom of the tank. The storage tank should be made
of 8 mm thick plate .The inner side of the tank shall be painted with 2 coats of heat
resistant, oil insoluble, insulating varnish. The outer surface shall be given a primary
coat of zinc chromate, second coat of oil & weather resistant varnish of a colour distinct
from primary and final two coats of glossy oil and weather resisting light grey paint in
accordance with shade No. 631 of IS-5. Adequate size of inspection window should be
provided so that tank can be cleaned by manual labour. A vent pipe of adequate
diameter shall be provided a breather fitted on it in order to allow breathing of air.
CUBICLE (FEC)
The Cubicle Frame shall be made of CRCA sheet of 3 mm (minimum) thick complete
with the base frame, painted inside and outside with post office red colour (shade
538 of IS -5). It shall have hugged / hinged split doors fitted with high quality
tamper proof lock. The doors, removable covers and panels shall be gasketted all
round with neoprene gaskets. The degree of protection shall be IP55. The
following items shall be provided in the Cubicle.
• Nitrogen gas cylinder with regulator and falling pressure electrical contact
manometer.
• Oil drain pipe with mechanical quick drain valve.
• Electro mechanical control equipment for draining of oil of pre-determined
volume and injecting regulated volume of nitrogen gas.
• Pressure monitoring switch for back-up protection for nitrogen release.
• Limit switches for monitoring of the system. Limit switch for pressure
switch/sensor
• Butterfly valve with flanges on the top of panel for connecting oil drain pipe and
nitrogen injection pipes for transformer.
• Panel lighting (CFL Type)
• Oil drain pipe extension of suitable sizes for connecting pipes to oil storage tank.

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• Space heater.

Control box:
Control box is to be placed in the control room for monitoring system operation, automatic
control and remote operation. The following alarms, indications, switches, push buttons,
audio signal etc. shall be provided.
• System Oil.
• TCIV open.
• Oil drain valve closed.
• Gas inlet valve closed
• TCIV closed
• Detector trip
• Buchholz relay trip
• Oil drain valve open
• Extinction in progress
• Cylinder pressure low
• Differential relay trip
• PRV trip
• Transformer trip
• System out of service
• Fault in cable connecting fault detector
• Fault in cable connecting differential relay
• Fault in cable connecting Buchholz relay
• Fault in cable connecting PRV
• Fault in cable connecting transformer trip
• Fault in cable connecting TCIV
• Auto / Manual / Off
• Extinction release on / off
• Lamp test
• Visual / Audio alarm for AC supply fail
• Visual / Audio alarm for DC supply fail
• Nitrogen cylinder pressure indication.
• Fire in Transformer.
• Oil drain started.
• Conservator oil isolation valve closed.
• Nitrogen injection started.
As far as possible the control box should be such devised that all the transformers and or group
thereof should be controlled from single spot.
The control box shall have one IEC 61850 compliant IED (BCU) of GE/Alstom/ ABB/ Siemens/SEL
make, wherein operation of all the major components of NIFPS shall be logged in as time tagged
events for analysis and evaluation of operation of NIFPS.
This IED shall be a separate state of art Numerical Bay Control Unit dedicated for this purpose. It
shall have 20 % spare input and output contacts over what has been utilised in the scheme. This IED
(BCU) shall have freely configurable input and output contacts. The BCU shall also have Ethernet/RJ
ports for achieving redundancy in Ethernet switch connection. The IED (BCU) shall have self
monitoring feature and shall have event logger, disturbance Recorder and on initiation of event, it
shall automatically be downloaded at the workstation of substation.
The IED (BCU) shall have IRIG –B port for GPS time synchronizing.
Transformer Conservator Isolation Valve:
Transformer conservator isolation valve (TCIV) to be fitted in the conservator pipe line, between
conservator and buchholz relay which shall operate for isolating the conservator during abnormal flow
of oil due to rupture / explosion of tank or bursting of bushing. The valve shall not isolate conservator
during normal flow of oil during filtration or filling or refilling, locking plates to be provided with
handle for pad locking. It shall have proximity switch for remote alarm, indication with visual
position indicator. The TCIV should be of the best quality as malfunctioning of TCIV could lead to
serious consequence. The closing of TCIV means stoppage of breathing of transformer. Locking
plates shall be provided for pad locking.

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Detectors:
The system shall be complete with adequate number of detectors (quartz bulb) fitted on the top cover
of the transformer oil tank. The bulbs should be provided to ensure monitoring of all the HV, IV, LV
& neutral bushings. Redundancy of detectors should be ensured & clearly brought in the drawing
submitted for approval.
Signal box:
It shall be mounted away from transformer main tank, preferably near the transformer marshalling
box, for terminating cable connections from TCIV & detectors and for further connection to the
control box. The degree of protection shall be IP55.
Cables:
Fire survival cables (capable to withstand 750º C.) of 4 core x 1.5 sq. mm size for connection of
detectors in parallel shall be used. The fire survival cable shall conform to BS 7629-1, BS 8434-1, BS
7629-1 and BS 5839-1, BS EN 50267-2-1 or relevant Indian standards.
Fire Retardant Low Smoke (FRLS) cable of adequate size shall be used for connection of signal box /
marshalling box near transformer and FEC mounted near transformer with control box mounted in
control room. Fire Retardant Low Smoke (FRLS) cable of 4 core x 1.5 sq. mm size shall be used for
connection between control box to DC & AC supply source, FEC to AC supply source, signal box /
marshalling box to transformer conservator isolation valve connection on transformer. Separate cables
for AC supply & DC supply shall be used.
Pipes:
Pipes complete with connections, flanges, bends and tees etc. shall be supplied along with the system.
Other items to be supplied:
(a) Oil drain and nitrogen injection openings with gate valves on transformer tank at suitable
locations.
(b) Flanges between Buchholz relay and conservator tank for fixing TCIV.
(c) Detector brackets on transformer tank top cover.
(d) Spare potential free contacts activating the system i.e. in differential relay, Bucholz relay.
Pressure Relief Device, Circuit breaker of transformer.
(e) Pipe connections between transformer and FEC and between FEC and oil pit required for
collecting top oil.
(f) Cabling for detectors mounted on transformer top cover.
(g) Inter cabling between signal box, control box and FEC.
(h) Butterfly valves / Gate valves on oil drain pipe and nitrogen injection pipe which should be
able to withstand full vacuum.
(i) Supports, signal box etc. which are to be painted with enameled paint.
(j) Any other item required for satisfactory operation of system.

Power supply
For Control Box 220 V / 110 V DC
For FEC Auxiliary 230 V AC
Spares for three (3) years Operation & Maintenance
The bidder apart from the below mentioned spares shall submit a list of recommendation spares for
three years trouble free operation of the equipments and also furnish unit rates. The owners will
scrutinize the said list and decide on the items on spares to be ordered and the quantities. These spares
shall be supplied by the bidder before end of guarantee period. The owner reserves right to order the
spares with twelve (12) months from the date of order for main equipments and the rate shall be kept
valid till this date. The prices of these spares shall not be considered for evaluation of the bid.
Mandatory Spares
Cylinder filled with Nitrogen of required Capacity per transformer - 1 No.
Detectors per transformer 3 no.
Regulator assembly per sub-station 1 No.

Modification on the transformer

No modification on the transformer shall be allowed which affects its performance (i.e. efficiency,
losses, heat dissipation ability etc.) safety, life etc. or it‘s any other useful parameter. This requirement
shall be paramount importance and shall form the essence of the contract. However, in any case,
performance of transformer should not be affected in any manner by having Nitrogen Injection Fire

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Prevention Cum Extinguishing System (NIFPES) and the Bidder / Sub-vendor shall give an
undertaking to this effect. All pipes should be washed / rinsed with transformer oil. If any damage is
done to the transformer and / or any connected equipment during installation & commissioning full
recovery therefore shall be effected from the Bidder /Sub-vendor, of NIFPES system.
It shall be solely the responsibility of bidder / Sub-vendor to install, carry out pre-commissioning tests
& commission NIFPES at the mentioned Sub-Station in this specification, to the entire satisfaction of
the CSPTCL.

Interlocks:
It shall be ensured that once the NIFPES gets activated manually or in automode, all the connected
breakers shall not close until the system is actually put in OFF mode. Also PRV shall get closed only
if all the connected breakers are open.
Tests:
Bidder has to carry out the type test as per relevant IS/IEC. Specifically IP 55 on FEC or have to
produce the report from NABL approved Lab. Reports of all routine test conducted as per relevant
IS/IEC standards in respect of various bought out items including test reports for degree of protection
for FEC / control box / signal box shall be submitted by the supplier.
The supplier shall demonstrate all the functional test associated with the following as Factory
Acceptance Tests:
• FEC, Control Box
• Fire Detector
• Transformer Conservator Isolation Valve
The performance test of the complete system shall be carried out after erection of the system with
transformer at site. Detailed layout drawings, equipment drawing along with 4 sets of Operation and
Maintenance manual along with soft copies (In CDs) shall be submitted by the supplier along with the
consignment. The guaranteed and other technical particulars for the offered system are indicated in
Section - "Guaranteed and Other Technical Particulars". Any other particulars considered necessary in
addition to those listed in that Section may be furnished by the Bidder.
Terminal Block:
(i) The terminal blocks to be provided shall be fully enclosed with removable covers and made
of moulded, non inflammable plastic material with block and block and barriers moulded
integrally. Such block shall have washer and binding screws for external circuit wire
connections, a white marking strip for circuit identification and molded plastic cove. All
terminals shall be clearly marked with identification numbers or letters to facilitate
connection to external wiring.
(ii) All internal wiring to be connected to the external equipment shall terminate on terminal
bocks, preferably vertically mounted on the side of each panel. The terminal blocks shall be
1100 V grade and have 10 amps continuous rating, molded piece, complete with insulated
barriers, non-disconnecting stud type terminals, washers, nuts and lock nuts. Terminal block
design shall include a white fiber-marking strip with clear plastic, slip-on / clip-on terminal
cover. Markings on the terminal strips shall correspond to wire number and terminal numbers
on the wiring diagrams.
(iii) Terminal blocks for current transformer secondary leads shall be provided with test links and
isolating facilities Also current transformer secondary leads shall be provided with short-
circuiting and earthing facilities.
(iv) At least 20% spare terminals shall be provided on each panel and these spare terminals shall
be uniformly distributed on all terminal blocks.
(v) Unless otherwise specified, terminal blocks shall be suitable for connecting the following
conductors on each side.
(a) For all circuits except current transformer circuits minimum of two nos. 2.5 mm2
copper.
(b) For all CT circuits minimum of two nos. 4 mm2 copper.
(vi) There shall be a minimum edge to edge clearance of 250 mm between the first row of
terminal block and the associated cable gland plate. Also the clearance between two rows of
terminal blocks shall be minimum of 150 mm.
(vii) Arrangement of the terminal block assemblies and the wiring channel within the enclosure
shall be such that a row of terminal blocks is run parallel and in close proximity along each

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side of the wiring duct to provide for convenient attachment of internal panel wiring. All
adjacent terminal block shall also share this field wiring corridor. A steel strip shall be
connected between adjacent terminal block rows at 450 mm intervals for support of incoming
cable.

5.12 Painting:
The internal and external surfaces including oil filled chamber and structural steel work to be
painted shall be shot or sand blasted to remove all rust and scale or foreign adhering matter or
grease. All steel surfaces in contact with insulating oil shall be painted with two coats of heat
resistant, oil insoluble, insulating varnish. All steel surfaces exposed to weather shall be given
a primary coat of zinc chromate, second coat of oil and weather resistant varnish of a colour
distinct from primary and final two coats of glossy oil and weather resisting Light Grey paint
in accordance with shade no.631of IS-5.
All paints shall be carefully selected to withstand extremes of weather. The paint shall not
scale off or crinkle or be removed by abrasion due to normal handling.
The minimum thickness of outside painting of tank shall be 20 microns and the total thickness
shall be minimum 80 microns.
5.13. Bolts and nuts:
All bolts and nuts exposed to weather shall be hot dip galvanized. Bolts and nuts below H12
(1/2 inch) size shall be stainless steel.
5.14 Wiring and cabling.
(a) Cable box/ sealing end shall be suitable for following types of cables:-

i) 415 volt 1100 Volt grade PVC insulated aluminum conductor cable
Power
ii) Control 1100 Volt grade PVC insulated 7/0.737 mm stranded copper
conductor cable.
(b) Compression type cable connector shall be provided for termination of power and control
cables.
(c) All controls, alarms, indicating and relaying devices provided with the transformer shall be
wired up to the terminal blocks inside the Local Control Cabinets (both cooler and OLTC
Control Cabinets)
(d) Not more than 2 wires shall be connected to one terminal. Each terminal shall be suitable for
connecting two 7/0. 73 mm stranded copper conductors from each side.
(e) All terminal wiring shall be securely supported, neatly arranged, readily accessible and
connected to equipment terminal blocks.
(f) Engraved code identification plastic ferrules marked to correspond with schematic diagrams
shall be fitted at both ends of wires. Ferrules shall fit tightly on wires and shall not fall off
when the wire is disconnected from terminal block.
5.15 Marshalling box:
Some of the manufacturers have a practice to directly install winding temperature indicator
and oil temperature indicator on the body of the transformer in open. It is obligatory on the
part of the bidders to offer a separate marshalling box to enclose such accessories as required
in the Tender specification.
5.16 Fittings:
The following fittings shall be provided with each transformer covered in this specification.
(a) Conservator for main tank, with oil filling hole and cap, isolating valves, drain valve,
magnetic oil level gauge with low level alarm contacts and dehydrating breather.
(b) Conservator for OLTC with drain valve. Buchholz relay, filling hole with cap, prismatic
oil level gauge and dehydrating breather.
(c) Oil preservation equipment.
(d) Pressure relief device alarm contact.
(e) i) Buchholz relay double float type with isolating valves on both sides, bleeding pipe
with pet cock at the end to collect gases and alarm and trip contacts.
ii) Separate surge relay with above features to be provided for OLTC chamber.
(f) Air release plug
(g) Inspection openings and covers.

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(h) Bushing with metal parts and gaskets to suit the termination arrangement.
(i) Winding temperature indicators for local and remote mounting. One RWTI with a four
point selector switch shall be provided for all the winding (HV/LV).
(j) Oil temperature indicators.
(k) Cover lifting eyes, transformer lifting lugs, jacking pads, towing holes and core and
winding lifting lugs.
(l) Protected type mercury or alcohol glass thermometer.
(m) Bottom and top filter valves with threaded male adapters, bottom sampling valve and
drain valve.
(n) Rating and diagram plates on transformers and auxiliary apparatus.
(o) Earthing terminals.
(p) Flanged bi-directional wheels.
(q) Cooler control cabinet.
(r) On load tap changing equipment and OLTC control cabinet.
(s) Drain valves/plugs shall be provided in order that each section of pipe work can be
drained independently.
(t) Bushing CTs for WTI & REF protection (u) Insulating oil.
(v) Cooling fans.
(w) Terminal marking plate.
(x) Jacking pads.
(y) Lifting bollards
(z) Haulage lugs.
(aa) Cover Lifting lugs.
(ab) Valve schedule plate
(ac) RTCC panel
(ad) Bushing terminal clamp & connector
(ae) On line DGA monitor
(af) Insulating Oil
(ag) NIFPS along with all accessories
Note: The fittings listed above are only indicative and any other fittings which generally are
required for satisfactory operation of the transformer are deemed to be included.

5.17 Limits of temperature rise:

The temperature rise on any part of equipment shall not exceed the maximum temperature
rise specified below under the conditions specified in test clauses. The permissible
temperature rise indicated is for a maximum ambient temperature of 50 deg. C. If the
maximum ambient temperature rises, permissible values shall be reduced accordingly. For
actual maximum temperature at the location of installation, refer prefect synopsis.
Maximum Value of
Temp. rise at a
Sl.
Nature of the part or of the liquid max. ambient air
No. Temp.
temp. not
exceeding 50oC
1. Contacts in air, silver-faced copper, copper alloy or 95 40/45
aluminum alloy [see notes (i) and (ii)]
Bare copper or tinned aluminum alloy. 75 25
2. Contacts in oil: 90 40
Silver-faced copper, copper alloy or aluminum alloy
(see note ii)
Bare copper or tinned aluminum alloy. 80 30
3. Terminals to be connected to external conductors by 105 55
screws or bolts silver faced (see note iii)
4. Metal parts acting as springs see note iv (see note iv)
5. Metal parts in contract with insulation of the
following classes:
ClassYfor non-impregnated materials) 90 40

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Class A: (for materials immersed in oil or 100 50

impregnated)
Class E: in air 120 70
in oil 100 50
Class B: in air 130 80
in oil 100 50
Class F: in air 155 105
in oil 100 50
Enamel: oil base 100 50
Synthetic, in air 120 70
Synthetic, in oil 100 50
6. Any part of metal of or insulating material in 100 50
contact with oil, except contacts
7. Oil 90 40
Notes: i) When applying the temperature rise of 40/45 deg.C. care should be taken to
ensure that no damage is caused to the surrounding insulating materials.
ii) The quality of the silver facing shall be such that a layer of silver remains at
the points of contact after the mechanical endurance test. Otherwise, the
contacts shall be regarded as ―bare‖.
The values of temperature and temperature rise and valid whether or not the conductor
connected to the terminals is silver-faced.
The temperature shall not reach a value where the elasticity of the material is impaired. For
pure copper, this implies a temperature limit of 75 deg.C.

5.18 Specification for control CABINETS:

Control cabinets shall be of the free standing floor mounting type.
Control cabinet of the operating mechanism shall be made out of 3mm thick sheet or 10mm
thick 133odelling plate or casting. Hinged door shall be provided with padlocking
arrangement. Sloping rain hood shall be provided to cover all sides 15mm thick neoprene or
better type of gaskets shall be provided. Colour of paint shall be olive Green in accordance
with shade no 220 of IS 5.
Bus bars shall be of tinned copper of adequate cross section to carry the normal current,
without exceeding the permissible temperature rise over an ambient temperature of 50 deg. C
outside the cubicle. The buses shall be designed to withstand forces corresponding to short
circuit current of 25 KA.
Motors rated 1 KW and above being controlled from the control cabinet would be suitable for
operation on a 415 V, 3 phase 50 Hz system. Fractional KW motors would be suitable for
operation on a 240 V, 1-phase, 50 Hz supply system.
Isolating switches shall be group operated units (3 pole for use on 3- phase supply systems
and 2 pole for single phase supply system) quick make quick break type, capable of breaking
safely and without deterioration, the rated current of the associated circuit. Switch handle
shall have provision for locking in both fully open and fully closed positions.
Push button shall be rated for not less than 6 Amps, 415 V A.C or 2 Amps, 220V/110V D.C
and shall be flush mounted on the cabinet door and provided with appropriate name plates.
Red, Green and Amber indicating Lamps shall be flush mounted.
For motors upto 5 KW, contactors shall be direct-on-line, air break, single throw type and
shall be suitable for making and breaking the stalled current of the associated motor which
shall be assumed equal to 6.5 times the full load current of the motor at 0.2 p.f. For motors
above 5 KW, automatic star delta type starters shall be provided. 3 pole contactors shall be
furnished for 3 phase motors and 2-pole contactors for single phase motor. Reversing
contactors shall be provided with electrical interlocks between forward and reverse
contactors. If possible, mechanical interlocks shall also be provided. Contactors shall be
suitable for uninterrupted duty and shall be of duty category class AC4 as defines in IS: 2959.
The main contacts of the contactors shall be silver plated and the insulation class for the coils
shall be class E or better. The dropout voltage of the contactors shall not exceed 70% of the
rated voltage.

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Contactors shall be provided with three elements positive acting, ambient temperature
compensated, time lagged, hand reset type thermal overload relay with adjustable setting.
Hand reset button shall be flush with the front door at the cabinet for resetting with starter
compartment door closed.
Single phasing preventer relay shall be provided for 3 phase motors to provide positive
protections against single phasing.
Mini starters shall be provided with no volt coils whenever required.
Power cables of 1100/650 volts grade stranded 134odelling conductor. PVC insulated, PVC
sheathed single steel wire armoured and PVC jacketed shall be used. All necessary cable
terminating accessories such as glands, crimp type tinned copper lugs etc. for power as well
as control cables shall be included in Bidder‘s scope of supply. Suitable brass cable glands
shall be provided for cable entry.
Wiring for all control circuits shall be carried out with 1100/650 volts grade PVC insulated
tinned copper stranded conductors of sizes not smaller than 2.5 mm. Atleast 20% spare
terminal blocks for control wire terminations shall be provided on each connecting stand type.
All terminals shall be provided with ferrules indelibly marked or numbered and these in
identifications shall correspond to the designations on the relevant wiring diagrams. The
terminals shall be rated for adequate capacity which shall not be less than 10 Amps.
Separate terminal blocks shall be provided for terminating circuits of various voltage classes.
CT loads shall be terminated on a separate block and shall have provision for short circuiting
the CT secondary terminals.
Control cabinet shall be provided with 240 V, 1 phase 50 Hz, 20 W fluorescent light fixture
and a suitable rated 240 V, 1 phase, 5 Amps, 3 Pin socket for hand lamps.
Space heaters shall be provided inside each cabinet complete with thermostat (preferably
differential type) to prevent moisture condensation. Heaters shall be controlled by suitably
rated double-pole miniature Circuit Breakers.
Single lamps provided shall be of neon screw type with series resistors, enclosed in
134odellin body. Each single lamp shall be provided with a fuse integrally mounted in the
lamp body.
Electric measuring instruments shall be of moving iron type. Ammeters for measuring current
upto 30 Amps shall be directly connected through suitable CTs. Ammeters shall be provided
with selector switches.
Items inside the cabinet of organic material shall be coated with a fungus resistant varnish.
Please note that all DC operated push buttons/ contactors/ coils should be provided such that
they have selection for operation with either 220 volt or 110 volt DC.

5.19 Motors:
Motors shall be ―Squirrel Cage‖ three phase induction motors of sufficient size capable of
satisfactory operation for the application and duty as required for the driven equipment.
Motors shall conform to IS 325.

6.0 Tests:
The type test reports of the transformer (as per latest version of IS: 2026) of offered or higher
rating conducted at Govt. / Govt. approved laboratory or witnessed by Govt. / Govt. approved
laboratory representative should be submitted along with the bid. The type tests should not be
older than five years.
Copies of all routine test reports as per latest version of IS:2026 on offered or higher rating
transformer conducted within five years on due date of opening should also be submitted with
the bid.
All routine and additional routine tests shall be carried out on each transformer. The type and
special tests mentioned in clause 6.2 shall be carried out on one unit out of the lot. All routine
& type tests shall be witnessed by representative of CSPTCL & ERDA/CPRI or any other
agency authorized by CSPTCL.
The charges for conducting each type test and special tests shall be indicated separately in the
relevant schedule.

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6.1 All standard routine tests in accordance with IS: 2026 (with latest amendment), with dielectric
tests as per IS:2026 part-III (with latest amendment) shall be carried out on the transformer.
Further some additional routine tests shall also be carried out.

The list of routine and additional routine tests shall be carried out on transformer according to
the methods specified in IS:2026 (Part-I):2011 and IS:2026 (Part-III):2009.

THE DETAILS OF THE TESTS TO BE CARRIED OUT ARE AS GIVEN HERE UNDER:-
Sl.No. Particulars
(A) Routine tests:
1 Measurement of winding resistance
2 Measurement of voltage ratio and check of phase displacement
3 Measurement of Impedance voltage/ short circuit impedance (Principal tap) & load
loss
4 Measurement of ‗No load loss & No load current‖ (Measured with suitable CT. The
CT should be calibrated on the measuring current)
5 Measurement of Insulation resistance
6 Dielectric routine tests as per IS:2026 (Part-III) i.e. lightning impulse tests on all
phases of HV/ LV windings, short duration induced AC withstand voltage tests,
separate source AC withstand voltage tests
7 Tests on load tap changers
(B) Addl. Routine Tests:
1 Dimensional checks as per approved drawing & specification
2 Magnetic circuit test. After assembly ,core shall be tested for 1 minute for 2000
volts AC between all bolts, side plates & structures steel works
3 Polarisation index – IR value for 15 sec, 60 sec & 600 sec duration shall be
recorded and PI for 600/60 sec and DAR i.e. ratio of IR values of 60/15 seconds
shall be recorded. The PI value (600/60 sec) should be >=2 and DAR value (60/15
sec) should be >=1.3. These values should be recorded both before and after HV
tests.
4 Tank oil leakage test – the complete transformer assly filled with oil shall be
subjected to nitrogen pressure of 0.35 Kg/cm2 above the normal oil head for a
period of 12 Hrs to ensure that there is no oil leakage.
5 Capacitance and tan delta measurement to determine capacitance between winding
and earth. This test should be carried out before and after series of dielectric tests.
6 Tan delta & capacitance Test on bushings (Before and after HV tests)
7 Checking of recording of IR values
(a) Between core & coil frame
(b) Between core & tank
Between coil frame & main tank
The measured IR values should be more than 1000 M Ohms.
8 Magnetic balance test (Before and after HV tests)
Magnetising Current Tests on all three windings with LT voltage (Before and after
HV tests)
9 Tests of PRDs for successful operation
10 Oil BDV test before & after HV tests
11 Sweep Frequency response analysis (SFRA) – SFRA shall be carried out at
manufacturer‘s works with his own SFRA test set. The test shall be repeated at site
with same test set.
12 Measurement of DEW point prior to dispatch of the unit filled with N2 gas prior to
dispatch – This test shall be carried out by manufacturer and results shall be
submitted to CSPTCL for reference.
13 Cooler Control and RTCC Functional checks
14 Functional checks on Air cell
15 Ratio and polarity tests on Bushing Turret CTs
16 Functional checks on Buchholz Relay

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Note: All testing equipments viz., CT, PT, ampere-meter, volt-meter, watt meter, frequency
meter, power analyzer, Insulation resistance test kit, winding resistance test kit, winding turns
ratio test kit, tan delta & capacitance measurement test kit, potential divider, temperature
sensors, etc. shall be of appropriate class of accuracy and shall havevalid calibration
certificates from NABL accredited labs. Minimum CTR and accuracy class required for CT
with valid calibration certificate for 1-120% rated current shall be used for measuring of ‗No
load loss & no load current‘.

6.2 Type/Special Tests to be carried out on the Power Transformer:

Following tests shall be conducted on power transformer:-

6.2.1 Temperature Rise Test:

This test as per cl. 16.8 of IS:2026 (Part-I) and IS:2026 (Part-II) shall be conducted at the
lowest voltage tap having maximum current with 10% over load condition. The manufacturer
before carrying out such tests, shall submit detailed calculations showing the alternatives
possible, on various taps and for different ratings (ONAN/ONAF), of the transformer and
shall recommend the combination that results in highest temperature rise, for the test. Gas
chromatographic analysis of oil shall be conducted before and after heat run test and the
values shall be recorded in the test report. The sampling shall be in accordance with IEC-567.
For the evaluation of the gas analysis in temperature rise test, a method will be proposed
which is based on the rate of increase of particular gases and the permissible limits of
minimum detectable value of gases and the maximum limit will be mutually discussed and
agreed upon between the CSPTCL and manufacturer. This shall be treated as reference during
maintenance of transformer in future.

The calibration of OTI and WTI shall be done by Transformer Manufacturer and these
calibrated OTI, WTI shall be used during testing of transformer. The Sl.No.of WTI, OTI shall
be recorded during testing of transformer and these indicators only shall be supplied with the
transformer. During test the manufacturer selects suitable tap from CT based on gradient
between the readings of WTI & OTI. This tap position is to be clearly recorded on test report
so that selection of correct tap could be done at site to avoid discrepancy in temperature
gradient recorded during factory test and the value recorded at site.

6.2.2 Tank vacuum test as per details given in this clause subsequently.
6.2.3 Tank pressure test as per details given in this clause subsequently.

6.2.4 Pressure Relief Device Test:

The pressure relief device of each size shall operate in case of increase in oil pressure inside
the tank. It shall operate before reaching the test pressure specified in ‗tank Tests‘
subsequently in this clause. Device shall seal off after the excess pressure has been relieved.
6.2.5 Following special tests other than above mentioned tests shall also be carried out as per ―IS:
2026 part-I and part-III (with latest amendment) as applicable on one unit out of the lot.
(i) Measurement of zero Seq. Reactance.
(ii) Measurement of acoustic noise level.
(iii) Measurement of power taken by fans.
(iv) Measurement of harmonic level in no load current.
(v) Lighting impulse with chop on tail on all 3 phase of HV and LV terminals.
(vi) One cooler cabinet and OLTC cabinet of the transformer shall be tested for IP:55
protection in accordance with IS: 2147. In case facility for this test is not available
with the manufacturer or their vendor; the test has to be carried out at the laboratory
of either CPRI or ERDA in presence of CSPTCL‘s representative and test report
should be furnished.

6.2.6 Tests on Assembled Transformer:

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a) Check completed transformer against approved out line drawing, provision for all f
ittings, finish level etc.
b) Jacking test on the assembled Transformer.

6.3 TANK TESTS

6.3.1 Routine Tests: Oil leakage test:

This test will be conducted on power transformer. All tanks and oil filled compartments shall
be tested for oil tightness by completely filling with air or oil of a 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/sq m measured at the base of the tank. The
pressure shall be maintained for a period of not less than 12 hours for oil and one hour on air
during which time no leak shall occur.

6.3.2 Tests to be conducted on tank:

(i) Vacuum Test
The transformer tank shall be subjected to the specified vacuum. The tank designed
for full vacuum shall be tested at an internal pressure of 3.33 KN/m² absolute (25
torr) for one hour. The permanent deflection of flat plate after the vacuum has been
released shall not exceed the values specified below.

Horizontal length of flat plate (in mm) Permanent Deflection (in mm)
Up to and including 750 5.0
751 to 1250 6.5
1251 to 1750 8.0
1751 to 2000 9.5
2001 to 2250 11.0
2251 to 2500 12.5
2501 to 3000 16.0
Above 3000 19.0

Pressure Test
The transformer tank together with its radiator, conservator, vessel and other fittings shall be
subjected to a pressure corresponding to twice the normal head of oil or to the normal
pressure plus 35 KN/m 2 whichever is lower, measured at the base of the tank and maintained
for one hour. The permanent deflection of flat plates after the excess pressure has been
released, should be within the limits specified in the table given at (i) above.

6.4 TESTS AT SITE: After erection at site, the transformer shall be subject to the following
tests, in presence of manufacturer‘s engineer.

6.4.1 Tests on reaching at site:

(i) Immediately upon receipt of transformer at site and before unloading of transformer
from trailor, core earthing, end frame earthing and tank earthing shall be checked.
Only after satisfactory verification that there is no multiple core earthing in
transformer, unloading of transformer shall be undertaken.
(ii) After receipt of transformer at site, physical inspections shall be done for checking
any physical damage to transformer tank and accessories. Further, data of impact
recorder shall be 137odellin for any changes before unloading of transformer.

6.4.2 Pre-commissioning tests at site:

(i) Insulation resistance test and polarization index.
(ii) Ratio and polarity test
(iii) DGA of oil and di-electric, tan delta and moisture content test of oil.
(iv) OLTC operational test at each tap for lower and raise operation of tap changer.
(v) Magnetic balance tests and measurement of magnetizing current.
(vi) Vector group test

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(vii) Short circuit current measurement at low voltage and at all taps
(viii) Measurement of winding resistance at all taps
(ix) Tangent delta and capacitance of Transformer
(x) Tangent delta, capacitance and insulation resistance tests of bushings
(xi) Leakage current between core & tank, core & end frame, end frame and tank and
between short circuited links and neutral in grounded and ungrounded conditions.
(xii) Dew point measurement & recording of pressure of nitrogen gas (if applicable)
(xiii) SFRA test.

The SFRA test and Dew point measurement shall be carried out in presence of manufacturer‘s
representative. The test kits shall be same as used for carrying out these tests in the factory
and shall be brought by manufacturer‘s representative.

6.4.3 Pre-commissioning checks at site:

a) Check the colour of silica gel breather.
b) Check the oil level in the breather housing, conservator tank, cooling system,
condenser housing etc.
c) Check the bushings for conformity of connection to the line etc.
d) Check for correct operation of all protection and alarms.
i) Buchholz relay
ii) PRV
ii) Excessive winding temperature
iii) Excessive oil temperature
e) Low oil level indication
f) Check for adequate protection on electric circuit supplying the accessories.
g) Check for cleanliness of the Transformer and the surroundings

6.5 Test reports

6.5.1 Copies of certified test reports and oscillograms shall be submitted for approval prior to
dispatch of the equipment.The equipment shall be dispatched only when all the required type
and routine tests have been carried out and test reports are approved by the CSPTCL.
6.5.2 Copies of the test reports for the tests carried out on the ancillary apparatus shall be furnished
to the CSPTCL for approval prior to dispatch.
6.5.3 All auxiliary equipment shall be tested as per the relevant standard. Test certificate shall be
submitted for bought out items.
6.6 Apart from rejection due to failure of the transformer to meet the specified test requirements
the transformer shall be liable for rejection on any one of the following reasons.
No load loss exceeds the values mentioned in GTP
Load loss/Auxiliary exceeds the specified values mentioned in GTP
Impedance voltage value exceeds the guaranteed value plus tolerance.
7.0 INSPECTION AND TESTING:
7.1 Inspection:
7.1.1 CSPTCL shall have access at all times to the works and all other places of manufacture
where the transformer is being manufactured and the manufacturer shall provide all facilities
for unrestricted inspection of the manufacturer works, raw materials, manufacture of all the
accessories and for conducting necessary tests as detailed herein.

7.1.2 The contractor shall keep CSPTCL informed in advance of the time of starting and of the
progress of manufacture of equipment in its various stages, so that arrangements could be
made for inspection.

7.1.3 No material shall be dispatched from its point of manufacture unless the material has been
satisfactorily inspected and tested.

7.1.4 The acceptance of transformer & its accessories shall in no way relieve the contractor of his
responsibility for meeting all the requirement of this specification and shall not prevent
subsequent rejection if such equipments are later found to be defective.

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7.1.5 Acceptance of condition regarding stage inspection at various stages, which will be intimated
to contractor, shall be an essence of this contract.

7.2 Inspection programme:

7.2.1 The contractor shall chalk out a detailed inspection and testing programme for manufacturing
activities for the various components. An indicative programme of inspection as envisaged
by CSPTCL is given in technical specification of transformer. Stage inspection of core &
winding and final inspection of the transformer shall be carried out at manufacturer‘s works
in presence of CSPTCL‘s representative and representative of a third party i.e. CPRI/ERDA
or any other agency authorized by CSPTCL. The expenses on witness of tests by third party
shall be borne by CSPTCL.

7.2.2 The routine tests on transformer shall be carried out free of cost. The rates for type & special
tests shall be included in the cost of transformer and the same shall not be payable by
CSPTCL.

7.3 Stage inspection:

7.3.1 The manufacturer shall indicate the inspections and checks carried out at various stages of
the manufacture of the transformers. A complete record of stage inspection would be kept by
the manufacturer and thus record should be made available for inspection by the
representative of CSPTCL. The manufacturer should indicate the manufacturing programme
and CSPTCL will have a right to depute its inspecting officers during the manufacture. Some
of the inspecting stages are coil winding and core building, assembly of coil on core, the
condition of the coil and core after the treatment in vacuum chamber, assembly within the
transformer tank together with application of tap changer.

7.3.2 It may be noted that stage inspection for transformer at CSPTCL‘s discretion shall be done at
manufacturer‘s works in presence of CSPTCL‘s representative and representative of third
party authorized by CSPTCL at the following stages.

(a) Fabrication stage of tank: After fabrication, tank shall be inspected for measurement
of its dimensions, thickness of sheets used and leakage test by applying requisite
pressure/ vacuum.
(b) Building up of core: After the core is built but before its clamping, our representative
will inspect the core to take complete weight of the core and also to measure
approximate core loss. If necessary, a small strip of core shall also be taken for
testing at CPRI/ ERDA or at any other testing laboratory of repute.
(c) Preparation of winding: Once the coils are prepared but before the same are fitted on
to the core, stage inspection shall be done to take various measurements and also for
weighment of total weight of coil of each voltage class. Measurement of resistance
shall be taken and for this purpose, a small piece of conductor for each type of
winding shall be made available by the manufacture.
(d) Core Coil Assembly: Apart from the above, CSPTCL also reserves the right to carry
out stage inspections at other stages also, for which advance intimation shall be given
and all necessary cooperation shall be rendered by the manufacturer.

7.4 FINAL INSPECTION AND TESTING:

7.4.1 All the routine, additional routine, type and special tests as mentioned in clause 6 shall be
carried out as per IS:2026 (Part-I & III) at manufacturer‘s works in presence of CSPTCL‘s
representative and representative of third party authorized by CSPTCL. At the time of final
inspection, the supplier shall identify each and every item/ accessories of the transformer
under testing. Unless all the items are identified, the manufacture will not be treated as
complete. Serial number of bushings, serial number of tap changer and other details shall be
entered into the test report to ensure that these items are not being applied to the subsequent
transformer units while testing. Various tests stipulated in IS shall be performed in the

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presence of our engineers or when the inspection waiver has been given, in such a case, the
testing shall be done at the manufacturer‘s works as per IS stipulations and same should be
confirmed by documentary evidence by way of Test Certificate which shall be got approved
by us.

7.4.2 The WTI & OTI shall be calibrated during testing of transformer and serial Nos. of these
instruments; shall be recorded in test reports. The WTI & OTI used during testing shall be
dispatched with the transformer so that installation of same OTI & WTI on transformer is
done which are utilized during testing of transformer at manufacturer‘s works. The Bushings
and Radiators on Transformer during testing of transformer at manufacturers‘ works are
required to be supplied with the same transformer to avoid any mismatch/misalignment etc.
during assembly of transformer. This should be noted for strict compliance and confirmed
specifically.

7.4.3 When inspection call for transformer is given, the letter of inspection call will accompany the
following:

List of various fittings and accessories, which are ready at the works and will be offered for
inspection. The Inspecting Officer will carry the list and check the items declared to have
been offered for inspection.

It is expected that before a transformer is finally offered for inspection, internal testing of the
transformer for various important parameters like winding resistance, transformer losses, IR
values etc. are already done. CSPTCL may ask for routine test report for such tests before
conducting the inspection.

List of testing equipments and instruments which will be used during the inspection of the
transformer with their makes, Sl. No. and date of calibration, agency who conducted
calibration and validity of calibration certificate should also be furnished along with the
inspection call.
7.4.4 Testing at an independent test laboratory:

CSPTCL at its discretion may get the transformer tested at a Govt. approved laboratory like
CPRI/ ERDA for all the routine and type tests at the expenses of CSPTCL. In case, the test
results are found to be deviating from the results during the inspection at manufacturer‘s
works or the test results are found to be beyond the permissible limits as per the tender
specifications and concerned standards, the transformer shall be liable for rejection.

8. Quality Assurance Plan:

8.1 The contractor shall invariably furnish following information at the time of detailed
engineering:-
(i) Statement giving list of important raw materials, names of sub-suppliers for the raw
material, list of standards according to which the raw material are tested, list of tests
normally carried out on raw material in the presence of manufacturer‘s representative,
copies of test certificates.
(ii) Information and copies of test certificates as in (i) above in respect of bought out
items.
(iii) List of manufacturing facilities available.
(iv) Level of automation achieved and list of areas where manual processing exists.
List of areas in manufacturing process, where stage inspections are normally carried
out for quality control and details of such tests and inspections.
(v) Special features provided in the equipment to make it maintenance free.
(vi) List of testing equipment available with the manufacturer for final testing of
equipment specified and test. Plant limitation, if any, vis-à-vis the type, special,
acceptance and routine tests specified in the relevant standards. The manufacturer
should have power analyzer for testing & all other routine & acceptance tests
facilities as per latest amendments of IEC.

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8.2 The manufacturer shall submit the following information to the CSPTCL-

Name of the raw material as well as bought out accessories and the names of sub-suppliers
selected from those furnished in the ―list of vendors for major items of transformer‖ attached
with technical specification for power transformer.
Type test certificates of the raw material and bought out accessories.
Quality Assurance Plan (QAP) with hold points for CSPTCL‘s inspection. The QAP and hold
points shall be discussed between the CSPTCL and the contractor before the QAP is finalized.
8.3 The supplier shall submit the routine test certificates of bought out item and raw material at
the time of routine testing of the fully assembled equipment.
9. Customers Specifications and Contract review: The quality assurance and failure prevention
starts with careful study and scrutiny of our technical specifications and requirements. The
manufacturer shall carefully study all the technical parameters and other particulars & the
contractor shall categorically give his confirmation that these requirements shall be met in a
satisfactory manner.
10. Design Control: The manufacturer shall furnish the checks exercise in design calculations
particularly in respect of short circuit forces and method of clamping end coil to show the
healthiness of the design. The salient features of design together with the certificates of design
engineers will have to be made available to the CSPTCL.
11. Engineering Documents: The manufacturer shall give complete information regarding copper
conductor, insulating paper, core materials, tap changer, gaskets etc. bringing out the detailed
description and specification of these items with explanation as to how our requirements are
being met in this respect.
12. Procurement document control & purchased material & services: The manufacturer shall
indicate the various sources from whom the items namely copper conductor, insulating paper,
core material, tap changer and other items such as gaskets etc. are being procured. The type
of check, quantum of check and acceptance norms shall be intimated and random test and
check results should be made available for inspection whenever so desired. The vendor list
enclosed with transformer specifications is only acceptable to us & in case any change in
vendor list is required, same shall be subject to approval of CSPTCL.
13. Programme chart: Based on above QAP and offered delivery schedule a tentative programme
chart indicating period for various manufacturing/ testing activities shall be submitted along
with QAP. The programme chart should specify periods for various activities i.e. design,
ordering of new materials, assembly, testing etc.
14. Documentation:
14.1 All drawings shall confirm to relevant international standards Organization (ISO)
specification. All drawings shall be in ink and suitable for micro filming. All dimensions and
data shall be in S.I. Units.
14.2 The Contractor shall furnish dimensional drawings of transformer and all other accessories as
indicated in specification. These drawings shall include the following information.
(i) Dimensions.
(ii) Tolerances on dimensions.
(iii) Material designation used for different components with reference to standards.
(iv) Fabrication details such as welds, finishes and coatings.
(v) Catalogue or part numbers for each component and the total assembly with bill of
materials.
(vi) Identification marking.
(vii) Weight of individual components and total assembled weight.
(viii) Foundation drawing.
(ix) G.A. drawings of cooler control cabinet and RTCC panels.
(x) Schematics drawings of OLTC, RTCC and cooler control.

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14.3 The contractor shall submit four sets of final version of all the above drawings for CSPTCL‘s
approval. CSPTCL shall communicate its comments/approval on the drawings to the
contractor within reasonable period.
The contractor shall, if necessary modify the drawings and resubmit four copies of the
modified drawings for CSPTCL‘s approval within two weeks from the date of comments.
After receipt of CSPTCL‘s approval, the contractor shall, within three weeks, submit three
prints and one good quality reproducible of the approved drawings for each location
separately for CSPTCL‘s use.
14.4 The contractor shall also furnish four copies of transformer to CSPTCL bound manuals
covering erection, commissioning, operation and maintenance instructions and all relevant
information and drawings pertaining to the main equipment as well as auxiliary devices.
Marked erection drawings shall identify the component parts of the equipment as shipped to
enable CSPTCL to carryout erection with his own personnel. Each manual shall also contain
one set of acceptance reports of the corresponding consignment dispatched. These manuals
shall be invariably furnished to CSPTCL before dispatch of transformer.
The manufacturing of transformer shall be strictly in accordance with approved drawings and
no deviation shall be permitted without the written approval of CSPTCL.

15. Packing and forwarding:

15.1 The transformer accessories shall be packed in crates suitable for vertical/horizontal transport
as the case may be and suitable to withstand handling during transport and outdoor storage
during transit. The contractor shall be responsible for any damage to the transformer & its
accessories during transit, due to improper and inadequate packing. The easily damageable
material shall be carefully packed and marked with the appropriate caution symbol.
Wherever necessary, proper arrangement for lifting, such as lifting hooks etc. shall be
provided. Any material found short inside the packing cases shall be supplied by contractor
without any extra cost.

15.2 Each consignment shall be accompanied by a detailed packing list containing the following
information:
(i) Name of the Organisation.
(ii) Details of consignment.
(iii) Destination.
(iv) Total weight of consignment
(v) Sign showing upper/lower side of the crate.
(vi) Handling and unpacking instructions.
(vii) Bill of material indicating contents of each packing.

16.1 Storage, Handling & Shipping:

When the transformer is declared ready, the manufacturer has to identify each and every item
associated with this unit and a complete packing list shall be prepared in advance. The
transformer shall be stored and handled properly in shipping depot, while the same is under
process of dispatch. The manufacturer should ensure dispatch of all the related items and
accessories with transformer along with tank.

Tap changer, bushing, radiators and other accessories of the transformer should not be
withheld for use subsequently on units for testing purposes. If there are any items procured
from sub-vendor which are to be directly installed like instrumentation, panels, control gear
etc. test and inspection report for the same will be kept separately and made available to our
inspecting officers.

It may be noted that no change in any accessories or associated equipments after passing all
the test successfully shall be allowed and if this is subsequently detected it shall be binding on
the manufacturer & contractor to replace with the same item with which the initial test were
conducted at his part failing which the entire test shall become null and void. CSPTCL at its
discretion may consider for rejection of the unit thus supplied. The entire cost, for

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replacement of such rejected units thus supplied and for repeating acceptance test, shall be
borne by the contractor.

16.2 Transportation:

The contractor shall include charges for fitting one Electronic impact recorder (on returnable
basis) during transportation of transformers to measure the magnitude and duration of the
impact in all three directions. The acceptance criteria and limits of impact in all three
directions which can be withstood by the equipment during transportation and handling shall
be submitted by the contractor during detailed engineering. The recording shall commence in
the factory before dispatch and must continue till the unit is installed in its foundation. The
data of electronic impact recorder(s) shall be down-loaded at site and a soft copy of it shall be
handed over to engineer-in-charge. Further, within three weeks, the contractor/manufacturer
shall communicate the interpretation of the data. In the unlikely event of impact recorder
output not available at site, the equipment shall be thoroughly internally inspected by the
manufacturer‘s representative before erection at site to ensure healthiness of the equipment.

(A) In order to conduct low voltage field testing on power transformers before
unloading/commissioning at site to determine the internal condition, the transformer shall be
transported with:
(a) Small bushing (12 KV) may be installed on the bushing cover plate to represent the
actual bushing.
(b) Winding leads may be routed, secured and electrically isolated from the tank walls
and active part.
(c) Temporarily tests leads may be used to connect the winding leads by the small
bushings (which will be removed before erection of the main bushings).
(B) Further, the contractor shall mount vehicle tracking system (GPRS/GPS/GSM based) to track
the exact position of the vehicle on which the power transformer is being loaded for
transportation and during detailed engineering take approval for the equipment installed.
The details of arrangement for transport configuration of power transformer (which shall be
adopted by contractor) shall be submitted by the contractor to CSPTCL for approval. The
price quoted by the contractor should take into account this requirement.

17 Completeness of Equipment and bought out items:

The contractor must furnish the following informations:-

17.1 A list of all the accessories which will be supplied with the transformer should be furnished
during detailed engineering. This should be as per ―List of fittings and accessories to be
provided with power transformer‖ and ―List of transformer accessories and test certificates‖
enclosed with this tender specification. While furnishing this list, items which will be
manufactured by the manufacturer and balance items which will be procured from sub-
manufacturers, should be clearly identified as stipulated in the tender.
17.2 It is obligatory on the part of contractor to ensure that supply of all accessories as per tender
specification are made along with Main Tank or prior to delivery of Main Tank so that
erection and commissioning work of Transformer can be completed properly and
uninterruptedly. The date of supply of last accessory will be treated as date of delivery of
transformer.
17.3 The responsibility for obtaining timely supplies of bought out items will rest on the
contractor.
17.4 It may be noted that in case of damages/ shortages due to improper packing or any other
negligence, replenishment shall be arranged within one month‘s time. If this is not done, date
of delivery of such accessory will be treated as date of delivery of main equipment.
For bought out items, responsibility for guarantee and obtaining immediate replacement in
case any defects are noticed and in case defective supply of any item is reported will rest on
the contractor.

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17.5 In case for attending to defect in any accessory or inspection/replacement of the accessory,
which may be bought out item for the contractor services of engineer of original manufacturer
is required, the same will be organized on immediate basis by the contractor at his cost.

18. Calculations/ design data required to be submitted for power Transformer:

All the important data of the transformer i.e. Net weight of bare copper in each winding,
Weight of core without clamping fixtures, Weight of core and windings, Cross section of the
core, Flux density calculations, Calculations for short circuit current and its duration, Current
density during short circuit, Calculations showing withstand capability of windings for
thermal & mechanical stresses during short circuit conditions, Mechanical Design of
transformer tank, final design calculations etc should be submitted by the contractor during
detailed engineering for our verification and records.

18.1 Short circuit withstands capability:

In order to ensure capability of transformer to withstand short circuit forces due to most
severe fault in our inter connected network the transformer should be designed on the basis
that winding are connected to an infinite bus and fault current is limited by transformer
impedance alone, ignoring system impedance. The calculations to prove dynamic and thermal
short circuit withstand capability of transformer shall be submitted considering the above for
transformer. The design of winding assembly which is to be furnished in the drawing should
be in commensuration with these calculations.

18.2 Design of Tank:

Complete mechanical design of transformer tank including details of stiffeners shall be
submitted. The tank shall be designed to withstand the following without permanent
distortion.
(i) Mechanical shocks during transportation.
(ii) Vacuum filling of oil at 10 milli torr in transformer with all fittings.
Continuous internal pressure of 35 kN/m2 over normal hydrostatic pressure of oil.
Short circuit forces &
Under seismic condition /events both horizontal/vertical.

The calculations for tank stiffeners shall be submitted to prove no. & sizes of stiffeners are
adequate to withstand full vacuum & pressure. Drawing of tank shall be submitted indicating
stiffeners.

18.3 Design of Static End Rings (SER) and magnetic shunts:

Details of Static End Rings (SER) and magnetic shunts, if provided, shall be submitted with
calculations. A drawing indicating locations, size, material of SER and magnetic shunts shall
be submitted.

18.4 Overfluxing Capability:

A curve to prove suitability of transformer to withstand various Overfluxing conditions for
the duration indicated in relevant clause without core saturation shall be furnished.

18.5 Cooling calculations:

Calculations of tank surface for heat dissipation, details of radiators, and fans for ONAN &
ONAF cooling shall be provided.

18.6 Design Data :

On the basis of offered flux density and current density, the manufacturer shall furnish
following design calculations &data :-

18.6.1 Core Data:

Details of core material i.e Name of Manufacturer, Manufacturer‘s type designation for core ,
thickness of core, curve for Loss Vs Flux density, No of steps of Core & No of limbs, gross

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core area , stacking factor, Net core area, height & width of core window, center to center
distance of limb, voltage per turn, wt. of core material, working flux density , core loss in
watts per kg marked on graph for grade of core material & selected flux density, building
factor & calculated no load loss in watts, guaranteed no load loss.

Design data for core shall be submitted. A drawing indicating details of core i.e. limbed
construction, step width & thickness, core belting, top & bottom yoke plate etc shall be
submitted.

18.6.2 Winding Data:

Weight of copper for windings ie,. For HV, LV, tap, cross sectional area ,current density, type
of coil, ID/OD/mean dia of coils, size of winding conductor including parallels, number of
turns per phase, number of spacers, length of mean turn, weight of copper without paper
covering, resistance per phase of winding at 75°C, I2R loss at 75°C & normal tap, eddy
current & stray loss at 75°C , total copper loss at 75°C , guaranteed transformer losses at 75
°C.

Complete details of Insulation components i.e. Top & Bottom clamping rings, washers,
Pressboard blocks & cylinders, Pressboard spacers & Phase barriers, Pressboard segments etc
shall be submitted indicating qty, thickness in mm, width & height, weight design data for
winding shall be submitted.

Dimensioned drawings indicating details of winding, ducts, insulation, take off arrangement,
clamping ring, pressure points etc shall be submitted.

18.6.3 Quantity of Oil :

Complete calculations of oil quantity to be utilized in transformer for first filling shall be
submitted. The calculations shall indicate-
Volume of tank including turrets, conservator main & OLTC, volume of headers &
Radiators, oil quantity in OLTC.
Oil displacement by Active parts i.e. core – coil assembly.

18.7 Capacity of Conservator & Size of Air Cell:

While furnishing details of conservator & air cell type sealing arrangement, the manufacturer
shall submit details & calculations for adequacy of size and capacity of air cell for the rating
of the power transformer and also for the quantity of oil required. Catalogue of AIR CELL as
per vendor list should be submitted clearly marking type designation of selected size of Air
cell. A drawing indicating complete details of conservator with Air cell shall be submitted.

18.8 Capacityof Pressure Relief Device:

Manufacturer shall furnish calculation to prove that the capacity/rating of pressure relief
device and locations of the same for the transformer will adequately meet CSPTCL‘s
requirement. Constructional and design details of pressure relief device must be furnished and
it should be proved by calculation that the size and setting of pressure relief device is
adequate considering the rating of the transformer and quantity of oil in the transformer.
A drawing indicating complete details of PRDs & their locations on tank shall be submitted.

18.9 Limitsof Temperature rise & hot spot winding temperature:

The limits of temperature rise for windings, oil and hot spot have been specified. Temperature
rise calculations at rated full load, 110% load and 125% load considering 100% cooler banks,
50% cooler banks and without coolers shall be furnished as indicated below:

a 100 % Loading 20 minutes duration 100 % cooler bank

50 % cooler bank
without cooler bank
10 minutes duration 100 % cooler bank
50 % cooler bank

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without cooler bank

b 110 % Loading 20 minutes duration 100 % cooler bank
50 % cooler bank
without cooler bank
10 minutes duration 100 % cooler bank
50 % cooler bank
without cooler bank
c 125 % Loading 20 minutes duration 100 % cooler bank
50 % cooler bank
without cooler bank
10 minutes duration 100 % cooler bank
50 % cooler bank
without cooler bank

The calculations shall indicate temperature gradient (for all windings i.e. HV,LV,tap), load
losses at lowest tap for all windings , Eddy current & stray losses, thermal Constant Value &
calculations with parameters affecting the values for above conditions for top oil temperature
& winding hot spot temperature.
The Calculations for Hot Spot winding Temperature and Calculations for Temperature Rise
shall also be submitted.

18.10 Capacity of Silica Gel Breather:

The manufacturer shall submit details & calculations for adequacy of size and capacity of
silica gel breather for the oil quantity in the power transformer.

18.11 Rating of Onload Tap changer (OLTC):

It has been our experience that due to inadequate rating of OLTC elements, the failure of
OLTC components or pitting of contacts has been observed before the claimed period for
maintenance. To verify the adequacy and suitability of the OLTC components, it is necessary
to furnish the calculations for selecting the proper rating of transition resistance as well as
normal current rating of OLTC. The calculations shall include the temperature rise of the
OLTC diverter switch and also the short circuit current considered for calculation of
temperature rise.

Calculations shall be submitted to prove that the current rating of OLTC is adequate for the
rating of the transformer winding taking in to account the over loading capability as per IS
6600. The basis for selection of transition resistance and its current carrying capacity shall
also be submitted. In this regard the circulating current in tap winding during tap change
operation through transition resistance shall be taken in to consideration. Adequacy of
insulation provided in the OLTC between various parts needs to be established with specific
reference to the voltage between two taps. Confirmation shall be given that the OLTC is
suitable for bidirectional flow of current. The through current capacity shall be adequate to
handle on continuous basis the winding current including over loading as per IS 6600. The
through current rating and the rating of transition resistance shall take in to account the short
time current rating of the winding. Capability to handle short circuit current to be established
by calculations and also by test reports. The above Calculations for OLTC shall be submitted.

18.12 The manufacturer shall carry out optimization of Dielectric design of insulation including
electromagnetic design, overload & short circuit withstand capabilities. During design,
transformer modelling shall be done & finite element software (FEM) may be used.It is
assured that these data will be kept strictly confidential by CSPTCL.

GUARANTEED TECHNICAL PARTICULARS

01. Name of the Manufacturers

02. Normal continuous rating of (MVA)

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(a). With ONAN cooling

(b). With ONAF cooling
03. Normal ratio of transformation
04. Phase connection:
a) HV winding
b) LV winding
c) Vector group reference no. & symbol
05. Current at rated no load and on principal taps
(Amps) - HV
- LV
06. Maximum temperature rise:
i) of oil by thermometer
a) at full ONAN rating
b) at full ONAF rating
ii) of winding by resistance
a) at full ONAN rating
b) at full ONAF rating
c) by hot spot temperature indicator
d) Ambient tep. Adopted
07. Temperature gradient between oil and winding
08. Voltage to earth for which the star point will be
insulated
09. LOSSES:
(a) No Load Losses :
i) Guaranteed no load losses at normal ratio, rated
voltage rated out put, rated frequency at 75oC
average winding temp. (KW) (no positive tolerance
is permissible)
ii) No load losses at 110% of rated voltage
(b) Load losses:
Guaranteed load losses at normal ratio, rated voltage
rated out put rated frequency at 75oC average
winding temp. at rated output (KW) (no positive
tolerance is permissible)
I Auxiliary losses:
Auxiliary losses at rated output (no positive
tolerance is permissible)
10. Guaranteed total losses at 75oC temp. (i.e. 9 (a)(i) +
9 (b)+9(c)
11. Efficiencies at normal ratio, rated voltage, rated At UPF 0.8 PF Lagging
frequency and average winding temp. for 75oC
average winding temp. for outputs of
(i) full load
(ii) ¾ full load
(iii) ½ full load
(iv) ¼ full load
(v) Maximum efficiency with load
12. Resistance per phase at normal tap of
(a) HV winding
(b) LV winding
13. Reactance per phase of (at normal tap of (in ohms.)
(a) HV winding
(b) LV winding
(c ) Reactance at rated MVA base
14. Resistance voltage drop at 75 degree centigrade
average winding temp. expressed as percent of rated
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voltage
15. Reactance voltage drop expressed as percent of
rated voltage on rated winding MVA
16. Positive sequence Impedance on rated MVA base at Normal Highest Lowest
rated current & freq. At 75 degree centigrade. Tap Tap Tap
Winding temp. between
(a) HV – LV
17. Zero sequence Impedance at 75 degree Centigrade
& at principle tap.
18. Impedence voltage at normal & 75 degree
centigrade average winding temp. expressed as
percentage of rated voltage.
(a) between HV & LV winding
(b) Positive sequence, HV
(c ) Positive sequence, LV
19. Regulation at full load and 75 degree centigrade
Unity power factor
b. 0.8 power factor (lagging)
20. Type of transformer (core or shell)
21. Width of track gauge.
22. Time in minutes for which transformer can be run at
full load without exceeding maximum possible
temp. above ambient temp. when:
(a) Supply to fan group 1 is cutoff
(b) When supply to both groups of fans are cutoff.
23. Permissible over loading
(a) HV winding
(b) LV winding
24. Terminal arrangement for
(a) HV winding
(b) LV winding
25. Insulation level:
(a). L.I. withstand (Kvp)
(b). P.f. withstand for one minute (dry and wet.)
26. Partial discharge level at 1.5xUm/ square root 3 KV
RMS in pico coulomb.
27. Noise level when energised at normal voltage &
frequency without load (db)
28. External short circuit withstand capacity (KA) and 132KV – KA for ------ seconds
duration (secs), 33 KV – KA for ------ seconds
29. Over fluxing capability of transformer at over
fluxing factor.
(a). 1.7
(b). 1.4
(c). 1.25
(d). 1.10
30. Details of core:
(a) Type of core construction of no. of limbs in frame.
(b) Type of core joins.
(c) Flux density at rated voltage and frequency and at
principle tap Tesla)
(d) Flux density at principal tap and at 10% over
Voltage (Tesla)
(e) Magnetizing current at normal ratio and frequency.
(i) 85% of rated voltage

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(ii) 100% of rated voltage

(iii) 105% of rated voltage
(f) Power factor of magnetizing current at normal
voltage ratio and frequency.
(g) Core lamination:
(i) Material and grade
(ii) Thickness
(iii) Voltage per turn
(iv) dia of circumscribing circle of core
(v) No. of steps in core
(vi) Dimensions of core
(vii) Net iron area
(viii) Specific Iron Loss in watts/Kg of core material
at working flux density.
(ix) Total Iron loss, KW
(h) Details of core Belting:-
(i) Material, grade, type
(ii) Width
(iii) Thickness
(iv) Fixing method
(i) Core clamping plate (YOKE):-
(i) Material
(ii) Thickness
(iii) Insulation
(iv) Depth & height of Yoke
(v) Net Yoke area
(vi) Flux density in Yoke
(vii) Weight of Yoke
(j) Describe Location/ method of core grounding
(k) Details of oil ducts in core
31. Details of windings:
(a) Type of winding
(b) Material of the winding conductor
(c) Maximum current density of windings (at rated
current and conductor area)
(i) Conductor Area (sq. cm)
(ii) Current density (A/sq. cm.)
(d) Whether HV windings are interleaved
(e) Whether winding are preshrunk
(f) Whether adjustable coil clamps are provided for HV
and LV windings
(g) Whether steel rings used for the windings, If so,
whether they are split.
(h) Whether electro-static shields are provided to obtain
uniform voltage. Distribution in the HV windings
(i) Insulating material used for:
(a) HV winding
(b) LV winding
(j) Insulating material used between
(a) HV winding
(b) LV winding and core
(c) Regulating winding and earth
(k) Type of axial coil supports
(a) HV winding
(b) LV winding

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(l) Type of Radial coil supports

(a) HV winding
(b) LV winding
(m) (i) Maximum allowable torque on coil clamping
bolts:-
(ii) clamping ring details
- Thickness of ring
- Dia of ring
- No.& size of pressure screw
(n) Power frequency Test voltage for 1 minute
withstand test on
(a) HV winding
(b) LV winding
(o) Impulse test on windings 1.2/50 micro sec. Full
wave withstand.
(a) HV
(b) LV
(p) Switching surge test
(a) HV
(b) LV
32 BUSHINGS
(a) Type & make
(b) Rated voltage class & rated current
(c) Dry & Wet flashover voltage
(d) Power frequency withstand test voltage for 1 minute
for wet & Dry (KV rms)
(e ) Visible corona discharge voltage (KV rms)
(f) Partial discharge level
(g) Under oil flashover of puncture withstand test
voltage (1.2/50 micro sec. Wave.)
(h) Full wave impulse withstand test voltage (1.2/50
micro sec.wave.)
(i) Positive
(ii) Negative
(i) Switching withstand test voltage (KV peal)
(j) Creepage distance in air (mm)
(k) Protected Creepage distance (mm)
(l) Recommended gap setting.
(m) Weight of assembled bushing, kg.
(n) Qty.of oil in ltrs.
(o) Whether test tap is provided.
(p) Cantilever & Torsional force withstand values.
(q) Type of connection lead arrangement & length of
condenser portion.
(r) Bottom PCD & Details of bolts.
(s) Details of bushing current transformers:
(i) Quantity
(ii) No. of cores
(iii) Ratio
(iv) V.A. burden
(v) Accuracy
(vi) Knee point voltage
(vii) Magnetizing current at Knee point voltage
(viii) Secondary resistance.
(ix) Free space required at top for removal of

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bushing (mm)
33. Minimum clearance (mm)
(a) HV
(b) LV
34. Approx. weight of following :
(a) Core excluding clamping
(b) Core with clamping
(c) Coil with insulation
(d) Wt. of steel
(e) Core and winding
(f) Fittings and parts
(g) Oil required for first filling including 10% extra.
(h) (i) Transportation wt. excluding accessories.
(ii) Shipping details:
- Approx. wt. Of heaviest package
- Approx. dimension of largest package
(i) Un-tanking weight
(j) Total weight of transformer with oil and fittings
35. Details of Tank
(a) Type of tank
(b) Approx. thickness of sheet
(i) Sides
(ii) Bottom
(iii) Cover
(iv) Details of stiffener & under carriage
(c) Vacuum recommended for hot oil circulation (torr.)
(d) Vacuum to be maintained during oil filling in
transformer tank (torr.)
(e) Vacuum to which the tank can be subjected without
distortion (torr.)
(f) No. of bi-directional wheels provided
(g) Please note that only bell tank design is acceptable.
Please confirm that offered transformers are of bell
tank design.
36. Conservator:
(a) Thickness of sheet
(b) Size
(c) Total volume (Liters)
(d) Volume between the highest and lowest visible
oil levels (Ltrs)
(e)Power required by heaters (if provided) (KW)
37. Details of oil preserving equipment offered (Air
Cell) please indicate type, make & size.
38. Radiator:
(a) overall dimensions, 1xbxh (mm)
(b) Total weight with oil (Kg)
(c) Total weight without oil (Kg)
(d) Thickness of Radiator tube (mm)
(e) Types of mounting
(f) Vacuum withstand capability
39. Cooling System
(a) Make and type
(b) No. of connected units
(c )No. of standby units
(d) Rated power input

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(e ) Capacity (cu. M/min or litres/min

(f) Rated voltage (volts)
(g) Locked motor current
(h) Efficiency of motor at full load (percent)
(i) Temperature rise of motor at full load (degree
centigrade)
(j) BHP of driven equipment
(k) Temperature range over which control is
adjustable
(l) Whether the fan suitable for continuous
operation at 85% of their rated voltage
(m) Estimated time constant in hours for
i) Natural cooling
ii) Forced air cooling
(n) Period of continuous working at full load with
out fans (in min.)
(o) Continuous MVA rating without fans, MVA
40. Gas and oil operated relay (make, type, rang of
setting etc.)
41. Temperature indicator
(a) Make and type
(b) Permissible setting rang for alarm & trip
(c ) Number of contacts
(d) Current rating of each contact
(e ) Whether remote indicators provided. If so
whether equipment required at purchaser‘s control
room‘s included
42. Approximate over all dimension of transformer in
mm.
(i) Length
(ii) Breadth
(iii) Height
43. Minimum clearance height for lifting core and
winding from tank
44. Minimum clearance height for lifting core and
winding from tank
45. Please confirm transformer will be transported with
oil/nitrogen gas
46. Lifting jacks
(i) Governing standard
(ii) No. of jacks on one set
(iii) Type and make
(iv) Capacity (tonnes)
(v) Pitch (mm)
(vi) Lift (mm)
(vii) Height in closed position (mm)
(viii) Mean diameter of thread (mm)
47. Marshalling kiosk
(i) Make and type
(ii) Details of apparatus proposed to be housed in
the kiosk
48. Details of anti earthquake device provided, if any
49. Tap changing equipment (these details refer to the
basic rating of OLTC. As guaranteed by
manufacturer)

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(i) Make
(ii) Type
(iii) Power flow direction /bi-directional /
restricted bi- directional
(iv) Rated voltage to earth (kv)
(v) Rated current (amps.)
(vi) Step voltage (volt)
(vii) Number of steps
(viii) Control manual /Local electrical /remote
electrical
(ix) Voltage control automatic /non automatic
(x) Line drop compensation provided /not
provided
(xi) Parallel operation
(xii) Protective devices
(xiii) Auxiliary supply detail
(xiv) Time for complete tap change (one step) in
sec.
(xv) Divertor selector switch transient time (cycles)
(xvi) Value of maximum short circuit current
(amps)
(xvii) Maximum impulse withstand test voltage
with 1.2/50 micro-seconds full wave between
switch assembly and ground (kv peak)
(xviii) Maximum impulse frequency test voltage
between switch assembly land earth (kv rms)
(xix) Maximum impulse withstand test voltage with
1.2/50 microseconds across the tapping range (kv
peak)
(xx) Approximate overall dimensions of tap
changer (hxwxd)
(xxi) Approx. overall weight (kg)
(xxii) Approx. mass of oil (kg)
(xxiii) Particulars of the O.L.T.C. control cubicle
50. Driving mechanism box
(a) Make and type
(b) Details of apparatus proposed to be housed in
the box.
51. Please enclose list of accessories and fittings being
provided on transformer. Please confirm these are as
stipulated in tender.
52. Whether the transformer covered have been fully
type tested and if so, whether copies of type test
certificates enclosed with tender.
53. Valves: indicate details of valves, their type, sizes
and no. required/ fitted
54. a) type and make of pressure relief devices
b) No. of each type pf devices per transformer
c) Minimum pressure at which device operates.
55. Please give details of PRV like make, rating etc.
56. Characteristics of Insulating oil to be used
(a) Density in gms/cu. Cm
(b) Kinetic viscosity in cst
(c ) Interfacial Tension at 27oC in N/M
(d) Flash point in oC
(e ) Pour point in oC
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(f) Acidity (Neutralization/Value)

(g) Corrosive Sulphur in %
(h) Electric strength Breakdown
a) As received Voltage (KV rms)
b) After treatment (KV rms)
(i) Dielectric dissipation factor (tan delta) at 90 oC
(j) Saponification value in mg of KOH/gm
(k) Water content in ppm
(l) Specific resistance
(i) at 90 oC ohm/cm
(ii) at 27 oC ohm/cm
(m) N-dm Analysis CA % CM % CP %
(n) Oxidation stability
(i) Neutralization value after oxidation
(ii) Total sludge after oxidation.
(o) Aging characteristic as per Border 140 h/110 oC
(p) Saponification value in mg of KOH/gm
(q) Dielectric loss after 90 oC
(r) Aging characteristics as per
NEMA 164 H/110 oC
(s) Neutralization value in mg of KOH/gm
(t) Sludge content weight %
(u) Pemitivity at 60 oC
(v) Specific heat at 60 oC
(w) Thermal conductivity at 60 oC
(x) Mean coefficient of expansion
57. Details of online DGA monitoring device:
(i) Make
(ii) Name of gases which will be monitored
(iii) Please confirm that necessary soft wares has
been provided
58. Details of nitrogen injection fire protection system
device
(a) Make & model
(b) Auxiliary supply required
(c) size & capacity of storage tank proposed to
be provided

SIGNATURE OF BIDDER
Date
Place NAME
DESIGNATION
(SEAL)

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LIST OF FITTINGS AND ACCESSORIES TO BE PROVIDED WITH EACH

POWER TRANSFORMER

(1) Each transformer shall be provided with the following accessories.

(i) Dial type Thermometers for oil: - A dial type indicating thermometer with repeater of robust
pattern mounted on the side of the transformer at a convenient height to read the temperature
in the hottest part of the oil and fitted with alarm and trip contacts. Remote oil temperature
indicator shall also be mounted on RTCC panel.
(ii) 3 no. Winding temperature indicator for HV , IV& LV winding:- It shall be indicating type
with repeater responsible to the combination of top oil temperature and winding current,
calibrated to follow the hottest spot temperature of the transformer winding,. The winding
temperature indicator shall operate a remote alarm before the hottest spot temperature
approaches a dangerous value and it shall automatically actuate the cooling fan Motors.
(iii) a) Remote winding temperature indicator is to be installed in the indoor control panel
i.e. fan control cubicle with its repeater on remote tap charger control cubicle.
b) In addition to the winding temperature indication device another device for
measurement of hot spot in transformer winding using fibre optic sensors should also
be provided. The probes shall be directly installed in each phase of power transformer
to measure the winding hot spot temperature. The fibre optic cables should be
brought out of the main tank to tank wall penetrator feed through a plate. The feed
through plate should be welded on the tank. The external fibre optic extension cable
shall then be run to the control cabinet. Separate temperature indicator should be
provided for hot spot measurement through this device. The fibre optic sensor
display shall be brought to the RTCC panel also.
(iv) a. One magnetic type oil level gauge with low level alarm contacts and dial showing
minimum, maximum and normal oil levels. The gauge shall be readable from the
gauge transformer base level.
b. One plain oil level gauge of over lapped type on other side of conservator.
(v) Minimum 3 no. pressure relief valves : The quantity of these valves should commensurate
with the quantity of oil in the transformer and also location of valves should be properly
designed to adequately release the excessive pressure.
(vi) A set of air release valves on the top and on the radiators and also at appropriate place
(vii) A safety valve of the chimney type with an equalizer pipe interconnecting the top of the
conservator and upper most part of the safety valve should be provided to prevent rise of oil
in the safety valve pipe. Any other substitute arrangement shall also be acceptable.
(viii) One thermometer pocket for mercury in glass type thermometer.
(ix) The safety valve pipe shall preferably take off from the side of the transformer tank near to
the tank cover and not from the top of the tank cover. The requirements shall be met as
specified in ‗CBIP‘ specification.
(x) One double float gas detector relay (Buchholz relay) with alarm and tripping contacts to
detect accumulation of gas and sudden changes of oil pressure, complete with shutoff valves
and flanges couplings to permit easy removal without lowering oil level in the main tank, a
blend valve for gas venting, and test valve. Make of buchholz relay shall be as per our
approved list of vendors.
(xi) Heat exchangers or radiators complete with shut of valves and with facility for oil draining
arrangement.
(xii)a/ Two oil conservator, with required accessories, one for main tankand other for OLTC.
b/ Air cell type breathing arrangement with oil preserving equipment complete in all respects.
(xiii) Eye bolts and lugs on all parts for easy handling.
(xiv) Two grounding earth terminals at diagonally opposite corner of tank.
(xv) One rating and diagram plate.
(xvi) A set of minimum 4 nos. flanged bi-directional wheels for rail mounting (for 1676mm rail
gauge).
(xvii) A set of fans required for ONAF cooling of the transformer with following information.
a. Number of Radiator Banks.

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b. No. of cooling fans of adequate voltage & rpm) provided in each bank to ensure
100% ONAF rating of the transformer. As per our specification, for each bank one
additional cooling fan is to be included which will be duly wired-up.
(xviii) Suitable jacking lugs and haulage holes.
(xix) Thermosyphone filter assembly with complete details.
(xx) Inspection window & main holes with bolted cover as per Annexure-IV.
(xxi) Lifting arrangement for the complete transformer, core coil assembly and also tank.
(xxii) One foldable ladder on main tank.
(xxiii) For the purpose of taking earthing connection from the neutral bushing, adequate number of
brackets with small support insulators shall be provided on the body of the tank so that
earthing could be arranged by us near the earthing pit of transformer itself.
(xxiv) A separate weather proof FCC (Fan/Cooler control) cubicle shall be mounted on the
transformer containing dial type thermometer and winding temperature indicator and
terminals of dial, type thermometer, winding temperature indicator, buchholz relay, MDG,
control of fans etc.
Please note provision of separate Fan Control Cubicle (FCC) is a must. FCC shall be suitably
dimensioned to accommodate following:-
(a) The wiring from RTCC shall be brought to marshalling box and for terminating the
same adequate number of suitably rated terminal connectors shall be provided.
(b) Necessary cable glands shall be included in the scope of supply.
(c) Arrangement for terminating the connecting leads of OTI, WTI, buchholz, magnetic
oil level gauge etc. shall be made in the marshalling box. It should be possible to
read OTI and ETI readings without opening the box through suitable glass window.
All trip alarm and repeater signals will be transferred to control room for which
arrangement will have to be made.
(d) Starters for cooling fans shall be housed in marshalling box and necessary switches
for local operation of fans shall be provided.
(e) Local remote control switch for OLTC shall be provided.
(f) Space heater with switch, cubicle illumination lamp, fuses, links overload protection
arrangement for motors and other accessories shall be included in the scope of
supply.
(xxv) One set of indoor RTCC (Remote tap changer control) cubicle complete with provision for
remote operation of OLTC, as independent or master/follower scheme, with oil and winding
temperature repeater, tap position indicator with annunciation for fan group ON/OFF and
cooler supply fail indicator and Tap changer in progress.
(xxvi) One set of erection manual/relevant drawing/leaflets should be secured permanently inside the
RTCC cubicle as a guideline for site erection and commissioning.
(xxvii) Three separate connection i.e. connection from core, connection from end frame and
connection from tank shall be brought out on to a terminal box with cover. Arrangement for
inter connecting these terminals in the terminal box shall also be provided. This arrangement
shall facilitate verification of core, end frame and tank insulation.
(xxviii) Mounting of radiators on the IV bushing should be avoided. In no case, the radiators should
be projected above the main tank height.
(xxix) All transformers shall be supplied with a full outfit of tools, spanners, jacks, special tools for
assembly and all spanners shall be single ended and of very good quality of ―Gedore‖ or
―Ttaparia‖ make.
2. The equipments and accessories furnished with the transformer shall be suitably mounted on
the transformer for ease of operation, inspection and maintenance and the mounting details
shall be subject to the approval of the purchaser. All valves shall be provided either with
blind companion flanges or with pipe plugs for protection.
3. Indication, alarm and relay equipment shall have contacts suitable for operation with
220V/110V DC supply. Any other accessories or appliances recommended by the
manufacturer for the satisfactory operation of the transformer shall also have 110 DC as input.
4. (a) OLTC and its controls shall be as per Clause 5.10 Section-II of specification.
(b) All cabinets & panels shall be conforming to stipulations under Clause-5.18 of
specifications.

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(c) All 220/132KV and neutral bushings shall be of OIP condenser type and as per
Clause 5.7.1 Section-II of specifications.
5. NIFP system as per clause 5.10.5.
6. On line DGA Monitoring device as per clause 5.6.1(b).
Accessories, which are not included in the above schedule but details of which are given in
tender specification and which are necessary for satisfactory operation of Transformer shall
be deemed to have been included in the accepted price without any extra cost to the CSPTCL.

*****

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LIST OF TRANSFORMER ACCESSORIES AND TEST CERTIFICATES REQUIRED

S.N Accessory Test-certificates required
o
Condenser Appearance, construction and dimensional check.
Bushing Test for leakage of internal filling at a pressure of 1.0 Kg/cm for 12
hours.
Insulation resistance measurement with 2000V megger.
Dry/wet power frequency voltage withstand test.
Dry/wet power frequency voltage withstand test for test tap insulation
Partial discharge measurement upto 1.5 UN 3Kv.
Measurement of tangent delta and capacitance.
Pressure Gauges/ Appearance, construction and dimensional check.
Differential Calibration test.
Pressure Gauges 3. Alarm contact setting test.
OLTC. Oil tightness test for the diverter switch oil chamber at an oil pressure of
0.5 Kg/cm2 at 100 degree centigrade for 1 hour.
Mechanical operation test.
Operation sequence measurement
Insulation resistance measurement using 2000V megger.
Power frequency voltage withstand test on diverter switch to earth and
between even and odd contacts.
Power frequency voltage withstand test on tap selector- between
stationary contacts, between max. and min. taps, between phases and
supporting frames, between phases.
Operation test of complete tap changer.
Operation and dielectric test of driving mechanism.
Winding & Oil Calibration test.
Temperature Dielectric test at 2 KV for one minute.
Indicator Accuracy test for indication and switch setting scales.
Test for adjustability of switch setting.
Test for switch rating.
Measurement of temperature rise with respect to the heater coil current.
PRV Functional test with Compressed air to check bursting pressure,
indicating flag operation and switch operation.
Dielectric test at 2 KV for one minute.
Switch contact test at 5A, 240 Volt AC.
Cooling fans Insulation resistance measurement.
Dielectric test at 2 KV between winding and body for one minute.
Operation check.
Appearance, construction and dimensional check.
Buchholz relay Leak test with transformer oil at a pressure of 3 Kg/cm2 for 30 minutes
at ambient temperature for relay casing.
Insulation resistance measurement with 500V megger.
Dielectric test at 2KV for 1 minute.
Elements test at 1.75 Kg/cm2 for 15 minutes using transformer oil at
ambient temperature.
Loss of oil and surge test.
Gas volume test.
Mechanical strength test.
Velocity calibration test.
Appearance construction and dimensional check.
Oil level indictor Test for oil levels.
Switch operation for low level alarm.
Switch contact test at 5A 240V AC.
Dielectric test at 2 KV for 1 minute.
Appearance, construction and dimensional check.

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Pressed steel Air pressure test at 2 kg/cm2 under water for 15 minutes.
radiators Appearance, construction and dimensional check.
OLTC control Appearance, construction and dimensional check.
cubicle/ cooler Electric operation.
control cabinet Insulation resistance measurement using 500V megger at ambient
temperature.
Dielectric test at 2 KV for 1 minute.
Bushing current Appearance, construction and dimensional check.
transformer Polarity check.
Measurement of insulation resistance.
High voltage power frequency test.
Determination of ratio error and phase angle of measuring and protection
BCTs.
Determination of Turns ratio error for PS class BCT.
Determination of composite error for protective class BCT.
Interturn insulation withstand test.
Exciting current characteristic test.
Secondary winding resistance measurement.
Knee-Point voltage, measurement for PS class BCT.

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SCHEDULE OF INSPECTION WINDOW

Qty
Sl. No. Particulars
( in no.)
01. Main hole 01

02 Inspection cover to facilitate full inspection and tightening of all 01

connections of diverter switch of OLTC fitted in position. This
inspection window can also be used as main hole at S.No. 1 above.

03. Inspection cover for facilitating inspection/ connections of R, Y & B 02

phase HV bushings.

04. Inspection cover to facilitate inspection and connection of R, Y & B 02

phase LV bushings.

05. Inspection cover to facilitate inspection and connection of HVN & LVN 02
bushings.

06. Inspection cover to facilitate inspection and connection of delta 01

formation.

07. Inspection cover considered necessary for inspection of active parts/ Qty. as per
connections etc. as per manufacturer‘s design. requirement

LIST OF VENDERS FOR MAJOR ITEMS OF TRANSFORMER

S. Name of Item Supplier/manufacturer
No.
1. CRGO M/s. Nippon steel corporation, Japan
M/s. Kawasaki Corp., Japan (M/s JFE, Japan)
M/s. Armco, USA,
M/s. Covefi, France
M/s. Salzgittar, Germany
M/s. S Usinor, France
M/s Transfer, France
M/s Mitsubishi, Japan.
M/s AST Terni, Italy
M/s. EBG India Pvt Limited, (Indian Agent) for
M/s GELSE NKIRCHEN, Germany
M/s British Steel Corporation , UK
M/s Thyseen Krupp Group of Companies
M/s. POSCO, Korea
M/s A.K.Steel USA

2. Winding conductor M/s Invex Filli Isolati Speciali s.p.a. Italy

(a) M/s. Asta
M/s. Smit Draad, Holland
M/s. Incab Industries, Jamshedpur
M/s. Sterlite Industries, Mumbai
M/s. Bhandari Conductor, Mumbai/ Mandideep.
M/s. Shakti Insulated Wires, Mumbai
M/s KSH International Pvt Limited, Taloja
M/s Delta-Trans Conductor, Mumbai
M/s Vijay Electricals, Hyderabad

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M/s RIMA Transformers & Conductors (P) Ltd, Bangalore.

M/s Lacroix and Kress (GMBH) Germany
M/s Pirellicavi Italy
M/s Shree Cable & Conductors
M/s. Hindalco
M/s. Chandra Metals
M/s. BCPL Conductors

(b) CTC Conductor M/s Sam Dong Korea

M/s Invex Filli Isolati Speciali s.p.a. Italy
M/s Loc Roix AND KRESS – Germany
M/s. KSH International (P) Ltd.
M/s. Chandra Metals

3. Precompressed press M/s. H. Weidmann, Switzerland

Board & press Board M/s. Fige Holms Brruk, Swedan
components M/s. Senapathy Whiteley, Banglore
M/s. Raman Board, Mysore

4. Insulating Material M/s. Dupont, USA

M/s. Senapathy Whiteley, Banglore
M/s. H. Weidmann, Switzerland
M/s. Munksio
M/s Amotfors, Sweden
M/s Krammerer

5. Air Cell M/s PRONL, France,

M/s. Swastik
M/s. Unirub
M/s. Rubber Products
M/s Sukrut Udyog
M/s Nu-cork Products (P) Ltd., Bhiwadi (Raj.)
6. Gaskets M/s. Talbros, Faridabad
M/s. Cortica, Chennai
M/s. Packing & Jointing, Chennai
M/s Indian Rubber Products, Haridwar
M/s Bombay Oil Seal Mfg. Mumbai
M/s MGM Rubber Kolkata
M/s Bharat Corrub Industries, Vadodara.
M/s Indian work Industries
M/s Works Product Pvt Ltd
M/s Nu-cork Products (P) Ltd., Bhiwadi (Raj.)
7. OIP Condensor bushing M/s. BHEL
M/s. CGL
M/s. TELK
M/s ASEA-MICAFIL
M/s. Trench
M/s. Alstom (earlier M/s. Areva)
M/s. Vijai Electricals Ltd.
M/s ABB

8. Terminal Connector M/s. Best & Crompton, Chennai

M/s. PeeVee Engg., Bangalore
M/s. Milind Engg., Mumbai
M/s. Nootan, Baroda
M/s Utsav, Baroda
M/s Vinayak and Co., Mumbai

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M/s Megha Engg. Enterprises, Chennai

M/s Klemmen Engg. Corporation , Chennai

9. OTI/WTI with repeater M/s. Accurate Control,UK

M/s. AKM, Swedan
M/s. Perfect Control, Chennai, India
M/s. Preci Measure, Banglore
M/s Radix Electrosystems Pvt. Ltd/ Radix Pyrotech India

10. Magnetic oil gauge M/s. Sukrut Udyog, Pune

M/s. Yogya, Jhansi

11. Buchholz Relay M/s. Fukuda Instrument, Japan

M/s. Atvus,Calcutta
M/s. English Electric, Chennai
M/s. Prayog; M/s BHEL
M/s Instrument and Control, Vadodara

12. Pressure Relief Device M/s. Qualtrol, USA

M/s. GE, USA;
M/s. Sukrut Udyog, Pune

13. Fan & Motor M/s. Alstom (earlier Areva)

M/s. CGL, Mumbai
M/s. Khaitan, Calcutta.
M/s EPC, Calcutta
M/s Marathan

14. Un-impregnated M/s. Permali Wallace Bhopal

Densified laminated M/s. Kit ply Assam
wood M/s. Mysore Polymers Banglore
M/s Narmada Forest Ind. Pvt. Ltd. Bhopal.
M/s Western India Plywood , Kerala
M/s Rochling Detonite

15. Valves M/s. Leader

M/s. Bombay Metal & Alloys
M/s. Audco
M/s. Petson
M/s. Manixon
M/s. Creseant
M/s Precision Engg. Kottayam,
M/s Eapen Joseph, Kottayam
M/s Apex Piping Systems, Jalandhar
M/s Liberty Engg., Mumbai
M/s Niton Valves, Mumbai
M/s Eapen Joseph & Co., Coimbatore
M/s Oswal Agra
M/s Neo Engg. Ahamedabad
M/s CG Valve Udaipur

16. MCB M/s. Sieman

M/s. MDS
M/s. S&S
M/s. Havell‘s

17. Fuse M/s. Siemens/ S&S / Areva / Havell‘s

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18. Tank Steel M/s. SAIL/Jindal/Essar steel

19. OLTC Complete M/s. BHEL
M/s. CTR
M/s. TELK
M/s Easun, Madras

20. Terminal Blocks M/s. ELMEX

M/s. Technoplast,
M/s. Tosha
21. Silica gel Breather M/s. Yogya Enterprises, Jhansi.
M/s. Anusen Industries, Pune.
M/s Instruments & Controls , Vadodara, India

22. Transformer oil M/s Apar Limited, Mumbai

M/s Savita Oil Technologies
M/s. Raj Petrochemicals

23. Radiator M/s CTR Manufacturing Industries, Pune

M/s Thermal Transformer Product, Bangalore
M/s Exotherm, Bangalore.
M/s P.E. Engg. Hyderanad.
M/s Hitech Switchgear, Mumbai
M/s Mahindra Electrical works
M/s Triveni Electroplast

24. On line DGA monitor M/s. GE Kelman- Transfix DGA500

M/s. Morgan Schaffer Calisto-5
M/s. A-Eberley Hydrocol-1005

25. NIFP System M/s. CTR

M/s Easun Reyrolle

Note: The contractor should submit their offer considering the above mentioned vendors.

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DRAWINGS AND DATA TO BE FURNISHED BY THE CONTRACTOR

***

The following drawings and data are to be submitted by the contractor for approval:

(a) Outline dimensional drawings of transformer and its accessories including conservator
complete with Bill of material and details of all parts, their quantity, rating & name of
Vendors indicating clearances of transformer body from live terminals i.e. HV,LV.

(b) Drawing of transformer tank with location of inspection windows, thickness of side/bottom/top
of tank, details of stiffener.

(c) Drawing indicating limbed core construction with complete details of no., width and wt. of
core laminations with size of steps; thickness of core laminations ; dimension of window; size
of limbs; Gross and net core ; wt. of complete core.

(d) Drawing indicating core belting arrangement with details of belting, belting material etc.

(e) Large scale dimensioned drawings for HV & LV windings of the transformer; size and no. of
parallel of HV, LV and of cooling ducts, coil clamping arrangement, no./size & location of
pressure screws, clamping ring; top yoke arrangement etc. The details should commensurate
with the short circuit calculations submitted by you for each rating of transformer

(f) Detailed drawing of transformer tank with complete core and winding indicating clearances
inside transformer tank as also passage and space for free movement of at least two
persons for inspection of active parts etc .

(g) Schematic diagram showing the flow of oil in the cooling system as well as each limb and
winding. Longitudinal and cross-sectional views showing the duct sizes, cooling pipes etc. for
the transformers/radiators drawn to scale .

(h) Drawings giving the weights for foundations.

(i) Combined Rating and diagram plate including tap changing, which should also include details
of guaranteed and measured no load and load losses as also winding resistances and percentage
impedances at all taps.

(j) Schematic control and wiring diagram for all auxiliary equipment and control cubicle.

(k) Drawing showing constructional details, dimensions, mechanical & technical particulars of
bushings. Arrangement of terminals and details of connection of bushing shall also be indicated
in drawing with their technical particulars.

(l) Transportation drawing of transformer.

(m) Details of fittings and cable box.

(n) Drawing showing arrangement and details of tap changing gear including selector switch,
diverter switch and drive mechanism.

(o) Valve Schedule plate.

(p) Oil filling instruction plate for conservator fitted with Air cell breather arrangement including
equalizing arrangement if any required at the time of taking full Vacuum at site.

(q) Drawing and instruction for fitting ofAir Cell.

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(r) Drawing of conservator indicating internal details of air cell MOG, oil level gauge and silica gel
breather pipe fitting arrangement.

(s) Drawings of all HV & LV bushings with complete details meeting TS requirement.

(t) Drawings of HV, LV& neutral terminal connectors indicating plate thickness, no. of nut bolts
with size and other details.

(u) Drawing of foldable & detachable ladder with its complete details and fitting arrangement on
transformer/ conservator tank.

(v) Drawing for HV/LV neutral earthing arrangement indicating voltage rating of insulators and its
fitting arrangements, size of copper strips, terminal connectors etc.

(w) Detailed drawing indicating two views of all valves provided in the transformer tank.

(x) Detailed internal drawing of transformer indicating transportation locking arrangement provided
to avoid shifting of core assembly.

(y) Drawing showing weights of transformers, cooling fan structures, FCC structures with distance
from central line of transformer for casting of civil foundation for transformer and associated
equipments.

Drawing of Earthing terminal box showing earthing arrangement for core, end frame, tank giving
details of voltage class and current rating of terminal bushings.

Drawing indicating insulation thickness details and other arrangement provided between core
assembly and bottom yoke and base of bottom of tank.

Drawing indicating details of ‗O‘ ring gasketting arrangement provided in transformer tank covers.
Detailed Drawing of jacks.
Drawing of stiffeners provided on top, each faces/sides of tank with their number and size.

Drawing indicating number, location, size of shields/ magnetic shunts and its material provided inside
the tank as per clause 11.1 (g).

Drawing indicating internal details of transformer giving complete details of clearances from live
parts.

Drawing of internal LV winding termination arrangement indicating minimum clearance between

core and LV take off lead.

Drawing for Lead termination to bottom of HV & LV Neutral Bushings

Drawing for Lead termination to bottom of HV & LV bushings.

Internal drawing & design of Core & Winding indicating all attachment with identification numbers,
description including take-off arrangement of lead connection for Core & End frame and related Bill
of Material

Locking arrangement drawing for tank top cover, core & winding with complete dimension & details.

Plan view of the bottom of Bell Tank for complete details of core coil resting arrangement, indicating
clearly dimensional details, material of insulation, clamping arrangement with details of nuts/ bolts,
clearance from all sides provided at bottom.

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Drawing indicating complete details, dimension & mounting arrangement of OLTC inside the tank
with respect to End frame.

Drawing indicating complete details, dimensions & fixing arrangement of static end rings if used.

Other relevant drawings.

The manufacturer shall supply four (4) copies of the drawings as listed out above, which will
describe the equipment in details for approval.Three sets of instruction books, operation and
maintenance manuals and spare part bulletin, shall be supplied. In addition to above two sets of
manuals and drawings with test certificates for each unit to be despatched as per despatch instructions.
It will be obligatory on the part of the manufacturer to ensure that the weight of core lamination,
weight of copper, weight of steel, weight of transformer tank along with fitting and accessories,
quantity of oil for first filling including wastage and 10 % extra of that quantity, total weight of core
plus winding after assembly, total weight of transformer and other dimension of transformer are
worked out carefully. It may be noted that at the time of submission of final drawings, variation in
these weights beyond the limits of (+) 5% shall not be permitted.

***

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DETAILS OF INSPECTION PROGRAMME

***

(A). Inspections to be performed at manufacturer‘s works in presence of CSPTCL‘s representative

and/ or a representative of NABL accredited third party.

Stage Inspection:
It may be noted that stage inspection for all the units at CSPTCL‘s discretion shall be done at
manufacturer‘s works in presence of CSPTCL‘s representative and representative of third
party authorized by CSPTCL at the following stages.

After the core is built but before its clamping, CSPTCL‘s representative will inspect the core
to take complete weight of the core and also to measure approximate core loss. If necessary, a
small strip of core shall also be taken for testing at ERDA/ CPRI at our discretion.

Once the coils are prepared and are fitted on to the core, stage inspection of the core coil
assembly shall be done to take measurements of HV/ LV windings. A small piece of
conductor for each type of winding shall be made available by the manufacture. The magnetic
balance test shall also be carried out during this stage inspection.

Apart from the above, the CSPTCL also reserves the right to carry out stage inspections at
other stages also, for which advance intimation shall be given and all necessary cooperation
shall be rendered by the manufacturer.

Final inspection:
After satisfactory stage inspections, ovening of core coil assembly and tanking thereafter shall
be carried out by the manufacturer. Call for final inspection of the transformer shall be given
after readiness of transformer in all respects. During the final inspection, all routine and
additional routine tests shall be carried out on each unit according to the methods specified in
IS:2026 (Part-I):2011 and IS:2026 (Part-III):2009. These tests shall be witnessed by
CSPTCL‘s representative and representative of third party authorized by CSPTCL The details
of the tests to be carried out are as given here under:

Sl. Particulars
(A) Routine tests:
1 Measurement of winding resistance
2 Measurement of voltage ratio and check of phase displacement
3 Measurement of Impedance voltage/ short circuit impedance (Principal tap) & load loss
4 Measurement of no load loss at 90%, 100% & 110% of rated voltage and no load
current
5 Measurement of Insulation resistance
6 Dielectric routine tests as per IS:2026 (Part-III) i.e. lightning impulse tests on all phases
of HV/LV windings, short duration induced AC withstand voltage tests, separate source
AC withstand voltage tests
7 Tests on load tap changers
(B) Addl. Routine Tests:
1 Dimensional checks as per approved drawing & specification
2 Magnetic circuit test. After assembly ,core shall be tested for 1 minute for 2000 volts
AC between all bolts, side plates & structures steel works
3 Polarisation index – IR value for 15 sec, 60 sec & 600 sec duration shall be recorded
and PI for 600/60 sec and DAR i.e. ratio of IR values of 60/15 seconds shall be
recorded. The PI value (600/60 sec) should be ≥2 and DAR value (60/15 sec) should be
≥1.3. These values should be recorded both before and after HV tests.
4 Tank oil leakage test – the complete transformer assly filled with oil shall be subjected
to nitrogen pressure of 0.35 Kg/cm2 above the normal oil head for a period of 12 Hrs to
ensure that there is no oil leakage.

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5 Capacitance and tan delta measurement to determine capacitance between wingding and
earth. This test should be carried out before and after series of dielectric tests by ANSI
II method.
6 Test on bushings and tan delta capacitance and IR values
7 Checking of recording of IR values
(a) Between core & coil frame
(b) Between core & tank
(c) Between coil frame & main tank
The measured IR values should be more than 1000 M Ohms.
8 Magnetic balance and magnetizing current (3 ph.& 1 ph. at normal tape) test
9 Tests of PRDs for successful operation
10 Oil BDV test before & after HV tests
11 Sweep Frequency response analysis (FRA)- SFRA shall be carried out at
manufacturer‘s works with his own SFRA test set. The test shall be repeated at site
with same test set.

Further, following type & special tests as per clause 6.2, Section-II of tender specifications
shall be carried out on one unit out of the lot.

(i) Temperature rise test as per IS:2026 (part-I) & clause 4 of IS:2026 (part-II) on both
ONAN/ONAF ratings.
(ii) Tank vacuum test and tank pressure test
(iii) Test on pressure relief devices
(iv) Measurement of zero Seq. Reactance.
(v) Measurement of acoustic noise level.
(vi) Measurement of power taken by fans.
(vii) Measurement of harmonic level in no load current.
(viii) Lighting impulse with chop on tail on all 3 phase of HV and LV terminals.
(ix) One cooler cabinet and OLTC cabinet of the transformers (preferably for the first unit of the
lot) shall be tested for IP:55 protection in accordance with IS: 2147. In case facility for this
test is not available with the manufacturer, the test has to be carried out at the laboratory of
either CPRI or ERDA in presence of CSPTCL‘s representative and test report should be
furnished.
Tests on Assembled Transformer:
a) Check completed transformer against approved out line drawing, provision for all
fittings, finish level etc.
b) Jacking test on the assembled Transformer.

Tests to be conducted at destination site of CSPTCL:

On delivery / receipt, after erection at site, the transformer shall be subject to the following
tests, in presence of supplier‘s engineer.

3.1 Tests on reaching at site:

(i) Immediately upon receipt of transformer at site and before unloading of transformer
from trailor, core earthing, end frame earthing and tank earthing shall be checked.
Only after satisfactory verification that there is not multiple core earthing in
transformer, unloading of transformer shall be undertaken.
(ii) After receipt of transformer at site physical inspections shall be done for checking
any physical damage to transformer tank and accessories. Further, data of impact
recorder shall be analyzed for any changes before unloading of transformer.

3.2 Pre commissioning tests:

(i) Insulation resistance test and polarization index.
(ii) Ratio and polarity test
(iii) DGA of oil and di-electric, tan delta, resistivity & moisture content test of oil.
(iv) OLTC operational test at each tap for lower and raise operation of tap changer.
(v) Magnetic balance tests and measurement of magnetizing current.

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(vi) Vector group test

(vii) Percentage impedance test at all taps
(viii) Short circuit current measurement at low voltage and at all taps
(ix) Measurement of winding resistance at all taps
(x) Tangent delta, capacitance and insulation resistance tests of bushings
(xi) Measurement of IR values between core & coil frame, core & tank end coil frame and
tank.
(xii) Dew point measurement and recording of pressure of nitrogen gas.
(xiii) SFRA test.

The SFRA test and Dew point measurement shall be carried out in presence of manufacturer‘s
representative. The test kits shall be same as used for carrying out these tests in the factory
and shall be brought by manufacturer‘s representative.

(B). Checks to be performed by the manufacturer during various stages of manufacturer of

transformer. The in house test reports may be reviewed by CSPTCL‘s representative during
stage / final inspection.

Tank and conservator:

Certification of chemical analysis and material tests of plates.
Welder‘s qualification and weld procedure.
Testing of electrodes for quality of base materials and coatings.
Inspection of major weld preparation and joint.
Crack detection of major strength weld seams by ‗dye penetration test‘.
Measurement of film thickness of:
Oil insoluble varnish.
Zinc chromate paint.
Finished coat.
Check correct dimensions between wheels, demonstrate turning of wheels through 90 degrees
and further dimensional check.
Check for physical properties of materials for lifting lugs, jacking pads etc. All load bearing
welds including lifting lug welds shall be subjected to NDT.
Tank vacuum & Tank pressure tests as per CBIP manual on transformer & as per this
specification.
Leakage test of the conservator and tank.
Measurement of thickness of tank plates i.e. top, Bottom & Sides.
All double welds shall be tested for leaks with dry nitrogen, at the pressure not less than 7
kg/sq.cms. (atm)
All tanks, single welds, cooling coils, radiators valve and other parts necessary for complete
transformer shall be tested for leaks and strength by applying pressure not less than 0.7 atm
for a period of 24 hrs or not less than 1 atm for a period of 06 hours. If leaks occur, the tests
shall be conducted after all leaks have been stopped.
Certification of all test results.

2. Core:
Sample testing of core material for checking thickness of lamination, special loss, bend
properties, magnetization characteristics (B-H Curve) and Epstein curve.
Check on the quality of varnish, if used on the stampings.
Measurement of thickness and hardness of varnish on stampings.
Solvent resistance test to check that varnish does not react in hot oil.
Check overall quality of varnish by sampling to ensure uniform shining colour, no bare spot,
no over burnt varnish layer and not bubbles on varnished surface.
Check on the amount of burrs.
Bow check on stampings.
Check for the over lapping of stampings, Corners of the sheets are to be apart.
Visual and dimensional check during assembly stage.

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Check on completed core for measurement of iron loss characteristic and check for any hot
spot by exciting the core so as to induce the designed value of flux density in the core.
Visual and dimensional checks for straightness and roundness of core, thickness of limbs and
suitability of clamps. Weightment of core with belting after building up.
High voltage test of 2KV for one minute between core and clamps.
Certification of all test results.

3. Insulating material:
Sample check for physical properties of materials.
Check for dielectric strength,
Visual and dimensional checks.
Check for the reaction of hot oil on insulating materials.
Dimensional stability test at high temperature for insulating material.
Tracking resistance test on insulating material.
Certification of all test results.

4. Winding:
Sample check on winding conductor for mechanical properties and electrical conductivity.
Check insulating distance between high voltage/low voltage connection, cable and earth and
other live parts.
Check for proper cleanliness and absence of dust.
Visual dimensional checks on conductor for scratches, dent marks etc.
Sample check on insulating paper for PH values bursting strength and electric strength.
Check for bonding of insulating paper on conductor and absence of short circuit between
parallel strands.
Check for brazed joints wherever applicable.
Measurement of voltage, when yoke/core is completely restocked and all connection are
ready.
Measurement of no. of turns in each winding and cross sectional area of windings.
Weightment of windings.
Certification of all test results.

5. Checks before drying process:

Weight of complete core, winding and insulation.
Check condition of insulation of the conductor and between windings, Insulation gap between
HV connection, cables, earth and other live parts. Similarly check for HV/LV connections.
Insulation of core shall be tested at 2KV /min between core to bolts and core to clamp plates.
Check for proper cleanliness and absence of dust etc.
Certification of all test results.

6. Checks after drying process:

Record measurement of temperature, vacuum and drying time during vacuum treatment.
Check for completeness of drying by measuring IR values and Tan Delta.
DP test shall be carried out after jacking test.

7. Pre shipment check at manufacturer‘s works:

Check for inter changeability of components of similar transformers for mounting
dimensions.
Check for proper packing and preservation of accessories like radiators, bushings, explosion
vent, dehydrating breather, rollers, buchholz relay, fans, control cubicle, connecting pipes,
conservator etc.
Check for proper provision of bracing to arrest the movement of core and winding assembly
inside the tank.
Gas tightness test to conform tightness.
Derivation of leakage rate and ensure adequate reserve gas capacity.
Note:
(i) Further tests:

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The Purchaser reserves the right to having other reasonable, tests carried out at his
own expenses either before shipment or at site to ensure that the transformer complies
with the requirements of this specifications.
(ii) Test reports:
After all tests have been completed seven certified copies of each test report shall be
furnished. Each report shall supply the following information:

(i) Complete identification data including serial number of the transformer.

(ii) Method application, where applied duration and interpretation of results for
each test.
(iii) Temperature data corrected to 75 degree centigrade including ambient
temperature.

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LIST OF HAND TOOLS & JACKS TO BE SUPPLIED ALONG WITH THE

POWER TRANSFORMER

No. Spanners of different sizes

A. One tool box consisting of the following hand tools of reputed
make shall be supplied
1 a) Open jaw double ended (Tapadia) 08 No.
b) Cranked ring double ended 03 No.
c) Tubular Box double ended 01 No.
2 Tommy Bar (for Tabular Box spanner)

3 Adjustable wrenches 02 No.

4 Pipe wrench 01 No.
5 Screw Drivers of different sizes (Set of 12) 1 Set.
6 Flat Nose, Round Nose, Side Cutting Pliers 01 No. Each
7 Gasket punches of different size 1 Set
8 Filkes with Handles 02 Nos.
9 Hammers with Handles 02 Nos.
10 Knife with Handles 6‖ & 8‖ 02 Nos.
11 Adjustable Hacksaw 02 Nos.
12 Cold Chisel 02 Nos

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ROUTINE AND ADDITIONAL ROUTINE TESTS

Remarks (mention
Sl. specific comments
Particulars
No. regarding tests results as
per standards or not)
(A) Routine tests:
1 Measurement of winding resistance – The resistance of HV,
IV & LV windings should be carried out at different taps and
values at the ambient temperature & converted values at 75
deg C should be recorded in a separate sheet.
2 Measurement of voltage ratio and check of voltage vector
relationship – The measurement of HV to LV ratio at all taps
should be recorded and ratio error should be mentioned in a
separate sheet. The voltage vector relationship should also be
recorded to ensure the vector group of the transformer.
3 Measurement of Impedance voltage/ short circuit
impedance (Principal tap) & load loss – Tests to be carried
out at normal, highest & lowest tap
4 Measurement of no load loss & current – The values of no
load loss and no load current at normal tap at 90%, 100% &
110% of rated voltage should be recorded before and after
dielectric test.
5 Measurement of Insulation resistance – The insulation
resistance between HV/tank, LV/tank & HV/LV should be
recorded with 5KV megger for 15 seconds, 60 seconds & 600
seconds. The values and PI of 60th / 15th& 600th / 60th
should be mentioned in a separate sheet. The values should be
recorded before & after HV tests.
6 Dielectric tests – Separate sources voltage withstand tests,
induced over voltage withstand test and lighting impulse
withstand tests on all phases of HV & LV as per IS: 2026
should be carried out in following sequence:
(i) One reduced full wave impulse
(ii) Three 100% full impulse
(iii) 650KV p for HV and 170KV p for LV winding. Results
should be indicated in separate sheet with Oscillograms output
should be enclosed.
7 Tests on load tap changers - The testing of OLTC should be
done as per clause 16.9.1 of IS:2026 part-I. After the tap
changer is assembled on the transformer, the following tests
should be performed at 100% of rated auxiliary supply
voltage.
(i) Eight complete operating cycles with transformer not
energized. (ii) One complete operating cycle with transformer
not energized with 85% of rated auxiliary supply voltage. (iii)
One complete operating cycle with the transformer energized
at rated voltage and frequency at no load loss. (iv) Ten tap
change operations with +/- two steps on either side of the
normal tap with as far as possible rated current of the
transformer with one winding short circuited.
(B) Addl Routine Tests:
1 Dimensional checks as per approved drawings &
specifications – All dimensions as per approved drawing
should be checked.
2 Magnetic circuit test. After assembly ,core shall be tested for

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1 minute for 2000 volts AC between all bolts, side plates &
structures steel works
3 Tank oil leakage test – the complete transformer assly filled
with oil shall be subjected to nitrogen pressure of 0.35
Kg/cm2 above the normal oil head for a period of 12 Hrs to
ensure that there is no oil leakage.
4 Capacitance and tan delta measurement to determine
capacitance between wingding and earth. This test should be
carried out before and after series of dielectric tests.
5 Test on bushings: All tests on bushings including capacitance,
creepage distance & tan delta measurement as per IS
6 Checking of recording of
(A) IR values
(a) Between core & coil frame
(b) Between core & tank
(c) Between coil frame & main tank
The measured IR values should be more than 1000 M
Ohms.
(B) Measurement & recording of currents with application of
400V 3 phase AC supply on HV side & LV side shorted
(a) Between core & coil frame
(b) Between core & tank
(c) Between coil frame & main tank
7 Magnetizing current measured with LT supply (before and
after HV tests)
Particulars With three/single phase supply
Volts Amp
8 Magnetic balance test (before and after HV tests)
9 Tests of PRDs for successful operation
10 Oil BDV test before & after HV tests
11 Frequency Response Analysis (FRA)

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TYPE AND SPECIAL TESTS

(TO BE PERFORMED ON ONE UNIT OUT OF THE LOT)

The following type tests shall be performed:

(i) Temperature rise tests as per clause-4 of IS: 2026 part-II. – The temperature rise of oil &
winding should not be more than the limits specified in the tender specifications.
(ii) Tank vacuum tests:
One transformer tank out of the whole lot shall be subjected to the specified vacuum. The
tank designed for full vacuum shall be tested at an internal pressure of 3.33 KN/m 2 absolute
(25 torr) for one hour. The permanent deflection of flat plate after the vacuum has been
releases shall not exceed the values specified below.

Horizontal length of flat plate (in mm) Permanent Deflection (in mm)
Up to and including 750 5.0
751 to 1250 6.5
1251 to 1750 8.0
1751 to 2000 9.5
2001 to 2250 11.0
2251 to 2500 12.5
2501 to 3000 16.0
Above 3000 19.0

(iii) Tank Pressure Test

Transformer tank together with its radiator, conservator, vessel and other fittings shall be
subjected to a pressure corresponding to twice the normal head of oil or to the normal
pressure plus 35 KN/m 2 whichever is lower, measured at the base of the tank and maintained
for one hour. The permanent deflection of flat plates after the excess pressure has been
released after conducting vacuum test should not be more than the values specified above.
(iv) Measurement of zero sequence reactance as per clause 16.10 of IS:2026 part-I.
(v) Measurement of acoustic noise level as per clause 16.12 of IS:2026 part-I.
(v) Measurement of harmonics of the no load current as per clause 16.13 IS:2026 part-I.
(v) Measurement of power taken by the fans as per clause 16.14 of IS:2026 part-I.
(vii) Lightning impulse tests with chop on tail as per clause 14 of the IE:60076. The sequence to be
followed for routine lightning impulse tests and chopped lightning impulse tests for this
particular unit shall be as mentioned here under:
One reduced level full impulse;
One full level full impulse;
One or more reduced level chopped impulse(s);
Two full level chopped impulses;
Two full level full impulses.
(viii) One cooler cabinet and one OLTC cabinet of the transformer shall be tested for IP:55
protection in accordance with IS:2147. This test may be conducted either at manufacturer‘s
works or any other Govt. approved laboratory.

Sequence of tests

The sequence of routine tests, type tests, special tests (whenever applicable) and routine tests
required to be conducted on the transformer is as mentioned hereunder:

Sl.No. DESCRIPTION
1 Dimensional checks as per approved drawings & specifications
2 Pressure relief device test.
3 Degree of protection IP 55 for OLTC & cooling control cabinets.
4 Magnetic circuit insulation test 2 KV- 1 Min. core to Yoke clamp, core to fixing plate,
core bolt to Yoke.

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Sl.No. DESCRIPTION
5 Checking of IR values
(a) Between core & coil frame
(b) Between core & tank
(c) Between coil frame & main tank
The measured IR values should be more than 1000 M Ohms.
6 Magnetic balance test at normal and extreme taps.
7 Magnetizing current measured with LT supply (both single phase and three phase)
8 Voltage ratio at all taps & polarity/phase displacement at normal tap.
9 IR value at 15, 60, 600 sec (before & after HV & Heat Run tests). PI value should not be
less than 2
10 Capacitance and tan delta (before & after HV & TR tests) at 5 KV & 10 KV, LV +
TANK, HV + LV to TANK under grounded, ungrounded and guarded specimen modes.
11 Winding resistance measurement at all taps.
12 Oil DGA test (before and after HV & TR tests)
13 Oil BDV test (before and after HV & TR tests)
14 No load loss and current (before & after HV & TR Routine Tests) at 90%, 100% and
110% of rated voltage with 3Watt meter, 3A and 3V meters methods.
15 Separate source voltage withstand test
16 Induced over voltage withstand test
17 Harmonic analysis of no load current at 90%, 100%, 110% of rated voltage
18 Zero sequence impedance test at 10%, 20%, 60%, 80%, 100% of test current at extreme
taps and normal taps.
19 Impulse test as per specifications on all phases.
20 Load loss at extreme taps & normal tap & impedance all taps by digital power analyser.
21 Temperature rise test at ONAN & ONAF ratings & quoted max. losses.
22 Measurement of power consumption by fans
23 Max. static head of oil measured at the base for 12 hrs.
24 Tests on OLTC: Circuit insulation test 2 KV- 1Min.
25 Operations tests: 8 Cy, 1 Cy at 85% V 1 Cy at no-load and Rated V, 10 Cy + / - 2 steps
from normal tap and rated current.
26 Cooler control test: Circuit insulation test 2 KV- 1 Min.Operation test.
27 Bushing current transformer ratio & polarity tests.
28 Acoustic noise level test.
29 Frequency Response Analysis (FRA)
30 Tests of PRDs for successful operation

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