TECHNICAL SPECIFICATION OF 500KVA UNIT AUXILIARY TRANSFORMERS

1.0 SCOPE OF WORK

1.1 This section of the specification covers the provision of all labour, plant &
material and performance of all works necessary for design, manufacture,
shop assembly & testing, delivery, erection, testing & commissioning, handing
over to HPSEBL & guarantee for two years of three (3) 500 KVA, 11/0.415
kV, 3 phase unit auxiliary transformers complete with all accessories and
fittings and for warranting a trouble free safe operation.

1.2 DETAIL SCOPE OF SUPPLY

The UAT's shall consists of:

- Three (3) unit auxiliary transformers 500 KVA, 11/0.415 kV, 3 phase,
ANAN cooled, dry type cast resin, vector group Dyn11, suitable for
indoor installation, complete with cubicle and all necessary
accessories.

- Set of spares.

- All special devices, tools, maintenance equipment etc., required for

installation, testing, commissioning and maintenance of the
transformers.

1.3 It is not the intent to specify completely all details of design and construction
of the equipment. However, the equipment shall conform, in all respect, to
high standard of design, engineering and workmanship and be capable of
performing in continuous commercial operations up to the contractor's
guarantee in a manner acceptable to engineer in-charge who will interpret the
meaning of drawings and specifications.

2.0 STANDARDS

2.1 Except where specified otherwise herein, all material, equipment and
construction shall conform to Indian Electricity Act and Rules and Indian
standards specified in clause no. 2.4 of this specification.

2.2 Equipment and accessories conforming to British Standards or International

Electro- technical Commission (IEC) Publication, ANSI standards, NEMA
standards, IEEE standards etc. which ensure equipment quality, shall also be
acceptable, but in such cases the supplier shall clearly indicate the standards
adopted.

2.3 Since the specification under the scope of work includes basic constructional
details etc. the bidders are not expected to take any deviations from this.
However, due to manufacturing limitations if some minor and non-critical
deviations are sought by the bidders then such deviations shall be clearly
explained in a separate sheet for the consideration of the owner.
2.4 LIST OF STANDARDS

i) IS-11171-1985 Dry type transformers.

ii) IS-2026 (Part-I)-1977 Power Transformer (General)

iii) IS-2026 (Part-II)-1977 Temperature Rise.

iv) IS-2026 ( Part-III)-1977 Insulation level and dielectric tests.

v) IS-2026 (Part-IV)-1977 Terminal marking, tapping and

connections.

vi) IS-2099 - 1986 Porcelain transformer bushing.

vii) IS-2147 - 1962 Degree of protection provided by

enclosures.

3.0 ELECTRICAL CHARACTERSTICS AND PERFORMANCE

3.1 S.No. Type and Rating 11kV System 415 V System

i) Nominal voltage 11 kV 415 V

ii) Highest system voltage 12 kV 457 V

iii) No. of phases Three (3) Three (3)

iv) Frequency 50 Hz 50 Hz

v) Voltage variation + 10% +10%

vi) Frequency variation + 3% +3%

vii) Combined voltage and +10% +10%

frequency variation .

viii) Neutral earthing Effectively Solidly

earthed earthed.

ix) Cooling ANAN

x) Type Enclosed dry type, Indoor

xi) Winding connections Delta Star

xii) Continuous kVA rating 500kVA 500 kVA

(at all tappings)

xiii) Vector group Dyn11

xiv) Power frequency 28 kV 3 kV

withstand voltage.
 xv) Lightening impulse 75 kV --
withstand voltage.

xvi) Neutral terminal of LV. To be brought out to solidly

grounded system through neutral C.T.

xvii) Tap changer

a) Type Off circuit.

b) Steps Five (5)

c) Range +2x2.5% (5 positions)

d) Location On H.V. windings.

xviii) Insulation Class Class ''F''

xix) Temperature Rise Limits:-

Maximum permissible
temperature rise limits over
maximum ambient air
temperature of 500 C.

a) Winding (temperature < 900 C.

rise measured by
resistance method)

b) Core, metallic parts and Temperature shall in no

adjacent materials. case reach a value that will
damage the core itself, other
parts or adjacent materials.

xx) Insulation Grading H.V. and L.V. winding shall

be fully insulated (uniform)

xxi) Terminal Connections

H.V. side The HV terminal shall be

directly connected to 11 kV
segregated phase bus duct.

L.V. side The L.V. terminals shall be

connected to 31/2 cores 1.1kV
PVC cable.

3.2 WINDING CONNECTIONS AND VECTORS

The primary winding (H.V side) of this transformer shall be delta connected
and secondary winding (L.V. side) star connected (vector symbol Dyn11) so as
to produce a positive phase displacement of + 300 from the primary to
secondary vector of the same phase. The neutral of the secondary winding
shall be brought to a separate insulated terminal.
3.3 The transformers shall be dry type, cast resin insulated, naturally air cooled
inside and outsides the enclosure (''ANAN type'') with a protective enclosure,
three phase, 50 Hz, double wound, indoor type suitable for use on voltage of
11kV. The transformers shall be provided with all fittings and accessories as
mentioned in clause 7.11 and in accordance with provision of Indian standard
2026 Part (I). This shal be fitted with necessary transformer rails and wheel
blocking devices.

3.4 FREQUENCY

The transformers shall be suitable for continuous operation at rated output

and permissible overload with a frequency variation of + 3% from normal
50Hz without injurious heating of the transformers.

3.5 IMPEDANCE

The percentage impedance at 750C shall be 4% subject to the tolerance as

per IS-2026 Part-I.

3.6 DUTY UNDER FAULT CONDITIONS

All the unit auxiliary transformers shall be capable of withstanding any

external short circuit without damage according to clause no. 8.1.1.4 of IS
-2026 Part-I. All the transformers under exceptional circumstances due to
sudden disconnection of load, should be capable of operating at a voltage
approximately 25% above the normal rated voltage for a period not exceeding
one minute and 40% above normal for a period of 5 seconds.

3.7 OVER FLUXING

The transformers shall be suitable for over fluxing up to 10% on any tapping
without injurious heating at full load conditions. The maximum flux density in
any part of the core under such conditions shall not exceed 1.9 Tesla.

3.8 VIBRATION AND NOISE

Special care shall be taken in the design and manufacture of transformer

cores to ensure highest degree of silence in operation. The average sound
level of the transformer in decibel should not exceed the values specified for
the respective transformers in NEMA standard publication TR-I.

3.9 SUPPRESSION OF HARMONICS

The transformers shall be designed with particular attention to the

suppression of harmonic voltage so as to eliminate wave form distortion and
any possibility of high frequency disturbances, inductive effects of the
circulating currents between neutral points of the different transformers
reaching such a magnitude so as to cause interference with the
communication circuits.

3.10 INSULATION

The transformers shall be adequately insulated and suitably designed to

permit continuous operation at highest system voltage. The insulation level of
the high voltage winding, high voltage-bushing etc. of the unit auxiliary
 transformers shall correspond to that of generator terminal equipment. The
dielectric strength of the winding insulation shall conform to the values as per
latest issue of IS-2026 Part-III.

3.11 TEMPERATURE RISE

The limits of permissible temperature rise for winding, core and other parts
shall be in accordance with the clause 3 of IS-2026 Part(II) for class F
temperature class of insulation.

3.12 The transformers shall be free from partial discharge upto 150% of the rated
voltage.

3.13 INTERCHANGEABILITY

The transformers, its parts and accessories shall be interchangeable with

each other.

3.14 All materials used in the manufacturing of the transformer shall be of best
quality of their respective kind obtainable in the market and shall conform to
relevant Indian standards or IEC standards. Workmanship shall be of highest
class and in accordance with latest practice.

4.0 CORE

4.1 The core shall consists of interleaved/ mitred joints, high grade, non ageing,
low loss, high permeability, cold rolled grain oriented silicon steel laminations
with double sided insulation specially suitable for transformer cores.

4.2 The design of the magnetic circuit shall be such as to avoid static discharges,
development of short circuit path within itself or to the earthed clamping
structure and the production of flux components at right angle to the plane of
laminations which may cause the local heating.

4.3 Every care shall be exercised in the selection of treatment and handling of
core steel to ensure that the laminations are flat and the finally assembled
core is free from distortion.

4.4 After being sheared, the laminations shall be treated to remove all burrs and
shall be re-annealed to remove all residual stresses. These shall be coated
with durable inorganic adhesive insulating material to minimise the excitation
losses. Particulars of proposed insulation shall be stated in the bid.

4.5 The core shall be rigidly clamped and bolted to ensure adequate mechanical
strength and to prevent vibration/noise during transportation and operation.
The bolts used in the assembly of core shall be suitably insulated and
clamping structure shall be so designed that eddy current flow is minimum.

4.6 All the parts of the core shall be of robust design capable of withstanding any
shock to which they are subjected during lifting, transportation, installation
and service.
4.7 Adequate lifting lugs shall be provided to enable the core and coil assembly to
be lifted and shall have the provision for jacking and rolling.
4.8 Adequate provision shall be made to prevent the movement of the core and
winding relative to the enclosure during the transport and installation or while
in service.

4.9 The core shall be electrically earthed by means of copper strips.

4.10 The core of transformers shall be applied with heat resistant resin coating not
less than 1mm thick for protection against corrosion.

4.11 All iron parts of the transformers except the core shall be hot dip galvanised.
The zinc coating shall not be less than 610 grams of zinc per square meter of
surface.

5.0 WINDINGS

5.1 The high and low voltage windings shall be of copper conductors and both
completely impregnated and cast under vacuum into moulds. The insulation
system shall be of uniform glass-fibre-epoxy laminate of highest electrical and
mechanical quality into which the windings are voidless embedded. Both the
H.V. and L.V. winding of one phase shall be separately cast as one rigid
tubular coil with no rigid key between their co-axial arrangement i.e. no
creepage path can be formed even under dusty and corroding ambient
conditions. The insulation laminate shall correspond to class F as per IS-2026
Part-II. Precautions shall be taken that the thermal stresses do not prove
detrimental to the insulation of winding. The crack resistance of resin shall be
such so as to guard against not only abrupt load variations but also
temperature changes i.e. moulded coils shall be of high crack resistance.

5.2 The insulation of the transformer windings and connections shall be free from
insulating composition liable to soften, ooze out, shrink or collapse. The
insulation used shall be glass fibre reinforced epoxy resin.

5.3 The winding shall be designed to reduce to a minimum out of balance forces
in the transformer at all voltage ratios.

5.4 The winding and connections of all transformers shall be braced to withstand
shocks, which may occur during transportation or due to short circuit,
switching and other transient condition during service.

5.5 High voltage/ Low voltage terminals shall be secured with support porcelain.
To overcome the under cooling problem in support system of cast resin spool,
it shall be provided with elastic support system.

5.6 All threaded connections shall be provided with locking facilities. All bolts and
bushing shall be rigidly supported to prevent the injury from vibrations. Guide
tube shall be used wherever practicable.

5.7 The transformer winding shall be protected against thermal overload by

winding temperature indicator (Scanner type) wherein PT-100 sensors are
embedded in each LV coils, core etc. Scanner shall have two sets of
contacts-one for alarm and one for trip. It shall also have the provision to
control/monitor the temperature through microprocessor based control
system. For this the transformer manufacturer should co-ordinate with
Generator and Computer based control system suppliers.
.5.8 The winding shall not absorb any moisture and shall be suitable for tropical
climate and 100% air humidity. Coils shall be non-inflammable and self-
extinguishing.

6.0 BUSHINGS

The bushings used on the transformers shall be epoxy cast resin-insulating

bushings and shall comply with latest edition of IS-2099 clause 2.10 or its
equivalent international standards.

7.0 TAPPINGS

7.1 Tappings will be provided for voltage adjustment on the HV winding, with
adjustment of high voltage of +5% to -5% in steps of 2.5%.

7.2 Tap changing shall be possible with the transformer off circuit by means of
externally operated switch capable of being locked in position.

7.3 Tap changing terminals shall be fitted with insulating caps to prevent bare live
parts from being exposed.

8.0 PARALLEL OPERATION

All the unit auxiliary transformers shall be capable to operate satisfactorily in

parallel with each other and shall be interchangeable.

9.0 UNITS OF LOSSES

The losses should not exceed the limits specified hereunder: -

No load losses: 1100 Watts.

Full load losses at 6500 Watts

rated voltage

These losses corresponds to the reference temperature of 75 0C and

subjected to the tolerance as per IS-2026 Part-I.

10.0 GUARANTEE AND PENALTIES

The no load loss in kW at rated voltage and rated frequency and load loss at
rated output, rated frequency and rated voltage shall be guaranteed under
penalty for each transformer. The penalties shall be evaluated from the
excess of difference between the test values of load loss/no load loss and the
guaranteed values of load loss/no load loss.

No tolerance shall be permitted, over the test figures of the losses. The
penalties shall be calculated at the following rates.

Iron losses (No load loss) US $ 3800/kW

(or its equivalent bid currency)
Copper losses (Load loss) US $ 3200/kW
(or its equivalent bid currency)

For fraction of a kW, the penalties shall be applied on pro-rata basis.

 For the purpose of comparison of bidders, the quoted prices shall be
enhanced by capitalisation of transformer losses at the same rates as given
for penalty on the basis of guaranteed loss figures. If the test figures are less
than the guaranteed values, no bonus shall be paid.

The owner reserves the right to reject the transformer, if during tests at works,
the total no load loss or total load loss exceeds the guaranteed values by
more than 15% individually or the total (no load plus load) losses exceeds by
more than 10%.

11.0 FITTINGS AND ACCESSORIES

11.1 The following standard fitting shall be provided on the transformers in

accordance with IS-2026 Part-I clause 14, unless otherwise modified.

i) Rating and diagram plate.

ii) Terminal marking plate.

iii) Eye bolts & lugs in all parts for ease of handling.

iv) Earthing terminal for frame- 2 nos.

v) Cable boxes for L.V. terminals. The details of terminals and

cable boxes to be specified clearly.

vi) Inspection covers.

vii) Temperature sensing devices (scanner type) and necessary

transducers for display of temperature and logging by microprocessor
based control system.

viii) Bi-directional rollers.

ix) A set of device for fitting the various parts of transformer and also the
complete transformer.

11.2 LOCATION OF FITTINGS

These shall be as per clause 19.1 of IS-1180 revised upto date.

12.0 NEUTRAL CURRENT TRANSFORMER

Neutral earthing shall be done through neutral CT's. The neutral CT shall be
provided inside the enclosure. The arrangement shall be such that, the CT
can be replaced easily. The secondary leads of the CT's shall be wired upto
the terminal block in the marshalling box.

The technical parameters of CT's are as under:

Rated voltage 415V

Current ratio 750/5

 Accuracy class PS

13.0 RATINGS AND TERMINALS MARKING PLATE

Each transformer shall be provided with rating plate as per clause 15 of IS-
2026 Part-I of weather proof material fitted in visible position showing the
appropriate item as given below: -

a) Type of transformer.

b) Number and year of specification.

c) Manufacturer's name.

d) Year of manufacture.

e) Manufacturer's serial number.

f) Number of phases.

g) Rated Power.

h) Rated frequency.

i) Rated voltage.

j) Rated current.

k) Impedance voltage.

l) Type of cooling.

m) Connection diagram.

n) Insulation level

o) Total weight.

p) Temperature class of insulation.

q) Standard adopted.

14.0 ENCLOSURE

14.1 The unit auxiliary transformers shall be provided with enclosure of IP-21
protection class as per IS-2147 for indoor installation and shall be fabricated
from electro-zinc coated mild steel of minimum 2.5mm thick. Double leaf
access door shall be provided with concealed hinge and neoprene gaskets for
easy access to H.V. links and also for withdrawal of core and coil assembly if
required. The enclosure door shall have provision of padlocking in closed
position.
14.2 SAFETY INTERLOCK

A safety interlock shall be provided to ensure that the enclosure door can be
opened only when the transformer is de-energised.

15.0 TRANSFORMER CHASIS

15.1 Each transformer shall be mounted on hot dip galvanised chassis with bi-
directional rollers.

15.2 Pulling/lifting eyes shall be provided on the chassis to facilitate moving/lifting

of the transformer.

16.0 TEST AND TEST CERTIFICATES

16.1 The transformer shall be subjected to all the routine tests at manufacturer's
works in presence of purchaser's authorised representative as per IS-11171
(revised up to date).

16.2 ROUTINE TESTS

The following shall constitute routine tests:

a) Measurement of winding resistance.

b) Measurement of voltage ratio and checking of voltage vector

relationship.

c) Measurements of impedance voltage (Principal tapping) short circuit

impedance and load loss.

d) Measurement of no load loss and current.

e) Separate source voltage withstands test.

f) Induced over voltage withstands test.

16.3 TYPE TESTS

In addition to the routine tests the following tests shall also be performed in
any one of the transformer as type test.

a) Lightning Impulse test.

b) Temperature rises test.

16.4 SPECIAL TESTS

The following tests shall be performed in any one of the transformers as

special test.

a) Partial discharge measurement.

b) Measurement of acoustic sound level.

 c) Short circuit test.

16.5 FIELD TESTS

The contractor shall furnish a complete outline of the proposed methods and
procedures to be followed for unit auxiliary transformer testing. The
equipment and instruments to be used, shall be included in the above and list
shall be submitted to owner for review at least 60 days before schedule
testing. After installation, transformers shall be field tested for functional tests
of all control & protection equipment, megger value test of insulation as per
relevant standard. The bidder shall prepare and hand over to the engineer,
details of all test results in a report in mutually agreed format.

16.6 The owner reserves the right of having other reasonable tests carried out at
his either before dispatch or at site to ensure that the transformer complies
with the requirement of this specification.

17.0 INSTALLATION AND COMMISSIONING

The contractor shall furnish all labour, tools, supplies, shims and supports and
all other items or materials necessary to assemble, erect and install the
equipment in a through workman like manner following the best modern
practice. The equipment and all its components shall be placed with great
care and accuracy and shall be aligned correctly to provide an installation
consistent with the close tolerances used in the manufacture of modern
equipment. The contractor shall establish the proper elevation and centre
lines, to which equipment is to be set.

18.0 SPARE PARTS

18.1 The following spare parts shall be supplied by the contractor. The price of
spare parts shall be stated separately in the bid form.

1) H.V. Bushing 1 No.

2) L.V. Bushing 1 No.

3) Set of HV and LV windings and

insulation for one limb in steel
container. 1 No.

4) Winding temperature relay

with contacts for alarm &
tripping. 1 No.

In addition, the contractor shall submit a list of recommended spare parts for
successful operation of the transformer along with its price for the
consideration of owner.