RURAL ELECTRIFICATION AGENCY

DISTRIBUTION TRANSFORMER
MANUFACTURING PROCESS MANUAL
Drafted by: Approved By:

PE Fred Asiimwe Eng. Turyagyenda John

PE- Onzia Joseph Manager Project Development & Management
SPE-Anthony Wamabuya
PPE-Deborah Nantume
Date: September 2015 Date: November 2015
Table of Contents

PART 1: PROCESS MANUAL............................................................................................... 5

1.0 Scope .................................................................................................................................... 5
2.0 Application ......................................................................................................................... 5
3.0 Certification ....................................................................................................................... 5
4.0 Documentation ................................................................................................................... 5
5.0 Management Commitment ............................................................................................. 6
6.0 Resource Management..................................................................................................... 6
7.0 Operations Control ........................................................................................................... 7
8.0 Product Realization .......................................................................................................... 7
8.1 Transformer Design ................................................................................................................... 7
8.2 Material Acquisition .................................................................................................................. 7
8.3 Production .................................................................................................................................... 8
8.3.1 Core Construction ................................................................................................................... 9
8.3.2 Primary & Secondary Winding Assembly ........................................................................ 9
8.3.3 Core & Winding Assembly ................................................................................................ 10
8.3.4 Core & Winding Assembly Drying .................................................................................. 10
8.3.5 Core & Winding Assembly Tanking ............................................................................... 10
8.3.6 Oil Filling................................................................................................................................ 11
8.3.7 Tank Fabrication .................................................................................................................. 11
8.4 Testing ........................................................................................................................................ 11
8.5 Product Handling & Packing ............................................................................................... 12
PART 2: MATERIAL MANUAL ........................................................................................ 13
1.0 Transformer Core .......................................................................................................... 13
2.0 Transformer Winding ................................................................................................... 15
2.1 Enameled copper winding wire ............................................................................................ 15
2.2 Enameled aluminum winding wire ..................................................................................... 18
2.3 Copper strip or foil.................................................................................................................. 20
2.4 Aluminum strip or foil ........................................................................................................... 21
3.0 Transformer Oil ............................................................................................................. 22
4.0 Insulating Paper ............................................................................................................. 23
4.1 Corrugated Boards.................................................................................................................. 23
4.2 Transformer Board ................................................................................................................. 24
4.3 Diamond Dotted Paper ........................................................................................................... 24
5.0 Offload Tap Changer .................................................................................................... 25
6.0 Pressure Relief Valve .................................................................................................... 26
7.0 Transformer Tank ......................................................................................................... 26
8.0 Radiator ........................................................................................................................... 27
PART 3: TESTING PROTOCOLS..................................................................................... 28
1.0 Introduction .................................................................................................................... 28
2.0 Transformer Tests ......................................................................................................... 28
2.1 Transformer Routine Tests ................................................................................................... 28
2.2 Transformer Type Tests ........................................................................................................ 28
3.0 TRANSFORMER TEST PROTOCOLS ................................................................. 29
3.1 Transformer Insulation Resistance Test ............................................................................ 29
3.2 Transformer Vector Group Test ......................................................................................... 29
3.3 Transformer Voltage Ratio Test .......................................................................................... 31
3.4 Transformer DC Winding Resistance Test ....................................................................... 33
3.5 Transformer Oil Dielectric Test ........................................................................................... 35
3.6 Transformer Separate Source Voltage Withstand Test ................................................. 35
3.7 Transformer Induced Over Voltage Test At High Frequency ................................... 38
3.8 Transformer No Load Test (Core Loss- Hysteresis Loss and Eddy current loss .... 40
3.9 Transformer Full Load Loss Test (Copper Losses) ........................................................ 42
3.10 Zero Sequence Impedance Test ......................................................................................... 44
3.11 Sound Level Test (Type Test). ............................................................................................ 44
3.12 Temperature Rise Test (Type Test) .................................................................................. 46
3.13 Measurement Of Electrical Break Through Voltage Of Copper Wire .................... 48
3.14 Dry Power Frequency Voltage Withstand Test ............................................................. 50
3.15 Transformer Pressure Testing ........................................................................................... 50
4.0 Post Shipping Inspection .............................................................................................. 53
APPENDICES .......................................................................................................................... 54
Appendix A: Plant & Process Checklist ....................................................................................... 54
Appendix B: FAT Checklist ............................................................................................................ 61
PART 1: PROCESS MANUAL

1.0 Scope
This process manual describes the minimal requirement for any transformer
manufacturing plant intending to supply transformers to REA. The manual is designed to
assist REA deal with manufacturing plants that have established and certified
management systems addressing all aspects of Health, Safety, Environment and Quality
(HSEQ) either independently or jointly through an Integrated Management System
(IMS).
The manual defines the minimal processes required to ensure that the transformer
manufacturing plant adequately meets the customer requirements and applicable statutory
and regulatory requirements and aims to enhance customer satisfaction through effective
application of the system, including processes for continual improvement and assurance
of conformity to customer and regulatory requirements.
It is prepared based on the criteria governing ISO 9001:2008, ISO 14001:2004 and
OHSAS 18001:2007 International Standards.

2.0 Application
The process and system describe in this manual shall be applicable to all functional area
of the transformer manufacturing plant

3.0 Certification
The transformer manufacturing plant systems and processes shall be certified in
accordance with ISO 9001:2008, ISO 14001:2004 and OHSAS 18001:2007
international standards as a minimum requirement. Relevant certification certificates shall
be submitted at tender stage.
Audit: (Valid Certification Certificates)

4.0 Documentation
The transformer manufacturing plant shall have all the systems and processes
documented for effective planning, operation and control. Every step involved in the
process of manufacturing transformers for REA shall be document and this
documentation shall be kept for the specified period as required by the standard and
should be presented to REA when called upon. These shall include but not limited to;
HSEQ Policies and Manuals, Process Manual, System Procedures, Quality Plans,
Manufacturing Procedures, Inspection Instructions, Test Methods, Process Checklists and
Forms.
A document control system shall be maintained, detailing procedures for changes,
authorization, revisions, approvals, indexing and achieve amongst other.
Audit: (Availability of above documents & a Document Control System)

5.0 Management Commitment

Management of the transformer manufacturing plant shall demonstrate their commitment
of promoting all aspects of HSEQ in the manufacturing processes of REA transformer.
This shall be done through a written and signed off HSEQ Policy indicating SMART
objectives, actions, responsible persons and support for ensuing adherence to health,
safety, environment, quality, statutory and regulatory requirements.
Audit: (Availability of HSEQ Policy Statement, Procedure for Environmental Aspect
Evaluation, Hazard Identification, Risk Assessment, Legal requirement identification)

6.0 Resource Management

The quality of the product not only depends on the materials but also on skills,
workmanship and infrastructure involved in the product realization process. Management
shall establish a resource management system with the aim of planning and controlling
resources and determine the required resources to implement and maintain the
management systems put in place to ensure HSEQ objectives are achieved.
The following shall be in place: Staff Competency Analysis Records, Job Descriptions,
Training Records, Sufficient Physical Infrastructure and Machinery.
Audit: (Staff Competency Analysis Records, Job Descriptions, Training Records,
Sufficient physical Infrastructure and Machinery)
7.0 Operations Control
The manufacturing operations shall be standardized by activities that are performed by
qualified resources under defined conditions. The process conditions shall be specified in
standards, Instructions, Work Orders, Manuals, Procedures, Protocols and contractual
relations with suppliers and customers.
The plant shall have systems in place for safe guarding the environmental, promoting
quality and health and safety. (HSEQ)
Audit: (Availability of Hazards Register, Environmental Aspect Register, Process
Manuals, Work Instructions, Inspection Checklists, Test Certificates, Calibration
Certificates, Safety manuals and Risk Register amongst others)

8.0 Product Realization

8.1 Transformer Design

The Transformer manufacturing plant shall have processes in place to aid transformer
designing.
Clients specifications and the relevant IEC standards shall be the main input to the
design process, any necessary requirement not specified but necessary for fitness purpose
shall be identified and communicated in writing to the client for clarification at design
stage.
A system should be in place at design stage to establish and record clients technical
requirements, statutory and regulatory requirements, clarifications, delivery, quality and
maintenance requirements.
Product information, outline drawing, design report and fully filled and signed
Guaranteed technical parameters shall be submitted
Audit: (Availability of REA Specification, Procedure for identification & review of
customer requirements, Design Action Plan, Design review checklist)

8.2 Material Acquisition

The transformer manufacturing plant shall have an established purchasing process, which
guides suppliers.
Based on the design output, materials specification customized for REA transformers
shall be development for the supplier. This shall address technical requirements for;
copper winding wires, core materials, bushings, tank, insulating oil, Surge arrestors,
arcing horns and Insulating paper.
The specifications shall also address the appropriate quality, safety and environmental
management requirement.
All purchased and outsourced service shall be inspected, verified and tested at receipt
according to a documented procedure. Both parties shall sign acceptance test reports and
copies shall be submitted to the client for verification.
All materials purchased for REA transformers shall be used and where production is not
yet started, such materials shall be quarantined.
Audit (Availability of materials specifications and Material acceptance test reports)

8.3 Production
The production process shall be carried out under controlled conditions, the information
that describes the characteristics of the product shall be provided to the responsible staff
in form of detailed drawings, charts, instructions, etc. These shall be made available at
point of use.
A production quality plan shall be established and this shall highlight process specific
quality checks, equipment required, resources requirement, suitable monitoring and
measuring devices.
At every stage in the transformer manufacturing, quality & technical compliance checks
shall be performed by a qualified engineer before part is progressed to the next stage in
the production line
There shall be adequate equipment required for each production activity and these shall
be properly maintained
Traceability shall be established and maintained in the production process right from
materials acquisition, part assembly and product testing. Information regarding; material
supplier, staff name responsible for each activity, approvals at each stage, test done and
testing personnel among other shall be recorded using a transformer assembly form/card.
In the production process, items shall be identified by either labels, rating plates, stickers,
hang-on cards, hard stamping or marking with ink to indicate rating, drawing number,
etc. wherever standards are available for identification purposes such standards shall be
followed.

8.3.1 Core Construction

The core shall be of high grade cold rolled grain oriented silicon sheet steel and securely
clamped. The core material shall be as per REA material specification and the materials
test report shall be submitted upon request.
The transformer core shall be of three limbs, step lap stacked at joints to minimize losses
and sound levels
Core sheets should be cut using a semi auto or automated cutter. In a semi-auto
arrangements, the controls shall be the one manually operated but the cutting shall be of
automated.
Samples of core sheet shall be measured for correct dimensions and recorded on the
transformer inspection board.
The core flux density shall be as per the specifications and required loss values

8.3.2 Primary & Secondary Winding Assembly

The primary and secondary windings shall be constructed from high conductivity E.C
grade copper. All turns of the windings shall be adequately supported to prevent
movement
The High voltage winding shall be of layered winding and the Low voltage winding shall
be of either layered or foil winding using copper sheets
The Primary and secondary winding shall be wound using appropriate winding machines
with turns counter.
The name of the staff winding a particular transformer shall be noted on the transformer
inspection board together with the personnel who checked and approved.
An appropriate insulating barrier shall separate the primary and secondary windings;
Inter winding insulation shall be of Diamond Dotted Paper with cooling ducts
8.3.3 Core & Winding Assembly
The windings shall be inserted on the core leg using appropriate tools (Crane, lifting
bracket with a belt), Insulation strips shall be carefully inserted between core and
windings
Insulation resistance between core and LV coil shall be checked using an insulation
resistance meter and result recorded on the transformer assembly inspection cards.
Insulation boards shall be placed between the top of the coil and the yoke and no gap
shall be left between strips of the core leg to complete the core.
The yoke shall be clamped with wooden frame and earthing strips shall be inserted into
the core closer to the LV side-lifting traverse
Stay rods shall be inserted and earthing strip inserted on the stay rod, the upper wooden
frame must be tightened & the frame foot shall be fixed to stay rods.
Correct lifting traverses shall be fixed to stay rods and tightened properly, LV copper bus
bars shall be fixed using appropriate tool & LV flexible leads shall be fixed properly
using correct bolts with spring washers.
Insulating paper tubes shall be inserted to tapping leads & the timber used must we
properly impregnated for 24hrs

8.3.4 Core & Winding Assembly Drying

The core and winding assembly shall be dried in an oven to drive away all moisture in
optimum time (minimum of 24hrs)
Minimum time shall be taken between drying, tanking and filling with oil (maximum 30
minutes) to avoid re-absorption of moisture in the active parts. After drying, tank, cover
plate with accessories and oil should be ready.

8.3.5 Core & Winding Assembly Tanking

Cover plate, Rating, surge arrestors, bushing and bushing accessories shall be prepared
and appropriate tools shall be used.
Transformer tank shall be kept clean all the time & all required components to the cover
shall be fixed using appropriate tools.
Appropriate clearances and seal shall be insured using wooden blocks and silicon sealant
& cork gaskets. The transformers shall be hermetically sealed.
The cover plate with all accessories shall be first mounted to the core & winding
assembly before tanking, all connections must be checked for strength.

8.3.6 Oil Filling

Transformer oil shall be filled in a vacuum chamber to prevent air bubbles

8.3.7 Tank Fabrication

The tank fabrication process shall be parallel to active part assembly. The tanks for REA
transformers shall be of fin type with a base, radiator, flange and cover plate.
The transformer tank and tank cover shall be made of mild steel, hot dip galvanized and
then powder coated as per the specification
The welding shall be done using an appropriate method suitable not to damage the
materials. Preferably Arc & Metal Inactive Gas (MIG) welding shall be used accordingly
Appropriate machines preferably semi-auto or automated shall perform all the machining
processes of shearing, bending, punching & drilling
The materials thickness for the base, cover plate, flange and radiator shall be as per REA
specification
The finished tank and cover plate shall be properly cleaned before dipping and painting
processes.
Audit (Availability of product information at point of use, production quality plan,
adequate equipment, traceability system in-place, Approved method and procedures,
Transformer assembly inspection record, tank fabrication inspection record)

8.4 Testing
Test protocols according to IEC standards shall be established and the required
equipment put in place in a testing laboratory. All transformers shall be inspected and
tested as per IEC standards & REA specifications
New design shall be type tested by an internationally recognized testing laboratory and
type test reports shall be submitted to the client
Audit: (Availability of test protocols, Type test and routine test reports, Calibration
Reports)
8.5 Product Handling & Packing
All products shall be handled properly to prevent damage or deterioration throughout the
production process. Special handling tool should be in place for example cranes and
forklifts, and these should be inspected regularly.
Secure storage areas shall be provided to prevent transformers from getting damaged or
deteriorated before dispatch and all finished transformers shall be suitably marked for
clear identification.
Inspection, packing and delivery of finished transformers shall be done according to
REAs specification
Audit: (Availability of proper handling tools, secure storage space, Procedure for
handling, Packaging, Storage & Dispatch)
PART 2: MATERIAL MANUAL

1.0 Transformer Core

The material for production of the transformer core shall be cold rolled grain orientated
silicon steel sheet (CRGO) with high permeability, low core loss, low magnetostriction,
high inter-laminar resistance and high lamination factor manufactured in accordance with
BS EN 10107:2005, JIS C 2553:2000 standards or any other national and international
standard that can offer equal or higher but not less quality the standards mentioned above.
The core shall be of three limbs stacked core type and shall be securely clamped.
The material shall be free from holes, inclusions, cracks and other imperfections that
would make it useless for manufacture of transformer cores. The material shall also be
free of flakes, particles, or other forms of separable electrically conductive materials.
The maximum thickness of CRGO laminations shall be 0.23mm. Thickness tolerance
shall not be more than 3% and edge burr height when cut shall be within permissible
limits (for production 90% below 0.010mm and 100% below 0.02mm). The flatness
(waviness) must not exceed 15mm/1000mm. the edge deviation (Camber) must not
exceed 0.3mm over measuring length of 1.5m. The maximum flux density shall not
exceed 1.6 Testa.
An inorganic coating shall be applied to both sides of the steel sheets and it shall have the
following properties:
1. Shall offer high inter-laminar properties
2. Shall be thin and bonded to the steel surface so that it never peels off even when
subjected to shearing or bending.
3. Shall not be affected by mineral transformer oil, machine oil owing to its anti-rust
property

The minimum physical, mechanical and magnetic properties shall be as listed in table
below.

Physical, mechanical and magnetic properties of CRGO

Properties Unit Value
 Physical Properties
Si content Approximately 3%
Density Kg/dm3 7.65
Lamination thickness mm 0.23
Edge Burr height mm 0.01 0.02
Flatness (Waviness) mm Shall not exceed 15mm over
1000mm length
Edge deviation (Camber) mm Shall not exceed 0.3mm over
1.5mm length
Mechanical Properties
Yield strength Rp 0.2 MPa 350
RD (Rolling Direction)
90 degrees to RD 360
Ultimate tensile strength MPa 350
RD
90 degrees to RD MPa 400
Elongation RD 10%
90 degree to RD 30%
Hardness, HV5 180
Equivalent Rockwell B 76
Modulus of elasticity RD MPa 120103
55 degrees to RD MPa 260103
90 degrees to RD MPa 140103
0
Curie temperature C 746
Electrical Properties
Resistivity m 0.48
Magnetic Properties
Specific core loss at 50Hz W/kg 0.69 1.11
for 1.5T
Specific core loss at 50Hz W/kg 1.17 1.57
 for 1.7T
Saturation induction T 2.03

2.0 Transformer Winding

Shall be made of Enameled copper winding wire and copper strips. However, aluminum
may be used if expressly asked for in REA specifications.

2.1 Enameled copper winding wire

The enameled copper wire used shall conform to the following standards and or the latest
editions thereof:
IEC 60317-0-1:2013
IEC 60317-8:2010 Class 180 (Grade 2)
IEC 60264-3:1999
IEC 60851:1996

Items conforming to other national or international standards, which give equal or higher,
but not less quality requirements can be accepted.
Enameled round copper winding wire shall be of class 180, with a sole coating based on
polyesterimide resin. The film coating shall be essentially smooth and continuous, free
from streaks, blister and foreign material when examined with normal vision as wound on
the original spool. The copper for electrical purposes E-Cu 57 according to DIN 40500
teil 4 with minimum copper content of 99.90% shall be used.
The overall diameter, electrical characteristics and insulating properties of the enamel
covering shall be in accordance with the standards specified. In addition, copper wire
shall withstand electrical break through voltage of at least 450V in a salt solution (Water
+ 5% NaCl, weight to weight).
The maximum resistance value shall not be greater than the calculated with resistivity of
1/58 mm2/m. the value shall be calculated for the minimum tolerated cross-sectional
area of the conductor. The maximum current density shall not exceed 2.5 3.0 A/mm2.
The nominal diameter of copper, its tolerances and the minimum values for elongation at
fracture shall be as indicated in table below.
 Nominal diameter and minimum elongation at fracture of enameled for primary
winding
Nominal Minimum Conductor Minimum Maximum
diamete elongation (% of tolerance (-,+) increase due to overall diameter
r (mm) nominal diameter) m the insulation (mm)
(m)
Grade Grade 2 Grade Grade 2
1 1
0.250 22 4 17 32 0.281 0.297
0.280 22 4 18 33 0.312 0.329
0.315 23 4 19 35 0.349 0.367
0.355 23 4 20 38 0.392 0.411
0.400 24 5 21 40 0.439 0.459
0.450 25 5 22 42 0.491 0.513
0.500 25 5 24 45 0.544 0.566
0.560 26 6 25 47 0.606 0.630
0.630 27 6 27 50 0.679 0.704
0.710 28 7 28 53 0.762 0.789
0.800 28 8 30 56 0.855 0.884
0.900 29 9 32 60 0.959 0.989
1.000 30 10 34 63 1.062 1.094
1.120 30 11 34 65 1.184 1.217
1.250 31 13 35 67 1.316 1.349
1.400 32 14 36 69 1.468 1.502
1.600 32 16 38 71 1.670 1.706
1.800 32 18 39 73 1.872 1.909
2.000 33 20 40 75 2.074 2.112
2.240 33 22 41 77 2.316 2.355
2.500 33 25 42 79 2.578 2.618
2.800 34 28 43 81 2.880 2.922
 3.150 34 32 45 84 3.233 3.276
3.550 35 36 46 86 3.635 3.679
4.000 35 40 47 89 4.088 4.133
4.500 36 45 49 92 4.591 4.637
5.000 36 50 50 94 5.093 5.141

Springiness of enameled copper wire

Nominal diameter Mandrel Tension (N) Minimum
(mm) Diameter (mm) springback degrees
Grade 1 Grade 2
0.250 12.5 2 49 56
0.280 12.5 2 47 53
0.315 19 4 50 55
0.355 19 4 48 53
0.400 19 4 45 50
0.450 25 8 44 48
0.500 25 8 43 47
0.560 25 8 41 44
0.630 37.5 12 46 50
0.710 37.5 12 44 47
0.800 37.5 12 41 43
0.900 50 15 45 48
1.000 50 15 42 45
1.120 50 15 39 41
1.250 50 15 35 37
1.400 50 15 32 34
1.600 50 15 28 30

For nominal conductor diameter above 1.600mm, the wire shall not exceed the maximum
spring back of 5 degrees.
Breakdown Voltage of enameled copper wire
 Nominal Minimum breakdown voltage (r.m.s value) V
diameter (mm)
Grade 1 Grade 2
Room Elevated Room Elevated temperature
temperature temperature temperature
0.250 2100 1600 3900 2900
0.280 2200 1700 4000 3000
0.315 2200 1700 4100 3100
0.355 2300 1700 4300 3200
0.400 2300 1700 4400 3300
0.450 2300 1700 4400 3300
0.500 2400 1800 4600 3500
0.560 2500 1900 4600 3500
0.630 2600 2000 4800 3600
0.710 2600 2000 4800 3600
0.800 2600 2000 4900 3700
0.900 2700 2000 5000 3800
1.000 up to and 2700 2000 5000 3800
including 2.500
0ver 2.500 1300 1000 2500 1900

2.2 Enameled aluminum winding wire

The enameled aluminum wire used shall conform to the following standards and or the
latest editions thereof:
IEC 60317-0-3: 2008 Grade 1 Class 180
DIN 40501
IEC 60851
IEC 60264-3: 1999
BS 1489: 1972
Items conforming to any other international or national standards, which are equal to
higher but not less, rigid than the specifications stipulated may be offered.
Aluminum for electrical purposes E-Al F7 according to DIN 40501 with a minimum
aluminum content of 99.5% shall be used.
Nominal Diameter and minimum breakdown voltage
Nominal Conductor Minimum Maximum Minimum
diameter tolerance (- increase due to overall diameter breakdown
(mm) ,+) the insulation (mm) voltage at room
m (m) temperature (V)
Grade 1 Grade 2 Grade 1 Grade 2 Grade 1 Grade
2
0.250 4 17 32 0.281 0.297 2100 3900
0.280 4 18 33 0.312 0.329 2200 4000
0.315 4 19 35 0.349 0.367 2200 4100
0.355 4 20 38 0.392 0.411 2300 4300
0.400 5 21 40 0.439 0.459 2300 4400
0.450 5 22 42 0.491 0.513 2300 4400
0.500 5 24 45 0.544 0.566 2400 4600
0.560 6 25 47 0.606 0.630 2500 4600
0.630 6 27 50 0.679 0.704 2600 4800
0.710 7 28 53 0.762 0.789 2600 4800
0.800 8 30 56 0.855 0.884 2600 4900
0.900 9 32 60 0.959 0.989 2700 5000
1.000 10 34 63 1.062 1.094 2700 5000
1.120 11 34 65 1.184 1.217 2700 5000
1.250 13 35 67 1.316 1.349 2700 5000
1.400 14 36 69 1.468 1.502 2700 5000
1.600 16 38 71 1.670 1.706 2700 5000
1.800 18 39 73 1.872 1.909 2700 5000
2.000 20 40 75 2.074 2.112 2700 5000
 2.240 22 41 77 2.316 2.355 2700 5000
2.500 25 42 79 2.578 2.618 2700 5000
2.800 28 43 81 2.880 2.922 1300 2500
3.150 32 45 84 3.233 3.276 1300 2500
3.550 36 46 86 3.635 3.679 1300 2500
4.000 40 47 89 4.088 4.133 1300 2500
4.500 45 49 92 4.591 4.637 1300 2500
5.000 50 50 94 5.093 5.141 1300 2500

2.3 Copper strip or foil

Copper strip (rectangular) and copper foil shall be used for low voltage winding. The
copper strip used shall comply with or latest editions of EN 1652 or any other standard
that offers a higher performance. The foil or strip shall be free of short, sharp
deformations and edge wrappings. The foil or strip shall also be free of holes, bubbles,
dragons teeth, bumps, edge cracks, notches and other deformations which may be
defined as manufacturing defects. The foil or strip surface shall be shiny and free of
grease and other impurities. Grease test according to DIN 53364: Testing of plastic films,
which can also be applied for copper foils or strips can be conducted if required. The
edges shall be without any blurr.
In accordance with DIN 40500 Teil 1, material E-Cu57 F20. The minimum copper
content shall be 99.90%. Current density shall not exceed 3.5A/mm2. Thickness and
width of the copper strip shall be within the range of 0.1 2.5mm and 350 1250mm
respectively. Thickness and width tolerances shall be kept within reasonable limits.
Physical and mechanical properties
Property Unit Type
Density Kg/dm3 8.90
Tensile strength, Rm N/mm2 Minimum 200
Proof stress, RP0,2 N/mm2 Minimum 120
Elongation, A5
Thickness (T) = 0.1 1mm Minimum 38%
 T = (1) 10mm Minimum 40%
Hardness
HV 40 65
HB 45 70
For cold pressure welding
hardness, HV 50 56
Thermal conductivity W/(K.m) 398
Resistivity m Maximum 0.01754

2.4 Aluminum strip or foil

The items used shall be in accordance with standards specified below or latest editions
and amendments thereof;
DIN 1783
DIN 1784
DIN 40501
DIN 53364
BS EN 13599: 2002

Items conforming to any other international or national standards, which are equal to or
higher but not less rigid, the standards and specifications stipulated may be offered.
The foil or strip shall be free of short, sharp deformations and edge wrappings. The foil or
strip shall also be free of holes, bubbles, dragons teeth, bumps, edge cracks, notches and
other deformations, which may be defined as manufacturing defects. The foil or strip
surface shall be shiny and free of grease and other impurities. Grease test according to
DIN 53364: Testing of plastic films, which can also be applied for copper foils or strips
can be conducted if required. The edges shall be without any blurr.
Aluminum for electrical purposes E-Al F7 according to DIN 40501 teil 4 with a
minimum aluminum content of 99.5% shall be used.
 Physical and mechanical properties
Property Unit Type

Density Kg/dm3 2.70

Tensile strength, Rm N/mm2 65 95
Proof stress, RP0,2 N/mm2 Max. 55
Elongation, A5 Minimum 40%
Hardness
HV Approximately 25
HB Approximately 20
Thermal conductivity W/(K.m) 203
Resistivity m Maximum 0.0282

3.0 Transformer Oil

Transformer oil shall be used dissipate heat generated in the windings and to also provide
electrical insulation. The raw material for production of transformer oil shall be low
viscosity transformer oil base stock (TOBS) obtained by fractional distillation and
subsequent treatment of crude petroleum which is further refined by acid treatment
process to yield transformer oil. Any other transformer oil shall be accepted as long as
its demonstrated that such oil offers superior performance.
The oil shall be produced in accordance with standards specified below or later editions
and or amendments thereof;
BS 148: 2009 Class 1
IEC 60296: 2003

Any other national or international standard that offers higher but not less quality
requirements can be used with prior approval from REA.
The transformer oil shall have the minimum characteristics of given in table below
Minimum characteristics of transformer oil
Test Test Method Value
 Relative density ISO 3675:1998 0.871
Viscosity 40 deg. C.Cs ISO 3014:1993 12.0 (max)
Viscosity 20 deg. C.Cs ISO 3014:1993 31.0
Viscosity 0 deg. C.Cs ISO 3014:1993
Viscosity -15 deg. C.Cs ISO 3014:1993 350
Viscosity -30 deg. C.Cs ISO 3014:1993 1800 (max)
Flash point deg. C ISO 2719: 2002 154
Pour point deg. C ISO 3016: 1994 -40
Neutralization value mg.KOH/g IEC 60296: 2003 < 0.03
Corrosive sulphur BS 2000-315:1998 Non corrosive
Water content mg/kg IEC 60814: 1997 1.5
Breakdown Voltage kV IEC 60156: 1995 70
Resistively m 20 deg. C IEC 60247: 2004 20
Dielectric dissipation factor 90 IEC 60247: 2004 0.001
deg. C
Gassing tendency mm/min IEC 60628: 1985 -1
Antioxidant additive IEC 60666: 1979 None
Oxidation Test:
Acidity mg.KOH/g IEC 61125: 1992 0.4
Sludge value % IEC 61125: 1992 0.1
PCB IEC 61619: 1997 None

4.0 Insulating Paper

Insulating paper shall be used to offer inter turn winding insulation as well as insulation
between MV and LV windings.

4.1 Corrugated Boards

Corrugated boards shall be used provide insulation between MV and LV windings. The
corrugated board shall be manufactured in accordance with;
IEC 60641-1: 2007
DIN EN 60641-3-1: 2009
The board shall be of Class A insulation in transformer oil, shall not affect the properties
of the transformer oil and shall have a minimum dielectric strength of 60 kV/mm in oil.
Cutting edge of the corrugated board must be free from burrs, any deformations and
thickness shall not be increased. The designed thickness and curvature of the corrugation
shall ensure adequate insulation and circulation of transformer oil.

4.2 Transformer Board

The transformer board shall be used to provide insulation between core and LV windings,
between MV phase to phase winding and between the end of windings of every phase
and the core.
The board shall be manufactured in accordance with standards specified below or latest
editions and or amendments thereof; IEC 60641-1: 2007
The transformer board shall be of class A insulation in transformer oil, shall not affect the
properties of the transformer oil and shall have a minimum dielectric strength of
60kV/mm in oil.

4.3 Diamond Dotted Paper

Diamond dotted paper shall be used to provide inter-turn winding insulation for both
primary and secondary winding.
It will be manufactured according to the following standards;
IEC 60641-1:2007
DIN EN 60641-3-1:2009

The diamond dotted paper shall be diamond patterned epoxy papers and have shall the
following minimum properties;
Paper shall contain both sulphate wood pulp and cotton in a 50/50 mixture to
impart a combination of both favorable stiff and tensile properties.
The resin shall be on both sides of the paper and shall result in partial adhesion of
the electrical conductors to the layer insulation at a temperature between 100 0C
130 0C.
Approximately 36% of the total area on each side should be printed with epoxy
resin of 9.59.5mm2
The thickness of the partial coating of resin shall be 0.01mm on each side.
 The epoxy resin must not affect the properties of mineral oil used in the
transformer.
Single layer diamond dotted paper shall generally have a nominal thickness of
0.13mm and 0.25mm.
When the insulation is specified as double layer diamond dotted paper (DDP), it
shall have two layers of DDP glued under dry conditions. Double layer DDP shall
generally have a nominal thickness of 0.15mm, comprising of two 0.075mm thick
insulation paper.

5.0 Offload Tap Changer

Offload tap changer shall be manufactured in accordance with the following standards;
IEC 60893-1: 2004
EN 12420: 1999
EN 13599: 2002

The tap selector shall be suitable for off load operation and immersing in transformer oil
and to be used in hermetically sealed transformers. These shall be operated generally at
nominal voltages of 36kV and 12kV with different current ratings. The number of tap
positions shall be as per REA specifications.
The materials to be used in different parts of the tap selector are shown in table below
Materials for different parts of tap selector
Part Material
Steel Parts Stainless steel
Polyamide Parts Nylon 66, Strong against UV light
Aluminum Parts GAlSi12Cu, Protected from anodic
oxidation
Brass Parts CuZn40Pb2 Ms60F34
Copper Parts E-Cu F25
Insulator Parts Paper phenol plastic resin based laminates
Any changes to material shall be given prior approval.
6.0 Pressure Relief Valve
Pressure relief valve shall be manufactured in accordance with IEEE Std C57.12.22-1993
or any other national and international standard that offers equal or higher but not less
quality requirements.
The pressure valve shall operate at 0.35 bars and shall reseal at the same pressure.

7.0 Transformer Tank

Mild steel shall be used to manufacture transformer lifting traverse, lifting hook, lifting
lug, and tank, base, top cover and the flange. This shall be in the form of;
Mild steel sheets
Mild steel angles
Mild steel channels
Mild steel flat bars
Mild steel rods

Items supplied shall be in accordance with the standards specified below or later editions
and or amendments thereof
BS EN 10029: 1991
BS 7668: 2004
BS EN 10025-1:2004
BS EN 10025-3:2004
BS EN 10025-4:2004
BS EN 10210-1:2006

Items conforming to any other international or national standards, which are equal to or
higher but not less, rigid than the standards and specifications stipulated may be offered.
The mild steel components shall be free from corrosion, oil/grease and burrs. The
minimum thickness of the mild steel for up to 400kVA transformer shall be between
4mm to 6mm and for 500 600kVA shall be 6mm to 10mm.
8.0 Radiator
The radiator shall be used convectional cooling of the transformer so that designed
temperature rise in the inside transformer is with desired limits. The items used shall be
formed out of steel in compliance with standards specified below or later editions and or
amendments thereof;
DIN EN 10131: 1992
DIN 1623: 2009

The (items formed out of) steel conforming to any other international or national
standards which are equal to or higher but not less rigid than the standards and
specification stipulated may be offered.
All radiator surfaces should be free from oil and the minimum thickness shall be 0.2mm.
PART 3: TESTING PROTOCOLS

1.0 Introduction
The Client in accordance with the relevant IEC and ISO standards shall inspect the
manufacturing plant, its process and products. The tests on the products shall include:

2.0 Transformer Tests

2.1 Transformer Routine Tests

1. Transformer insulation resistance test
2. Vector group test
3. Voltage ratio test
4. DC resistance test/winding resistance test
5. Oil dielectric strength test
6. Separate source voltage withstand test
7. Induced overvoltage withstand test at high frequency.
8. No load test
9. Full load test/ short circuit test

2.2 Transformer Type Tests

1. Impulse voltage withstand test (Dry power frequency voltage withstand test)
2. Electrical break through voltage of copper wire
3. Transformer pressure testing
4. Sound level test
The following information about the transformer test equipment shall be provided by all
transformer manufacturers as it may be required from time to time to ensure acquisition
of result with minimal errors; Equipment name, Manufacturer, Date of purchase and Last
date of calibration
3.0 TRANSFORMER TEST PROTOCOLS

3.1 Transformer Insulation Resistance Test

Purpose:
This test is intended to assess the condition of insulation of all insulated parts of a
transformer.
Apparatus:
Megger Insulation Tester
Preparation of Sample
Isolate the transformer.
Clean all bushings with a clean piece of cloth.
Procedure
Set a scale indicator to the discharge position before each test.
Connect the probes of the tester (P1 & P2) to the points between which insulation
is measured (e.g. In the case of H/E, connect probes to the winding terminal and
Earth).
Select the proper scale:
Select 1000V scale for winding voltages below 1.0KV.
Select 5000V scale for winding voltages above 2.5kV.
Acceptance Criteria
Measurements taken between Minimum acceptable value
HV & LV 600 Mega Ohms
HV & E 600 Mega Ohms
LV & E 600 Mega Ohms
Safety
Make sure the test leads are not damaged
Do not touch the leads while the meter is switched ON
Always follow general safety instruction of the area

3.2 Transformer Vector Group Test

Purpose
To confirm the vector group is provided. Test should be performed as per IEC 60076
test standards.
Apparatus
Transformer Ratio meter (PWR 3A)
Manual of Transformer Ratio Meter.
Preparation of samples
Keep the transformer open circuited
Make sure that the insulation resistance (Megger) values are sufficient.
Procedure
Before the test, the following information about the transformer must be obtained
and checked
Primary and secondary voltage
Voltage ratio values.
Connect the HV and LV leads of the meter to the HV and LV terminals of the
transformer.
Switch ON the meter
Press Group button on Measurement column.
Acceptance criteria
On the top of the display screen, the vector group of the transformer will be displayed.
Work instructions for safety.
Do not touch the leads while the meter is switched ON.
Switch OFF the meter before remove of the leads.
Always follow general safety instructions of the area.
3.3 Transformer Voltage Ratio Test
Purpose:
To ensure that the turns ratio of the windings is correct and that the tapping on any of the
windings have been made at correct position. Tests should be performed as per IEC
60076 test standards.
Apparatus
Transformer turns ratio meter
Manual for transformer ratio meter
Preparation of sample
Keep the transformer open circuited.
Make sure the insulation resistances (Megger values) are sufficient.
Procedure
Before testing, the following information about the transformer must be obtained
and checked.
Primary and secondary voltage.
Voltage ratio values.
Select the tapping. Connect HV & LV leads of the meter to the HV and LV
bushing terminals of the transformer respectively.
Switch on the meter.
Press Ratio button on Measurement column.
Enter the vector group of the transformer.
Enter the required phase or A/N (To get ratio of all phases at selected position)
Record the readings.
Perform the test for all tap positions.
Note: The Transformer turns ratio meter has an inbuilt power supply with voltage used
being low such as 8 -10 Volts, 50HZ.
Acceptable criteria
In the event that the voltage ratio does not match the 0.5% tolerance is allowed from
specified values. (As per IEC 60076).

Measured values should be in the following range.

 11kV/415V (2.5% to -7.5% of 33kV/415V (2.5% to -7.5% of
Rated Voltage) Rated Voltage)
Tap 1: 46.82 Measured Value Tap 1: 140.46 Measured Value
47.29 141.88
Tap 2: 45.68 Measured Value Tap 2: 137.04 Measured Value
46.14 138.42
Tap 3: 44.54 Measured Value Tap 3: 133.61 Measured Value
44.99 134.96
Tap 4: 43.39 Measured Value Tap 4: 130.18 Measured Value
43.83 131.50
Tap 5: 42.25 Measured Value Tap 5: 126.76 Measured Value
42.68 128.04

Work instructions for safety:

Do not touch the leads while the meter is switched ON.
Switch OFF the meter before removal of leads.
Always follow general safety instructions on the area
3.4 Transformer DC Winding Resistance Test
Purpose:
To measure the DC resistance between lines of all windings and to detect faulty or poorly
made connections. Test should be performed as per IEC 60076 test standard. Test
results are important in full load loss measurement.
Apparatus
Transformer winding resistance meter.
Manual for the meter.
Preparation of the sample
Isolate the transformer.
Procedure
Connect the potential 1 output to the HV winding and potential 2 to the LV
winding of the transformer to be tested.
Test current output terminals should be connected to the upper point of the HV
terminals in which the resistance has to be measured. In the case of Dyn vector
connected transformers connection sequence for HV is A&B, B&C, C&A.
Connection sequence for LV is a&b, b&c, c&a.
Select appropriate ranges of resistance.
Then switch on the power switch.
Then press the start switch.
The meter will inject current and start measuring.
Do not touch the leads while the danger sign appears.
Record the resistance values when safe sign appears.
Winding temperature at the time of measuring the transformer winding has to be
recorded.
Work Instructions for safety
Always make sure the instrument body is earthed before switch ON.
Do not disconnect the leads until the RED warning light disappears
Always follow general safety instructions of the area.
NB: The winding resistance test results obtained above are used in calculating the Full
load loss
3.5 Transformer Oil Dielectric Test
Purpose
To confirm the electrical strength of the transformer oil.
Apparatus
Oil Dielectric Strength test se
Preparation of sample
The sample should be collected from the bottom of the container or transformer.
Sample should be collected to a clean, dry container.
Before collecting the sample, allow slug to drain off.
Procedure
Fill the oil sample to the test vessel up to a level about 10mm above the electrodes
level. Put the magnetic stir in to the test vessel.
The electrodes are set at 2.5mm/0.1mm gap. If there is any suspicion, check the
gap.
Select the mode of operation as Automatic or Manual. In manual operation, the
rate of rise of applied voltage should be 2kV/second 0.2kV/second.
In the case of automatic operation, machine allows a pause of 2 minutes after each
breakdown before re-application of the voltage. The machine conducts the test for
six times on the same cell filling and the mean value of the tests will be
automatically printed on the attached printer.
Acceptance criteria
Average breakdown voltage of the oil must be > 50kV for transformers.

Work instructions
Always make sure that the instrument body is earthed before the meter is
switched ON.
Do not try to open the instrument while testing oil.
Always follow general safety instructions of the area

3.6 Transformer Separate Source Voltage Withstand Test

Purpose:
To determine the integrity of the insulation between windings and earth. Tests should be
performed as per IEC 60076 test standards.
Apparatus
AC Dielectric test set. (6T CD 100-10)
Manual of the AC Dielectric Test Set
Preparation of sample
Transformer should be isolated
Clean the bushings thoroughly with a clean piece of cloth.
Make sure the oil level of the transformer is at the top level.
Procedure
Bushing terminals of the windings under test are connected together using a
conducting wire. The rest of the windings of the transformer are also connected
together as above and connected to the tank and then tank is earthed. Then the
appropriate test voltage is applied as per given under acceptance criteria below.
Select the rate of voltage rise and apply the voltage.
This is performed on both HV and LV sides at power frequency.
The voltage is gradually increased up to the value below. Holding at the above
voltage up to recommended duration. Reduce the voltage gradually before
switching off.
Note: Insulation failure during the test is indicated by sudden increase of leakage current
indicated on the test set. This would trip-off the test supply voltage.
Acceptance Criteria
For 33kV When the HV side is subjected to 70kV, it should withstand for 1
minute.
For 33kV/415V when the LV side is subjected to 3kV, it should withstand for 1
minute.
For 11kV when the HV side is subjected to 28kV, it should withstand for 1
minute.
For 11kV/415V When the LV side is subjected to 3kV, is should withstand for 1
minute.
Work instructions for safety
Never switch ON the HV Tester when someone is inside the testing area.
Switch off the output voltage before change the HV connections.
Do not operate other electrical instruments while HV Tester is switched ON.
Always follow general safety instructions of the area
3.7 Transformer Induced Over Voltage Test At High Frequency
Purpose
To verify voltage withstand strength between the windings and Earth, the withstand
strength between the phases, and between turns of a phase under test. The test should be
performed as per IEC 60076 test standards.
Apparatus
High frequency tester
Manual of the High frequency tester.
Preparation of sample
Transformer should be isolated
Clean the bushings thoroughly with a clean piece of cloth.
Make sure that the oil level of the transformer is at top level.
Make sure that the transformer tap selector is at rated tap position.
Procedure
Connect the high frequency generator output to the low voltage winding of the
transformer while high voltage windings are open circuited. Make sure that the
same output terminal sequence of the generator is connected.
Increase the voltage slowly by rotating the control switch on the control panel
until double the rated voltage of low voltage winding is applied. A gradual
increase of the brightness of the set of bulbs could be observed.
Note: If the transformer is faulty, the circuit is tripped off in the test set.
Since the frequency of the test supply is 120 HZ (This value is fixed for newest
High Frequency Generator), the test duration is 50seconds.
Acceptance Criteria
Sustaining the brightness at peak level for 50 seconds indicates the successful voltage
withstanding strength.
Work instructions for safety
Switch ON the HF panel only after connecting the test leads to the transformer.
Switch OFF the output voltage before remove the leads from the transformer.
Always follow general safety instruction of the area.
3.8 Transformer No Load Test (Core Loss- Hysteresis Loss and Eddy current
loss
Purpose
To determine the No Load losses of a transformer. It also checks whether any damages
have been caused to windings and insulation from prior tests. The test should be
performed as per IEC 60076 test standards.
Apparatus
AC Analyser.
Preparation
Transformer should be isolated.
Clean the bushings thoroughly with a clean piece of cloth.
Make sure that the oil level of the transformer is at top level.
Make sure that the transformer tap selector is at rated tap position.
Procedure
Connect n,a,b,c bushing leads to the respective test leads.
Maintain HV side open circuited.
Adjust current transformer tappings to get an appropriate current according to the
transformer to be tested. Generally, 5% of the rated current could be considered as
a guide.
Apply the desired CT, PT ratio values and guaranteed loss value.
Apply the rated voltage by use of Air Circuit Breaker.
Measure the parameters by pressing the start/stop button of instrument.
By pressing the start/stop button again the measured values will be stored.
Switch off the air circuit breaker.
Acceptance Criteria
No load current shall be less than 5% of the rated current.
The deviation of the No load loss value should be less than 15% of the specified
value.
Work instructions
Make sure the meter body is connected to the Earth before switch ON the meter.
 Always short circuit the secondary terminals of the current transformers before
switch off the voltage to the transformer.
Always follow general safety instructions of the area
3.9 Transformer Full Load Loss Test (Copper Losses)

Purpose
To assess the Full Load Loss (copper loss) and the impedance voltage of a transformer.
Tests should be performed as per IEC 60076 test standards.
Apparatus
AC Analyser
Manual for the AC analyser.
Preparation of sample
Transformer should be isolated
Clean the bushings thoroughly with a clean piece of cloth
Make sure the oil level of the transformer is at the top level.
Make sure that the transformer tap selector is at the rated tap position.
Procedure
Short circuit the low voltage winding bushing terminals using a thick flat copper
bar which is sufficient to carry rated low voltage current.
Connect A.B.C bushing leads to the respective test leads.
Calculate the rated current of the high voltage winding and select the CT tap
position according to it.
Apply the CT & PT ratio values to the meter.
Switch on the air circuit breaker.
Measure the parameters after injecting the desired rated current by pressing the
start/stop button of the instrument. Pressing the start/stop button again, the
measured values can be stored on the display of the meter.
Switch off the air circuit breaker.
Care should be taken to avoid supplying current for longer durations during the
test in order to prevent heating of the windings, which eventually introduce
additional losses.
Record the room temperature
Acceptance criteria
 Deviation of full load losses corrected to 750 C shall be within 15% of the
specified value.
Total losses deviation of the component losses should be within 15% while
maintaining the deviation of the total losses within10% of the specified value.
Work instructions for safety
Make sure that the meter body is switched to earth before switch ON the meter.
Always short circuit the secondary terminals of the current transformers before
switch off the voltage to the transformer.
Always follow general safety instruction of the area.
3.10 Zero Sequence Impedance Test
Purpose
To determine the zero sequence impedance of the transformer. Test should be done as per
IEC 76 test standards.
Apparatus
AC Analyzer
Votmeter
Preparation of sample
Transformer should be isolated
Clean the bushings thoroughly with a clean piece of cloth.
Make sure that the oil level of the transformer is at the top level.
Make sure that the transformer tap selector is at rated tap position.
Procedure
Short-circuit High Voltage bushing terminals of the three phases.
Connect the circuit as shown in the circuit arrangement.
Apply a single phase voltage of about 200V with the same frequency as the
operating frequency of the transformer across the neutral and the short circuited
point.
Measure the voltage (V) and current (I).
Calculate the zero sequence impedance (Z0) using the formula Z0 = 3V/I
Acceptance Criteria.
The zero sequence impedance should be within a 10% deviation from the
designed value.
Work instructions for safety
After completion of the circuit wiring, apply a lower voltage and gradually
increase the voltage up to the required value.
Switch off the circuit before disconnection.
Always follow general safety instruction of the area

3.11 Sound Level Test (Type Test).

Purpose
To determine the sound level of the transformer. Test should be performed as per IEC
60076 test standards.
Apparatus
Integrating sound level meter (NL-05)
Procedure
Transformer should be placed and mark points (at least 6 points) 0.3 meters away
from its boundary. Energize the transformer under rated condition. Measure the
noise level at the marked points holding the meter at the mid-point of the height
of the transformer.
Measure the noise level after shutdown the transformer on the same points, to get
the surrounding noise level.
Average value of difference of these two sets of readings give the noise level of
the transformer.
Expression of results
Noise level should be 52dB.
Work instructions for safety
Always stay away from the energized transformer.
For any reason, do not get closer or touch the transformer before switch it OFF.
Always follow general safety instruction of the area.
3.12 Temperature Rise Test (Type Test)
Purpose
To determine the temperature rise of the transformer. Test should be performed as per
IEC 60076 test standards.
Apparatus
AC Analyser
Manual of AC Analyser
Thermometer
Preparation of sample
Transformer should be isolated
Clean the bushings thoroughly with a clean piece of cloth
Make sure the oil level of the transformer is at the top level.
Make sure that the transformer tap selector is at rated tap position.
Procedure
Connect the A,B,C terminals to the respective test leads.
Insert a thermometer into the thermometer pocket.
Sum of the guaranteed of the transformer to be injected during the test. When the
steady state condition is achieved, the difference between the top oil temperature
and then room temperature is recorded at three consecutive readings. Reduce the
current to full load rated current and maintain it for another one hour. Again
record the top oil temperature and room temperature.
Maintain the lose figure by varying the current until steady temperature rise is
obtained. Record the thermometer for every thirty minutes. If constant
temperature appears at three consecutive readings, it will be considered as the
steady condition
Top oil temperature rise can be obtained from the difference between top oil
temperature reading and the room temperature.
Stop the supplying of the current and get the resistance values of both HV and LV
windings. This should be performed until at least six different readings at regular
intervals are recorded.
 Plot a graph using the above data and obtain the resistance value at the time of
switching off the current by extrapolating the graph. Using this value, temperature
rise of the winding can be calculated using the following formula.
2 = (235+1)xR2/R1 235
1= Room temperature 0C
R1 = Resistance at room temperature (Ohms)
Temperature rise = 2 Room temperature
R2 = Resistance at the time of switching off (Ohms)
Plot the graph for both HV and LV windings.

Acceptance Criteria
Top oil temperature rise should be less than 550 C
Winding temperature rise should be less that 600 C
Work instructions for safety
Make sure the meter body is connected to the earth, before switching ON the
meter.
Always short the secondary terminals of the current transformers before switching
off the voltage to the transformer.
Use hand gloves to remove the leads from heated terminals of the transformer.
Always follow general safety instruction of the area.
3.13 Measurement Of Electrical Break Through Voltage Of Copper Wire
Purpose
This test is carried out to assess the insulation of copper wire.
Apparatus
Voltage regulator (Variable between 0 440V)
Salt solution (Water +5% NaCl, weight to weight)
Plastic rod (for forming the copper thread according to the table below)
Safety
All safety procedures outlined in test method for dielectric voltage withstand test shall be
followed during this test
Procedure
Get a copper sampling with a length of at least 6m.
Wind the copper sample or the rod in spiral.
Prepare salt solution (water + salt in 1:5% weight ratio). Note: 1 g of water = 1ml
of water.
Place the prepared copper spiral in the salt solution with terminals at least 20mm
over the surface of the liquid.
Touch one set probe of voltage regulator to the salt solution and one end of
copper wire should be isolated and kept 20mm over the liquid level.
Start with 0V and then increase the voltage up to 440V and maintain it for 30secs
and check the break through voltage.
Acceptance Criteria
There should not be any flash over point throughout the selected length
Diameter of thread Diameter of rod
0.100mm 0.315mm 3.0mm
0.315mm 1.000mm 18.0mm
1.000mm 2.240mm 18.0mm
Work Instructions for safety
Connect the copper wire to the terminals and immerse in salt water prior to switch
ON.
Do not touch the test leads, sample or salt solution while switch ON.
 Always follow general safety instruction of the area.
3.14 Dry Power Frequency Voltage Withstand Test
Purpose
To identify any flashover or punch of the bushings
Apparatus
High voltage test set
Procedure
Clamp the bushing as its intended use and apply the power frequency voltage as in given
table
Acceptance Criteria
The bushing should be considered to have passed the test if no flashover or puncture
occurs. If there is a puncture, the bushing shall be considered to have failed the test. If a
flashover occurs the test shall be repeated once only. If during the repetition of the test no
flashover or puncture occurs the bushing shall be considered to have passed the test.
Nominal Voltage kV (rms) Dry lightning impulse Power frequency withstand
withstand voltage voltage dry & wet kV (rms)
1.2/50micro sec kV (peak)
3.6 40 10
7.2 60 20
12 75 28
17.5 95 38
24 125 50
36 170 70
Work instructions for safety
Never switch ON the HV tester when someone is inside the testing area.
Switch OFF the output voltage before change the HV connections.
Do not operate other electrical instruments while HV tester is switched ON.
Always follow general safety instruction of the area.

3.15 Transformer Pressure Testing

Purpose
To ensure that the finished transformer withstand high pressure and to detect any leak
points
Apparatus
Pressure testing device
Preparation of sample
Isolate the transformer
Clean all the surfaces of the transformer
Procedure
Pump No. 1 for pumping oil to the transformer under test.
Pump No. 2 for evacuating oil from the tested transformer
Fix the T-socket for transformers that have drain valve.
Connect the pressure socket to the pressure relief valve socket, for the
transformers not having drain valve.
Fully open the valve at pump No. 2
Fully close the valve at pump No. 1
Switch on the control panel
All sealed transformers (standard/special) 100 1000KVA (Having drain valve),
Transformers that are not having drain valve 100 1000 KVA pressure up to 0.27
bar. (Pressure at cover plate).
For the seal transformers above 1000 KVA pressure testing is done by pumping
the maximum temperature rise oil volume. (Design data output sheet for the oil
volume at maximum temperature rise)
For conservator type transformers, the conservator is isolated and pressure up to
0.20 bar. (Pressure at cover plate level).
Switch on pump 1 and pump the oil to the transformer.
Keep the tank at that pump for 12 Hours time. Check for any leaks.
Switch on pump No. 2 and open the respective valves.
Zero the meter readings. Retrieve the same oil from the tank.
Remove the T-socket after fixing the oil nut.
Check the pressurized transformer for leaks.
 To evacuate oil from pressurized transformer (tested), fully open the valve at
pump No. 1 and fully close the valve at pump No. 2
Get the reading of the flow meter. Then press the reset button for zero reading.
Switch on pump No. 2. Open the valve at pump No. 2 to control the flow and
evacuate oil from the transformer with reference to preceding flow meter reading.
Expression of results
The tested transformer should be free from leaks.
Work instructions for safety
Make sure all terminal ends, accessories, pressure relief valve, drain valve cover
plate bolts are tightened properly.
Fix the oil inlet hose and inject oil until the required internal pressure is reached.
Examine quickly whether there is any abnormal oil leakage and if so, remove the
injected oil as soon as possible.
Follow all the area safety rules
4.0 Post Shipping Inspection

It is important that inspection be made upon arrival of the transformer for any signs of
damage incurred during shipment. This inspection should be made after removal of the
transformer from the truck. The following items should be inspected closely for damage:
High voltage and low voltage bushings should be checked for cracks, chips, and
leaks.
All external accessories should be checked for breakage, loss, and leaks.
Tank and radiators should be inspected for leaks, dents, scratches, and other signs
of rough handling.
Paint should be inspected for damage.
Oil level gauge should be noted, along with the ambient temperature measurement
The factory shall be notified of any defects noted. External damage, or evidence of rough
handling, may be an indication of internal damage.
If any parts of the transformer have been removed for shipping, these will be noted on the
Bill of Lading as separate items. These items should be checked for shipping damage as
well.
Post shipping testing:
All transformers shall be subjected to routine tests according to IEC 60076, by REA
after delivery at REA Test Laboratory or any other approved testing facility
recommended by REA. Test certificates shall be issued before delivery to site.
Transformers that fail at this stage shall be rejected and the supplier shall replace them at
his cost.
 APPENDICES

Appendix A: Plant & Process Checklist

No Aspect of inspection /X Acceptance criteria Remarks
.
1 Check for Valid Certification
1. Quality Management Certificate ISO 9001:2008
2. Environmental Management ISO 14001:2004
Certificate
3. OHSAS Certificate OHSAS 18001:2007
2 Check Availability of Documentation Systems and processes
HSEQ Policies and Manuals should be documented
Process Manual
Quality Plans
Manufacturing Procedures
Inspection Instructions
Test Protocols
Test reports
Process Checklists
Type test certificates
Calibration Records
3 Check Availability for HSEQ Should have procedures in
Procedures place and updated
Procedure for Environmental documents on
Aspect Evaluation Environment,
(Environmental aspect register) occupational risk &
Hazard Identification (hazard hazard
register)
Risk Assessment (risk register)
4 Check for Availability of adequate
 structure of the production team
Adequacy of the structure of the
production facility Availability of adequate
Qualification of the staff structures and skills mix
5 Check availability of physical
infrastructure
Production space Sufficient space for
Storage space for raw materials production, raw materials
& finished products and finished products
6 Check availability of key production Availability of key
line equipment equipment
Crane
Fork lifts
Loading bay
Core cutting machines with step
lap technology
Oven
Testing lab
Vacuum chamber
Winding machines
7 Review Transformer Design Process
for compliance to specifications &
standards Design conformity to
Procedure for identification & Client specifications
review of customer
requirements
Design Action Plan
Design review checklist
Design report
8 Confirm the technical specifications of
the major inputs/ raw materials
Core Material
Core thickness (mm) 0.23 +-3%
Core Material Cold rolled grain
oriented silicon
steel

Core Type Three limb stacked

Core electrical resistivity (um) 0.48

Specific core loss at 50HZ for 0.69-1.11
1.5T
Specific core loss at 50HZ for 1.17-1.57
1.7T Coated with
Core sheet insulation inorganic layer

Windings Enameled Copper

Winding material wire or foil
180
Copper wire class 99.99%
Winding minimum copper
content 450V in salt
Minimum copper wire electrical solution
breakthrough withstand voltage
Winding maximum current 3.0 A/sqmm
density
Transformer Oil
Transformer Oil type Mineral oil
Transformer oil breakdown 70kV
voltage
 PCB None
Dielectric dissipation factor 0.001
900C
Water content 1.5mg/kg
Resistivity ohm at 200C 20
Insulation Boards
Insulation class A
Minimum dielectric strength in 60kV/mm
oil 50:50
Sulphate : Wood mixture for
diamond dotted paper (DDP) Yes
Resin on both side of DDP
Off-Load Tap Changer
Rated voltage 12kV or 36kV
Tap positions 5
Lockable in tap position Yes
selected 0,2.5,5
Tapping range (+-%)
Pressure Relief Valve 0.35
Operating pressure (bars)
Tank
Type Hermetically
sealed
Material Mild steel
Coating Hot dip galvanized
& powder coated
Coating thickness 100um (50
galvanized + 50
powder coating)
Lifting hooks Yes
 Tank comprises of: Base, tank, flange
& top cover
Top cover fitting Bolted, fitted with
gaskets
9 Ability to trace a transformer back up to
raw materials
Review transformer assembly Availability of fully
job card and drawings signed job cards

10 Core construction process

Check where core is securely Securely clamped
clamped

11 Primary & Secondary winding Process

Check availability of winding Availability of
instruction at place of work work instruction at
place of work
12 Drying Process
Check availability of Oven Presence of
which can accommodate biggest appropriate Oven
size of transformer
Minimum drying time of 24 Work method for drying
hours should take into
consideration:
24 hour drying
time
30 minutes lag
from drying to
tanking
13 Oil Filling process
Check weather oil filling is done Oil should be
in oven filled in oven
14 Tank Fabrication
Check conformity to minimum
dimensions 3mm for less than
Minimum Tank Thickness 400KVA & 6mm
for 400KVA &
above
3mm for less than
Minimum base thickness
400KVA & 6mm
for 400KVA &
above
Minimum Cover plate thickness
4 for less than
400KVA & 6 for
400KVA & above
Minimum Flange thickness
6mm
Minimum Radiator thickness
1.2mm for 1-
1000KVA, 1.5mm
for 1000KVA and
above
15 Testing Availability of test
Check availability of the following key equipment necessary to
test equipment carry out all the routine
High frequency voltage tests Presence of Test
generator Laboratory
Insulation resistance tester
Separate source voltage set
DC winding resistance meter
Transformer ratio & vector
 group meter
AC analyzer
Oil Dielectric strength tester
16 Product handling & Packing Ensure proper handling
Presence of proper handling
equipment forklifts, cranes,
etc.
Presence of appropriate &
sufficient storage space
Transformers to be securely
packaged in wooden palates
Palates to be labeled
 Appendix B: FAT Checklist

No. Aspect of inspection Acceptance criteria Equipment Remarks

Physical Inspection
1 Visual Checks for 100% Compliance Visual Checks
completeness of a
fully assembled unit.
Check for the
following key
components
Tank
Pressure relief
valve
Oil gauge
Bushing
Surge Arrestor
mounting
brackets
Rating plate
REA Name
plate
Earthing
terminal
Marked
terminals
Mounting
terminal on the
base
1 Check whether Hot dip zinc Galvanized, Elcometer
External surface powder coated, 100m (
coating of tank is Hot
dip zinc Galvanized
and powder coated
2 Confirm dimension Conformity to Approved
and construction drawing
3 Check:
(a) Outdoor a) 300mm for 11kV &
bushing 900mm for 33kV
Creepage
distance
(b) Phase to phase b) Min 294mm
clearance
(c) Phase to Earth
clearance c) Min 294mm
4 Check Oil level inside Should be above active part
tank when the Oil gauge is at
minimum.
5 Check Packing in line Packing done with wooden
with REA requirement palates and clearly marked
Routine Test
1 Insulation resistance 1000 M when 5000V is 5000V Insulation
measurement applied for 60 seconds for resistance meter
HV & E, HV & LV and
1000V applied for 60
seconds for LV&E
2 Separate source Test set should not trip AC Dielectric Test
voltage withstands. when 70kV is applied for 60 set
seconds for 33kV
transformer, 28kV for 11kV
 transformer, and 3kV for
LV windings.
3 Transformer ratio Transformer ratio with 5% Transformer turns
tolerance for the respective ratio meter
tap positions
4 Vector Group Test Vector group displayed Transformer Ratio
should Dyn11 Meter
5 Winding resistance at All phase resistance values DC Transformer
rated tap should be similar. winding resistance
meter
6 No load loss The deviation of no load AC analyzer
loss value should be
15% of specified value
No load current shall be
less than 5% of rated
7 Load Loss Deviation of full load AC analyzer
losses corrected to 750 C
shall be within 15% of
the specified value.
Total losses deviation
of the component losses
should be within 15%
while maintaining the
deviation of the total
losses within10% of the
specified value
8 Induced over voltage Should withstand double the High frequency test
at High frequency rated voltage at 120 HZ set
applied to LV windings for
50 seconds.
9 Testing the electrical Measure the electrical Oil dielectric
strength of transformer strength of Transformer oil strength test set
oil when a layer of oil is placed
between two electrodes,
which are placed at 2.5mm
apart. Average breakdown
voltage of the oil must be >
50kV.
10 Sound level test Noise level should be less Sound level meter
than specified
11 Zero sequence The zero sequence AC Analyzer
impedance impedance should be within And Voltmeter
a 10% deviation from the
designed value.
12 Dry lightning impulse No flashover or puncture HV test set
withstand voltage occurs to the bushing at
1.2/50micro sec kV 75kV for 11kV transformer,
(peak): 170kV for 33kV
Voltage withstand transformer and 6kV for LV

13 Power frequency No flashover or puncture HV test set

withstand voltage dry occurs to the bushing at
& wet kV (rms): 28kV for 11kV transformer,
70kV for 33kV transformer
and 3kV for LV.

14 Pressure testing Transformer should be free Pressure testing

from leaks device