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RAIL WHEEL FACTORY

TECHNICAL SPECIFICATION FOR

66/11 KV 15 MVA TRANSFORMER
WITH ON LOAD TAP CHANGER
FOR
MAIN RECEIVING STATION

Vide Indent No. 2011EHJC0201 dated:06.07.2011

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Index
Sl.No. Description Page No.
1 Scope of supply 3
2 Rating and General data 4&5
3 Design and constructional features 6
4 Temperature rise 6
5 Efficiency 6
6 Permitted losses 7
7 Details of Tank and Tank cover 7&8
8 Details of Core 8&9
9 Details of windings 9 & 10
10 Terminal arrangements 11 & 12
11 Cooling arrangements 12
12 Details of On load tap changer 13 to 15
13 Accessories 15 to 17
14 Rating & Diagram plate 17
15 Suppression of harmonics 18
16 Insulation co-ordination 18
17 Protection 18
18 Bushing type current transformers 18 & 19
19 Clearances 19
20 Painting 19
21 Test 20 & 21
22 Drawings 22
23 Accepted Makes 23
24 Warranty period 23
25 Special conditions 23
26 Payment terms 24
27 List of related specifications 25 & 26
28 Schedule of guaranteed performance & 27 to 30
technical particulars
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1. SCOPE OF WORK IN THE SCOPE OF SUPPLIER INCLUDES THE FOLLOWING :

 Design, Supply, Installation, Testing and Commissioning of 15 MVA, 66/11KV, 3

Phase, 50Hz, Power Transformer with ON load TAP CHANGER at Main Receiving
station – Rail Wheel Factory - Yelahanka, Bangalore.The bidder should be original
equipment manufacturer (OEM).

 All parts, accessories & fittings necessary for efficient operation. All such parts,
fittings & accessories shall be deemed to be with in the scope of this specification
whether mentioned or not specifically mentioned herein.

 Supply of Necessary Current transformers on HT side, LT side and on Neutral for

the purpose of protection and metering. (Protection covers over load, earth fault,
Differential, Neutral displacement).

 Erection of the newly supplied transformer (15MVA) in the place of the existing 10
MVA transformer, duly removing the power supply cable XLPE cable of 3 X 400
Sqmm in size from the LT side, HT jumpers from the Over Head Line on HT side, &
control cables and connecting the same after installation of the new transformer.

 Unloading of the supplied 15MVA transformer in RWF MRS Yard at the place of
existing transformer.

 Moving the released transformer (10MVA) to the location assigned by RWF with in
the premises of RWF is in the scope of supplier.

 The offer shall include charges for Type & Routine test if any which is part of
specification.

 The insulating oil for transformer shall, generally conform to IS: 335 (latest
edition). Sufficient quantity of oil for the first filling of complete transformer
(with accessories) plus 10% extra oil shall be supplied by the vendor in non-
returnable 210 litre capacity drums.

 Make of the OLTC shall be of OLG / EASUN MR / CTR only. Suitable for Outdoor
application.

 Commissioning shall mean the integral activity covered under Preliminary operation
Initial operation trial operation & carrying out Performance tests.
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2. The rating and general data of the transformer shall be as follows:

ONAN cooled, Three phase, 66/11KV Step

down Power Transformer, Double Limb wound,
01 Type of transformer.
Core type for OUT DOOR application.
Mounted on Rails with wheels.
02 No. of Phase THREE Phase
HV: Interleaved type / Disc type with static
end rings at both ends with uniformly
03 Type of windings insulated
LV: Continuous disc type / layer type wirh
uniformly insulated.
04 Winding connection for 3 phase HV winding – Delta, LV winding – Star.

05 Vector Grouping D-Y n 11 (as per IS: 2026 part-IV)

06 Type of insulation Uniformly insulated as per IS: 2026 Part III

07 Winding Material Electrolytic grade copper

08 Winding Insulation Class-A
09 System frequency 50Hz ± 3%
10 Rated CAPACITY in KVA 15000
11 Rated Primary Voltage in KV 66
Rated Secondary Voltage in KV
12 11
at No Load
Rated Primary Current at the
13 131.21 Amps. (Maximum)
principle tapping
Rated Secondary Current at the
14 787.79 Amps. (Minimum)
principle Tapping.
Maximum value of percentage
Impedance at the (Normal
15 11.76%
working) principle tap position at
15MVA
Non-cumulative over load
capacity after the transformer 110% for continuous,
16 has reached steady temperature 125% for 15 minute,
on continuous operation at rated 140% for 5 min
load ie. At rated power)
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A separate tapped winding on the primary

winding to give rated secondary voltage for
variation in primary voltage from 5% on
maximum & -30% 0n minimum in 20 steps, 21
position in steps of 1.155 KV each. OLTC shall
be of minimum 72 KV Voltage class and shall
17 Tapings (On load Tap Changer) have maximum rated through current not less
than 300 Amps at normal tap, short circuit
withstand current not less than 8kA for 3
Seconds.
And shall be of High Speed Resistor type,
housed in a separate tank outside the main
tank.
Maximum No load losses (KW) at
18 Shall not exceed 17.5 KW
100% rated voltage.
Maximum copper losses at
19 Shall not exceed 95 KW
75degree C at rated Voltage.
20 Total losses (KW) Shall not exceed 95 KW
21 Insulating medium Transformer oil as per IS: 12463
LV – Solidly earthed, HV- Non effectively
22 System neutral earthling
earthed
Insulation level for windings:

a) Impulse 1.2/50 Micro second

HV – 350 KV (peak) LV – 90 KV (peak)
wave impulse withstand voltage
23
(KVP)

b) Power frequency withstand

HV – 140 KV (rms) LV – 30 KV (rms)
voltage(KV rms)
24 Max Temp Rise of Oil 45 deg C over the ambient
25 Max Temp Rise of Winding 55 deg C Over the ambient
26 Terminal Arrangement HV –Bare Bushing, LV- Cable Box
Efficiency at 75 deg. C at unity
27 Not less than 99%at all loads.
power factor
Protection: The following protection shall be provided as per IS 2026 Part III –
1977 Buchholz alarm and trip. Thermal alarm and trip for oil and winding with
28
Digital Display temperature indicator for winding and oil. Pressure relief valve,
explosion vent & Breather.
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3. Design and constructional features:

Overall dimensions:
The overall dimensions of the transformer shall be kept as low as possible and in any
case the transformer with all parts / fittings shall not occupy more space than described
below:
1. Length x Width (in mm) – 5800x5500
2. Height of the top most point of primary bushing terminal – 4000mm
3. Center line of transformer shall be marked on top plate

It shall be possible to transport the transformer in semi knocked down condition to

RWF/Bangalore by rail / road.

Note: Rail Wheel Factory is located close to YELAHANKA Railway Station,

Bangalore, which is 1 KM away.

4. TEMPERATURE RISE:

The temperature rise shall not exceed the following values above the ambient
temperature indicated while the transformer is delivering the full rated KVA. The
ambient temperature for air is 40˚ C. The maximum output the transformer can deliver
may also be indicated by the tenderer.

(i) Winding:
The temperature rise of the windings for ON transformers as measured by the
resistance method, over an ambient air temperature of 40˚ C shall not be more
than 55˚ C.
(ii) Oil:
The temperature rise as measured by the thermometer in top oil shall not exceed
45˚ C above an ambient of 40˚ C.

5. EFFICIENCY:

a) The transformer shall be so designed that the maximum efficiency occurs at about
80% full load and the efficiency load characteristic shall be as flat as possible
between 80% and 100% rated capacity. The efficiency figures shall be subjected
to tolerance as per IS.
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6. LOSSES:

The losses of the power frequency shall not be more than the following figures specified
by Central Board of Irrigation and Power, New Delhi.

VOLTAGE CAPACITY NO LOAD LOSSES LOAD LOSSES

66KV/11KV 15 MVA 17.5 KW 95 KW

The above losses are maximum, without any positive tolerance.

7 (i). TANK AND TANK COVER:

a) The tank shall be constructed of welded boiler plates, suitably reinforced and
made of one or more pieces as necessary. All joints shall be hot oil tight and no
nulging shall occur either in service or during transport. The tank assemblies shall
be sufficiently rigid to withstand full vacuum against standard atmospheric
pressure. External lugs for lifting the entire transformer, tank cover and the coil
and core separately shall be provided. Jacking pads for jacking up the
transformer while changing the position of bi-directional wheels and hauling holes
in the under frame for haulage of the transformer shall also be provided.

b) Internal design of the transformer shall ensure that air is not trapped in any
location.

c) Materials in contact with oil shall be such as not to contribute to the formation of
acid in oil. Surface in oil shall not be galvanised or cadmium plated.

d) The tank cover shall be bolted on the flanged rim of the tank with waterproof hot
oil tightness. Surface where gaskets fit shall be machined. If the gasket is
compressible, metallic stops shall be provided in the cover to facilitate unseating
of the cover of the tank with the minimum damage to the gasket. Pockets and
sharp corners where gas may collect without passing through to the Buchholz
relay shall be avoided.

e) Access and inspection holes blanked off with oil tight gasket sealed cover plates
shall be provided for working on the connections of the leads of windings, the
bottom terminals of bushings and other parts. Bushings turrets, covers of access
holes, covers for pockets of thermometers and other devices shall be so designed
as to prevent any leakage of rain water into the tank and the tank covers as a
whole shall shed off all rain water.
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f) Each tank and its conservator shall after fabrication be fitted with the
respective valves and pressure tested with transformer oil for a minimum
duration of 24 hours to withstand a pressure equal to twice the stationary head
of oil upto the surface level plus atmospheric pressure of 5.00 lbs. Per sq.in. No
valve shall drip and no weld shall sweat. The interior of the tanks and other oil
filled chambers shall be cleaned thoroughly of all scales and painted with oil
resisting enamel or varnish.

7 (ii) AXLES & WHEELS:

(a) The transformer shall be provided with flanged bi-directional wheels & axle.
These shall be designed not to deflect excessively to interfere with the
movement of the transformer.

(b) The wheels are required to swivel and they shall be arranged so that they can be
turned through 90 Deg, when the tank is jacked upto clear of rail, Means shall,
also, be provided for locking the swivel movements in positions parallel & right
angle to the longitudinal axis of tank. The anti earth quake clamps should be
provided for protection against earth quake.

(c) The rail track gauge shall be 1436mm along longer axis as well as shorter axis.

8. CORE:

a) The core shall be built up of the highest-grade non-ageing, prime grade CRGO
laminations properly insulated to prevent eddy currents. The insulating materials
shall not disintegrate due to core vibration, and due to presence of moisture in a
humid and saline atmosphere. Paper insulation density (at rated voltage) in the
core shall preferably be limited to such a value on the magnetization curve that
the existing volt amperes required for 110 percent of the maximum induction
density shall preferably not exceed about 200 percent of the volt amperes
required for the maximum working induction density at full voltage.

b) The core laminations forming the yoke shall be inter-leaved with those of the
limbs in the core type of transformer.
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c) The assembled core shall be secured by clamps on the limbs and the yoke to
prevent any undue noise or vibration and against mechanical displacement. If
clamping bolts are arranged in two columns on a limb of the core due to its large
width, necessary measures shall be adopted to the occurrences of a short circuit
path for the eddy currents, which may result from failure of insulation of any one
of the bolts in each of the two columns. All clamping structure shall have
adequate mechanical strength to withstand all mechanical stresses that are likely
to arise during short circuits, lifting operations, transport, etc., and no element in
the clamping structure shall have any permanent deformation. The top core
clamping frame shall be provided with lifting eyes for the purpose of tanking and
untanking, of the entire core and coil assembly. The core shall be connected to
the tank by a metal strip to drain off electrostatic potentials.

Necessary cooling ducts for the efficient cooling of the core and to ensure free
circulation of the oil shall be provided. The maximum hot spot temperature in the
core shall be non-injurious to the insulation and materials of the core clamping
frame work. The supporting frame work of the core shall be so designed as to
avoid the presence of pockets which would prevent complete emptying of the tank
through the drain valve. Each of the core bolts and parts of the core clamping
frame work which are likely to form a closed circulation path shall be insulated
from the core laminations and tested after completion of the core assembly to
withstand a D.C pressure of 2500 volts for a duration of one minutes.

d) The core shall not be earthed at multiple locations. Terminal shall be brought on
top of tank and earthed through link. Core and Frame terminals should be brought
out on transformer top so as to enable megger.

9. WINDINGS:

a) Each of the coils shall be wound of Kraft paper insulated ( class - A insulation)
continuous and smooth, tinned or enameled conductor made of electrolytic copper
of more than 99.9% purity. Similar coils of a winding shall be connected by
accessible joints, which shall be brazed or welded. There shall be no sharp bends
in the connections or leads and no corona discharge shall result on the windings
during all specified factory insulation tests. Class ‘A’ insulation shall be used
throughout. Paper insulation shall be new and free from punctures. Wood
insulation shall be treated and seasoned.
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b) The arrangements of windings on the core shall be such that there is electrical
and magnetic balance under all conditions of operation to ensure free circulation
of oil and absence of hot spots. The high-tension windings shall be separated from
the low voltage windings by suitable insulating barriers so placed as to form
vertical oil ducts. The highest-grade sheet pressboard shall be used for -
the barriers and collars. One-piece pressboard flanged collars with the cylinders
shall form insulating spools on the coils wound. The high and low-tension windings
on each leg shall be so assembled as to admit their being placed on or removed
from the core leg as complete units. Robust supports, wedges and spacers of hard
insulation shall be so fitted that they will neither move nor permit relative
movement of any par of windings during normal service, or during terminal short
circuit, nor mechanically injure the paper insulation.

All leads and connections shall be mechanically strong, heavily insulated,

protected and rigidly clamped so that they withstand all short circuit stresses.
The arrangement of the connections shall be such that the high voltage and low
voltage connections do not cross one another. The winding connection for the HV
side shall be “Delta” and for the LV side “Star”.

c) The winding assembly shall be dried in vacuum thoroughly shrunk to final

dimensions & impregnated under vacuum with tested insulating oil. The insulation
resistance measured immediately after impregnation and the temperature at
which it is measured shall be reported for the purchaser ‘s record. Easily
accessible pressure adjusting devices shall be provided to compensate for any
further shrinkage in service.

d) The insulation levels of the winding shall satisfy the withstand tests specified in
the following table. The impulse tests shall be conducted in accordance with the
A.E.E.E./IS/BS Standards, negative waves being used for the test.

e) The material used in the insulation and assembly winding shall be insoluble, non-
crystallite and chemically inactive in the hot transformer oil and shall not softer
or otherwise be affected under the operating conditions.

f) The completely assembled transformer shall be dispatched to site after

necessary test in the manufacturer’s works. If required to limit the weight, the
tank shall be filled with an inert gas like Nitrogen and a pressure gauge to be
provided on each of the tanks. Necessary lifting lugs for the entire tank shall be
provided.
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10. TERMINAL ARRANGEMENTS:

a) The transformer shall be capable being moved on its own wheels from its
permanent plinth to the repair bay on bi-directional wheels for any maintenance
and repair works. The connections from the 66 KV, bushing shall be bare ACSR
conductors. The terminal connections on the 11KV side shall consist of
disconnecting chambers and cable box with gland suitable for cross linked PVC
Aluminium cables of 400 Sq. mm 3 runs. By disconnecting the 66 KV jumpers and
11 KV disconnecting chambers, it should be possible for the transformer to be
moved out for repairs. The location of the 66 KV and LV terminals and the
location of the ON load tap changer, marshalling kiosk, etc., shall be so arranged
that the supporting structures, connections, etc. shall not interfere with one
another. The terminal positions shall also be such that the bare tubular
connections will have the required minimum clearances to component parts of the
transformer itself such as oil conservator, piping, etc. The details of the
terminals on various voltage ratings are indicated below:

(i) 66 KV terminals of the transformer shall be of the oil filled condenser

type.
(ii) L.V terminals and its neutral bushings shall be solid porcelain type.

b) The bushing terminal fittings shall not only carry the full rated current of the
transformer corresponding to the rated output but shall also carry 105% more
than the rated output without the temperature rise of any part exceeding 25˚C
over an ambient of 40˚C. The bushing shall be made of two one piece wet process
brown glazed porcelain having high mechanical strength, stable insulation and high
puncture value to ensure an external flashover before a break-down occurs due to
high voltage. They shall be assembled together by clamping flanges. They shall
operate satisfactorily in heavy rain or in an atmosphere laden with sand or dust.
They shall be free from corona and shall not cause radio interference. All
porcelain surfaces in contact with gaskets shall be ground and machined to ensure
oil tightness.

c) The bushings on the 66 KV side be rated for 72.5 KV and shall be of the oil filled
condenser type completely sealed from external atmosphere. The following
fittings shall be provided.

(i) A non-breathing oil expansion chamber made of toughened amber glass to

filter all light rays which may cause the oil to sludge. A magnetic type of
gauge shall be provided to indicate the oil level.
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(ii) Metallic ground shield.

(iii) Removable oil filling and oil drain plugs.
(iv) Adjustable spark gap made of 0.5” round soft drawn copper rods for
insulation co-ordination.
(v) Terminal connectors.

1. The 72.5 KV bushing shall be provided with bimetallic type

connectors for vertical take off of flexible Canadian Size, “Goat”
ACSR conductor. The connector shall be designed to prevent
corrosion due to bimetallic action.
2. The connection on 11 KV side shall be with disconnecting chamber
suitable for 3 core 11 KV, 400 Sq.mm XLPE Aluminium cable.
3. The LV neutral bushings shall be provided with suitable connections
for connecting to strip type copper bus bars for ground connections.

d) All bushings shall be suitable for continuous operation at 10% above the nominal
voltage of the bushings.

e) The windings side connection terminal of the bushings shall preferably be of the
cable type suitable for brazing on the winding side and screwed on the cap side so
that the bushing can be removed without opening the top cover of the
transformer by sliding the lead down the central bushing tube. Alternatively, the
tenderer may also offer for screwed type clamp connections.

f) The insulation requirements shall confirm to IS 2099/1973 with latest

amendments.
Bushings mounted current transformers on 66 KV side shall be as per IS
standards.

11. COOLING ARRANGEMENT:

The transformers shall have ‘ONAN’ cooling. The cooling shall be effected by pressed
steel radiators conforming to IEEMA. The radiators fins provided shall have sufficient
surface to limit temperature rise to values specified under clause 4 (i) & (ii) .The tubes
shall be so arranged as to admit scrubbing without trouble when necessary. It will be so
designed that any scale forming inside will flake off and pass to the bottom of the tank
by gravity. Oil leak proof butterfly valves (positive operated) shall be provided to
facilitate taking out any of the radiators without disturbing the transformer. Necessary
gaskets in required nos. for fixing radiators and butterfly valve operating keys shall be
provided. The space between the bottom of tank and mounting rail shall be maintained to
minimum of 350mm, for free air circulation.
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12 (i). ON load tap – changer:

On load tap changer shall be sourced from the makes as in scope of supply only and it
should be type tested as per relevant IEC 60214 and test methods shall be in
conformance to the procedures indicated in IEC 60214. The OLTC shall have proven field
performance. Voltage shall be substantially constant at the untapped windings (secondary
windings) and variable at the tapped winding (primary winding). The category of
regulation applied shall be constant – flux variable voltage type (CFVV).

The 21 taps on – load tap changer shall be in tank type, diverter – selector type, three
phase enclosure type, installed in a separated oil tank. It shall have range from 5% to
-30% per tap voltage of 1.155 kV. The voltage ratio shall be checked according to the
guaranteed figures and the tolerances stipulated in the standards. The principal tap shall
be on tap no. 4. There shall be 3 taps for higher input voltage and 17 taps for lower input
voltage variation. On load tap changer shall have maximum rated through current of
300A to meet the normal rated load as well as non cumulative over load at all the taps as
mentioned in clause 5.3. The OLTC shall have BIL rating corresponding to 72kV class and
short circuit withstand current as per relevant IEC standard but not less than 8kA for 3
seconds.

The OLTC must be designed to ensure to the prescribed and expected harmonic levels of
the system. The design of transition resistance and contacts shall be adequately taken
care.
The OLTCs should also be suitable for paralleling of three transformer of different
loading. The loading pattern will be furnished during ordering stage.

The full technical description shall be given as regards power and auxiliary circuits;
periodicity for checking and overhauling the power circuit shall be indicated in the
transformer maintenance manual.

The transformer shall be provided with local OLTC control cabinet and RTCC panel. The
tap changer shall have the following characteristics:
i. The power circuit of the on- load tap changer shall be connected to the
primary windings and shall enable the required voltage variations.
ii. The oil volume of the on – load tap changer unit must be separated from the
tank for core and winding oil.
iii. 50 000 operations without any attention.
iv. Motor operated for local as well as remote operation and external handle for
manual hand operation.
v. Tap position indicators.
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vi. Commutation current compatible with the overload current of transformer.

Necessary provisions be available to ensure that OLTC will not operate during
overloading.
vii. Diverter switches shall be designed for high speed operation and shall be
interlocked to ensure that there is no possibility of an operation stopping in
mid – position. Arcing contacts shall be of tungsten alloy material.
viii. Operating mechanism for on load tap changer shall be designed to go through
one step of tap change per command. Subsequent tap changes shall be
initiated only by a new or repeat command.
ix. Local OLTC control cabinet shall be mounted on the tank in accessible position.
It should be adequately ventilated and provided with anti-condensation metal
clad heaters. All contactors relay coils and other parts shall be protected
against corrosion, deterioration due to condensation, fungi etc.
x. Limit switches shall be provided to prevent overrunning of the mechanism and
shall be directly connected in the circuit of the operating motor. In addition, a
mechanical stop shall be provided to prevent over – running of the mechanism
under any condition.
xi. A five – digit non resetable type counter shall be fitted to the tap changing
equipment to indicate the number of operations completed.
xii. It shall not be possible for any two controls to be in operation at the same
time.
xiii. A suitable protection relay shall be connected on the oil pipe between the load
tap changer and the expansion vessel.
xiv. Devices for ease of extraction for maintenance purpose.

12 (ii). OLTC Control of Transformers:

The on load tap changer of the three-phase transformer shall be suitable for local and
remote control. The control feature shall provide the following:

i) Local Electrical Control:

a. ‘Local – Remote’ selector switch mounted in the local OLTC control cabinet
shall switch control the load tap changers as follows:
1. When the selector switch is in ‘local’ position, it shall be possible to
operate the ‘raise-lower’ control switches specified below. Remote control
of the raise – lower functions shall be prevented.
2. When the selector switch is in ‘remote’ position the local OLTC control
cabinet mounted ‘raise-lower’ switch specified below shall be in-operative.
Remote control of the raise / lower function shall be possible from the
remote control panel.
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b. A ‘raise-lower’ control switch / push button shall be provided in the local

OLTC control cabinet. This switch shall be operative only when ‘local
remote’ selector switch is in ‘local’ position.

c. An OFF – ON tap changer control switch shall be provided in the local

OLTC control cabinet of the transformer. The tap changer shall be in-
operative in the OFF position.

ii) Manual Control:

The cranking device for manual operation of the OLTC gear shall be removable
and suitable for operation by a man standing at ground level. The mechanism
shall be complete with the following:
a. Mechanical tap position indicators that shall be clearly visible from near
the transformer.
b. A mechanical operation counter.
c. Mechanical stops to prevent over cranking of the mechanism beyond the
extreme tap positions.
d. The manual control considered as back up to the motor operated load tap
changer operation. The manual operating mechanism shall be labeled to
show the direction of operation for raising / lowering.

iii) Remote Tap Changer Control Panel:

The contractor shall supply a Remote Tap Changer Control Panel (RTCC) panel
suitable for remote operation of on load tap changing gear.

The RTCC panel shall house actuating switch for electrical raise / lower control,
tap position indicator, signal lamps for “Tap change in progress” and “Tap changer
out of step” and all other auxiliary devices for remote electrical control of the
OLTC.
Auxiliary supply of single phase AC 240 Volts (varying form 180 to 270 Volts) and
control supply of DC at 110 Volts (varying from 77 to 121 Volts) are available at
the Main Receiving Station – RWF for OLTC.

13. FITTINGS & ACCESSORIES:

a) Standard fittings as described in IS:2026 (latest issue) and stated below shall be
provided on the transformer.

b) All screw threads and nuts shall be cut to metric standard or other approved
practice. All valves shall be of brass of standard test quality, leak proof and shall
be able to withstand full vacuum inside the transformer tank.
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1. Conservator with filling hole and cap.

2. Isolating valve of the conservator.
3. Flanged drain valve for the conservator.
4. Magnetic oil gauge for the conservator with low and high oil level alarm
contacts.
5. Silica gel breather with connecting pipe.
6. Pressure relief pipe with necessary air equalizer connection with the
conservator.
7. Access holes with bolted covers for access to inner ends of the bushings
on the transformer cover (manjole)
8. Cover lifting eyes.
9. Lifting eyes for core frame with windings.
10. Air release plug in top cover and bushing turrets.
11. Upper filter valve 2”, baffled to reduce serration of oil and flanged to seat
½” BSP male threaded adopter for filter pipe connection, so fitted as to
drain off the oil completely.
12. Bottom filter valves 2” flanged to seat ½” BSP male threaded adopter for
filter pipe connection, so fitted as to drain off the oil completely.
13. Drain valve 4” flanged.
14. Three oil sampling valves one for the bottom oil, one for the middle oil and
one for the top oil.
15. Lifting lugs or bollards for the whole transformer.
16. Jacking pads with hauling holes. The pad shall be suitable for jacking the
transformer while changing the position of bi-directional wheels.
17. Transport lugs suitable for rail and road transport. The design and position
to be finalized in consultation with the purchaser.
18. Under carriage with flanged bi-directional boggie type wheels. The gauge
shall be confirmed from the purchaser.
19. Tank earthing terminal two numbers to provide double earth connections as
required in the Indian Electricity Rules.
20. Gas pressure testing valve with pressure gauge for testing the pressure of
inert gas on receipt of transformers at site.
21. Buchholz relay double float type separate for each diverter chamber and
transformer tank with one set of contacts for alarm and the other set for
trip with annunciation facility. A testing pot cock shall also be provided.
The contacts shall be wired upto the marshalling kiosk with weather proof
cables in metallic conduits.
22. Dial thermometer for oil and winding temperature indicator complete with
two sets of contacts, one for alarm and another for trip.
23. Pocket for inserting alcohal thermometer for oil temperature indication in
each of the radiator circuits.
 - 17 -

24. Weather proof and vermin proof terminal cabinet with hinged door and pad
lock for marshalling terminal connections from protecting and indicating
devices.
25. Rating plate.
26. Diagram plate.
27. Any other accessories as needed.
28. All the gaskets to be provided shall be of RC70C or RC80C grade. It shall
not be older than one year. Necessary test certificates from
manufacturer shall be submitted along with acceptance test report. Flat
gasket material will be SRBC (Synthetic rubber bonded cork) with
minimum joints. When chords are used it shall be provided in
fabricated groove. It shall be of Nitrile rubber. In fabricated groove
the inner strip shall be welded for its full length.
29. All fittings, accessories, or apparatus, which may not have been specifically
mentioned but which are useful or necessary for the efficient working of
the transformer shall be deemed to be included in the contract and shall
be provided by the supplier without any extra charge. The transformer
with accessories shall be complete with all details whether such details are
stated in the specification or not.

14. RATING AND DIAGRAM PLATES:

The following plates shall be fixed to the transformer tank at an average readable
height above the ground level:

a) A rating plate bearing specified in art 1 & 2 of IS 2026/1962 including the

temperature rise of the oil and windings, the BIL of the transformer
insulation and terminals etc.
b) A diagram showing in an approved manner the internal connections and also the
vector relationship to the several windings in accordance with IS 2026 or BS
171 and addition a plan view of the transformer giving the correct physical
relationship of the terminals. When links are provided for changing the
transformer ratio, means shall be provided for clearly indicating the
connections to be adopted for the several ratios.
c) A plate showing the location and function of all valves and air release cocks or
plugs. This plate shall warn the operators to refer to the maintenance
instructions before applying the vacuum treatments.
d) The quantity of oil for transformer (including accessories) and OLTC should be
indicated separately in the rating plate.

The above plate shall be stainless steel or of other approved materials withstanding
continuous outdoor services.
 - 18 -

15. SUPPRESSION OF HARMONICS:

The transformer shall be designed with particular attention to the suppression of

voltages especially the third and fifth harmonic so as to eliminate wave form distortion
and any possibility of high frequency disturbances, inductive effects or of circulating
currents, between neutral points of different transformer stations reaching such a
magnitude as to cause to interference with communication circuits.

16. INSULATION CO-ORDINATION:

The contractor shall furnish (i) impulse flash over (ii) Dry flash over characteristics for
the bushing spark gap set at different distances of separation. He shall also furnish the
impulse volt-time characteristics of the transformer winding and bushing to enable the
purchaser to obtain effective insulation co-ordination between the transformer, lighting
arrestor and the rest of the station equipment.

17. PROTECTION:

The following protection is proposed to be provided for the transformers:

Detecting or actuation devices required which forms part of the transformer

construction shall be incorporated.

(i) Buchholz alarm and trip.

(ii) Differential protection, overload protection, earth fault protection and
neutral displacement.
(iii) Winding temperature trip & alarm
(iv) Oil temperature trip & alarm.

18. BUSHING TYPE CURRENT TRANSFORMERS:

Suitable Bushing type CTS shall be provided on primary, secondary and on Neutral for
protection and metering purposes. (Differential protection, Over load protection, Earth
fault with tapings on the BCT for Winding temperature indication The BCTs shall
conform to IS: 2705.

The BCTs shall be so designed as to withstand thermal and mechanical stresses resulting
from short circuits experienced by the transformer on which these are fitted.

Apart from the BCTs required for the differential protection, a BCT of accuracy class
0.5 and conforming to IS: 2705, with suitable tapings, shall be mounted inside one of the
 - 19 -

bushings of the secondary side of the transformer for use with the winding temperature
indicator (WTI).

The BCTs and the bushings shall be so mounted that removal of a bushing without
disturbing the current transformers, terminals and connections or pipe work is easy and
convenient.

The leads from the BCTs shall be terminated in terminal boxes provided on the bushing
turrets. Suitable links shall be provided in the terminal boxes for shorting the secondary
terminals of the BCTs, when not connected to the external measuring circuits.

The leads from the secondary winding of the BCTs terminated in the terminal box on the
bushing turret upto the marshalling box shall be of 1100 V grade, PVC insulated, PVC
sheathed, armoured, stranded copper cable of cross-section not less than 4mm2 to IS:
1554 (Part-I).

Cable glands of proper size shall be provided in the terminal boxes to lead in / lead out
the cables.

19. CLEARANCES:

The relative orientation in space of the bushings fitted with terminal connectors, the
main tank, radiators, conservator, pressure relief device, oil piping and other parts when
mounted on the transformer shall be such that the various clearances in air from bushing
live parts shall not be less than the appropriate values as per IS.

The same distance shall apply for clearance phase – to – earth including oil piping work,
conservator, pressure relief device and such other parts), phase to phase, and towards
terminals of a lower voltage winding.

20. PAINTING:
The surface to be painted shall be shot or sand blasted to remove all rust, scale, grease
and other foreign matter. All steel surfaces in contact with insulating oil shall be given
two coats of heat and oil resisting insulating varnish. All steel surfaces exposed to
weather shall be given a priming coat of Zinc chromate and two coats of light grey paint.
All paints shall be suitable for subsequent application of approved paint.

All paints selected shall be suitable to withstand tropical heat and extremes weather.
The paint shall not scale off or crinkle or be removed by abrasion due to normal handling.

The transformer shall be thoroughly dried under vacuum in the factory and sealed with
positive pressure of dry inert gas or air for delivery.
 - 20 -

21 (i). TESTS:

The following tests shall be carried out in order to determine whether the materials and
performance comply with specifications and to provide the necessary operating data.
a) Not less than 10 days notice of all tests shall be given to RITES. So that the
test can be conducted in time for the delivery of the transformer within due
dates.
b) Three copies of all certified test reports shall be furnished to the Railway.
The advance copies shall be furnished by air mail for the purchaser’s scrutiny
and the equipment shall not be dispatched with out obtaining the Railway’s
written approval for the test reports.

21 (ii). STAGE TESTS:

The following tests shall be conducted during manufacture in addition to any other
customary tests of the manufacturer:
(i) Vacuum withstand strength of tank.
(ii) Test for oil tightness.
(iii) Material tests on core conductor and insulating materials.
(iv) Leakage tests for radiators.
(v) All welds shall be tested to ensure that no weld would sweat.

21 (iii). ROUTINE TESTS:

After the completion of the manufacture, the following tests shall be conducted on each
unit:

(i) Ratio test for all taps.

(ii) Check test for polarity, vector relationship and terminal markings.
(iii) No load test for losses and excitation current at 100% and 110% of the rated
voltage.
(iv) Measurement of load losses at rated load current and calculation of losses at
75˚C.
(v) Impedance voltage between windings at rated current and calculation of
Impedance at 75˚C.
 - 21 -

(vi) Resistance of windings, cold at test bed temperature and calculation of

corresponding values at 75˚C.
(vii) Insulation resistance between windings and windings to earth at 75˚C.
(viii) High voltage test.
a) Applied voltage test – the leakage current shall be recorded.
b) Induced voltage test – the values of the exciting voltage, current and
frequency shall be recorded in the test certificate.
(ix) Calculation of regulation at unity p.f and 0.8 p.f lag load.
(x) Determination of efficiency at full, three quarters, half & quarter loads at
unity p.f.
(xi) Zero sequence impedance test.

21 (iv). TYPE TESTS:

e) Equipment offered shall have Type Test Certificates from accredited laboratory
(accredited based on ISO/IEC Guide 25 / 17025 or EN 45001 by the National
accredition body of the country where laboratory is located), as per IEC / IS / technical
specification. The type test reports shall not be older than FIVE years and shall be valid
up to expiry of validity of offer.
(The tenderer shall submit with his tender the type test report for impulse test on a
similar transformer of this rating:)

21 (v). TEMPERATURE RISE TEST:

Temperature rise shall not exceed the specified various with reference to the ambient
temperature of 40OC for air.

21 (vi). IMPULSE TEST:

The tenderer shall conduct Full wave and chopped wave on all three phases of HV & LV
winding and submit enlarged copies of the oscillograms of the impulse test.

21 (vii). TESTS ON ASSOCIATED EQUIPMENT:

Porcelain bushings, tap changer gear, Buchholz relays, motors, radiators and other
associated equipment shall be tested according to standard practice. Certificates of
compliance shall be furnished. Dissolved gas analysis and Tandelta test for the oil as
certified by NABL accredit Laboratory for the oil used /supplied for this purpose shall
be supplied.
 - 22 -

22 (i). TENDER DRAWINGS:

The following tender drawings shall be submitted in triplicate:

(a) A general outline and shipping dimensions, net and shipping dimensions, net and
shipping weights, height of crane hook for lifting core and bushing, etc.
(b) Sectional views of bushings, heat exchangers, coolers etc.

22 (ii). CONTRACT DRAWINGS:

(a) General outline showing plan, elevation and end view dimensions, dimensions of
transformers stripped for shipment, physical center lines and position of center
of gravity relative to them. Drawings to indicate height of crane hook for lifting
bushing and untanking core, details of the top terminals, complete list of fittings
and devices, net weights of core frames, windings tank, conservator, total
quantity of oil, shipping weight, vacuum withstand strength of the transformer,
rating particulars of transformer.
(b) Diagram and rating plates as per details in the specifications, temperature rise of
oil and winding, high voltage test figures etc.
(c) Electrical connections of windings, numbering of taps, tapping switches, terminals,
vector group, polarity, terminal marking of C.T’s etc.
(d) Control circuits and wiring diagrams, schematic diagrams for paralleling interlock,
wiring diagrams of control cabinets, signaling and indicating devices, current
transformer, block diagrams showing interconnecting control cables schedule.
(e) Drilling details and internal wiring of devices supplied loose for mounting on the
purchaser’s control board.
(f) Shipping outline: Outline profile plan, elevation and view of transformer stripped
for shipment, dimensions of projections referred to the physical center lines, the
position of center of gravity. This shall be inset on the Railway clearance drawing.
(g) Foundation drawings.
(h) Assembly of core and coils: Details of winding connections, insulation spacers,
barriers, clearance core bolt insulation, etc., which will help the purchaser to
replace a set of windings in any future eventuality. The component parts shall be
suitably numbered and the parts shipped shall have similarly numbered tags.
(i) Bushing Assembly: Plan, elevation, sectional view and details of joints, seals etc.
(j) Radiator Assembly: Sectional view of radiator.
(k) Detailed assembly drawings to enable the purchaser to do the core and coil
assembly in future needs. Parts shall be identified by separate numbers.
(l) Dimensioned drawings showing cooling passages on transformers and windings.
(m) Documents: Three sets of operations, instructions & maintenance manual shall be
supplied in hard copy.
 - 23 -

23. MAKES:

 Only ISO certified companies can participate in this tender on producing valid
document evidence along with the offer. The bidder should be original equipment
manufacturer (OEM).

24. WARRANTY PERIOD:

a) Warranty period for Transformer (M&P) will be 24 (twenty four) months from
the date of commissioning and providing out of M&P. a maximum period of 2
(two) weeks will be allowed for attending and rectification of faults during the
warranty period.
b) Maximum down time during the warranty period will be 2% (two percent) for on
line M&P and 10% (ten percent) for of line M&P calculated on quarterly basis.
c) A penalty of 0.5% (zero point five percent) per week of the contract value will
be levied for delay in response time for attending and rectification of faults
beyond specified time during the warranty period as detailed above.
d) Maximum penalty to be levied on account of warranty failure will be 5% (five
percent) of the contract value calculated during whole of warrantee period and
after that if there is any delay on the part of supplier purchaser shall be
entitled for encashment of PG Bonds. In such cases the bad performance of
firm during the warranty period, the same should be recorded and circulated to
all Railways. The same should be given due regard in deciding future, orders on
the firm and when evidence to the contrary is not available, the firm’s offer
may be even rejected.

25. SPECIAL CONDITIONS:

1. Inspection shall be at firm premises by RITES

2. Firm shall submit relevant Reference to specification and grade of material,
source(s) of supply and manufacturing test certificates for the brought out
items during inspection.
3. Drawing showing general arrangement and design of transformer shall be
submitted before manufacturing of the transformer.
4. Delivery at RWF.
5. Only ISO certified companies can participate in this tender on producing valid
document evidence along with the offer. If OEM is not participating,
authorization certificate shall be enclosed by the distributors who participate
in this tender for transfer of authority of OEM in taking decision for Finance
and Technical matters.
6. List of recommended spares shall be enclosed along with offer. However this
will not be included while evaluating the offer.
 - 24 -

26 (i). PAYMENT:

i) Payment against supply: The standard payment terms subject to recoveries

in any, under the liquidated damages clause and general condition of
contract will be as under:

(a) 80% of the payment against proof of inspection certificate and

Receipt of material at RWF.

(b) Balance 20% payment after satisfactory installation, commissioning

and proving test of M&P.

26 (ii). Timely Commissioning of M&P:

In the event of contractors’ failure to have M&P commissioned by the time or

times, respectively specified in the letter of acceptance or contract, purchaser
may withhold, deduct or recover from the contractor as penalty, a sum @ 2%
(two percent) of the price of M&P which the contractor has failed to
commission as aforesaid for each and every month (part of a month being
treated as a full month) during which the M&P may not have been commissioned,
subject to an upper limit of 10% (ten percent) of contract value.

The firm/ tenderer shall enclose their Guaranteed performance of the transformer (to
be supplied) in the following format:
 - 25 -

27. LIST OF RELATED SPECIFICATION:

In the preparation of this specification, assistance has been derived form the following
standards and codes of practices (latest version), and Indian Electricity Rules wherever
applicable.

1 IS: 5 Colours for ready mixed paints and enamels

2 IS/EN: 12944 Protective Paint Systems
3 IS: 12463 New insulating oils
4 IS: 1554 PVC insulated (Heavy duty) electric cables for working
(Part – I) voltages up to and including 1100 Volts.
5 IS: 1570 (Part – V) Stainless and heat resisting steels
6 IS: 1576 Solid pressboard for electrical purposes.
7 IS: 1866 Code of practice for maintenance and supervision of mineral
insulating oil in equipment.
8 IS: 2026 Power transformers
9 IS: 2099 Bushing for alternating voltages above 1000 volts.
10 IS: 2705 Current transformers
11 IS: 2927 Brazing alloys
12 IS: 3024 Electrical steel sheets (oriented)
13 IS: 3637 Gas operated relays
14 IS: 3639 Fittings and accessories for power transformers
15 IS: 4253 Cork and rubber
16 IS: 5561 Electrical power connectors.
17 IS: 5621 Hallow insulators for use in electrical equipment.
18 IS: 13234 Guide for short circuit calculation.
19 IS: 6209 Methods for partial discharge measurements.
20 IS: 6600 Guide for loading of oil immersed transformers
21 IS: 8468 On load tap changers
22 IS: 10028 Code of practice for selection, installation and maintenance of
transforms
23 IS: 10593 Method of evaluating the analysis of gases in oil – filled
electrical equipment in service.
24 IS: 12676 Oil impregnated paper insulated condenser bushings
dimensions and requirements.
25 IEC: 60076 Power transformers
26 IEC: 137 Bushings for alternating voltages above 1000 volts.
27 IEC: 185 Current transformers
28 IEC: 60214 On load tap changers
29 DIN: 7733 Laminated products, pressboard for electrical engineering,
types,
 - 26 -

In case of any conflict between the contents of the above specifications and this
specification, the later shall prevail.

Any deviation from this specification, proposed by the tenderer, calculated to improve
the performance, utility and efficiency of the equipment, will be given due consideration
provided full particulars of the deviations with justification therefore, are furnished.

In such a case, the tenderer shall quote according to this specification and the
deviations, if any, proposed by him shall be quoted as an alternative / alternatives.
 - 27 -

28. SCHEDULE
SCHEDULE OF GUARANTEED PERFORMANCE AND TECHNICAL PARTICULARS

A. POWER TRANSFORMER:
Sl. PARTICULARS 15 MVA TRANSFORMER
No.
1. Name of manufacturer
2. Standard applicable
3. Guaranteed continuous maximum rating for KVA
specified cooling temperature rise and ambient
4. Guaranteed, equivalent continuous maximum rating KVA
based on B.S. 171 standard temperature rise and
ambient temperature
5. Guaranteed rated temperature rise over specified C
O

ambient (40OC for air and 35OC for water) C

O

i) Of oil by the thermometer

ii) Of Winding by resistance
6. No Load voltage ratio (Guaranteed)
7. Exciting current referred to HV at 50cps
(Guaranteed)
i) 90% rated voltage AMPS
ii) 100% rated voltage AMPS
iii) 110% rated voltage AMPS
8. Power factor of exciting current at 100% rated
voltage and 50 Cps.
9. Guaranteed iron losses at 100% rated voltage and
50 Cps.
i) 90% rated voltage KW
ii) 100% rated voltage KW
iii) 110% rated voltage KW
10. Guaranteed total full load losses KW
11. Guaranteed copper losses at 75OC and rated KW
voltage
12. Resistance voltage at 75OC and rated full load
i) HV 66KV %
ii) LV 11KV %
13. Reactance voltage at 75OC and rated full load
between the windings
66KV-11KV %
14. Guaranteed Impedance voltage at 75OC & rated
full load between the winding
 - 28 -

15. Resistance of HV winding per phase at 20OC Ohms

16. Resistance of LV winding per phase at 20OC Ohms
17. Guaranteed regulation at 75OC full load
a) Unity p.f %
b) 0.8 p.f %
18. Efficiency at 75OC at Unit p.f
i) 100% load %
ii) 75% load %
iii) 5% load
%
%
iv) 25% load
19. Zero sequence impedance (75OC. Temperature HV
to LV.
i) Highest tap %
ii) Lowest tap
%
%
iii) Normal tap
20. Guaranteed withstand time without injury with Sec
three phase short circuits at the terminals as per
IS: 2026
21. “Ideal fitting time” or the thermal time constant Hours

Sl. B. Core
No. Particulars 15MVA Transformer
01. Form of core
02. Induction density in the core, at rated voltage and Gauss
50 cps
03. Induction density at 110% voltage and 50 cps. Gauss
04. Thickness of iron stamping
05. Exciting KW per 1b of iron at
i) 15000 Gauss
ii) Rated induction (vide item 2)
iii) Induction as per item 3.
06. Quality of sheets (Hot or cold rolled)
07. Induction between core lamination
08. Type of joint between corelimb & Yoke
09. Bolt insulation test voltage (One volt minute)
 - 29 -

Sl. C. Windings
No. Particulars 15MVA Transformer
01. Type of winding
02. Current density in Amps./ Sq. in
i) HV winding
ii) LV winding
03. Insulation on the copper
04. Type of joints in the winding
05. Insulation strength of winding with 1.5 x 40 micro
second wave or 1 x 50 micro second wave
i) Impulse full wave (withstand values)
ii) HV KV
iii) LV KV
iv) Impulse chopped wave (withstand values)
v) HV KV
vi) LV KV
vii) Applied voltage test
viii) HV KV
ix) LV KV
a) Induced voltage test KV
06. Minimum clearance to earth
i) LV and core Inches
ii) HV and Yoke Inches
07. B.S.S. vector group
08. Estimated switching withstand voltage surge KV

Sl. D. ON Load Tap Changer

No. Particulars 15MVA Transformer
01. Type of Tap Changer
02. Tap Voltage as percent of no load rated voltage
i) Plus
ii) Minus
03. Number of taps
04. Percentage impedance
i) Lowest tap
ii) Highest tap
iii) Normal tap
05. Position of taps on the HV winding
 - 30 -

Sl. E. Bushings
No. Particulars 15MVA Transformer
01. Name of manufacturer
02. Standard specification
03. Type of bushing
04. Guaranteed impulse withstand voltage (Full wave)
i) High voltage KV
ii) Low voltage KV
05. Guaranteed one minute dry withstand voltage
i) High voltage KV
ii) Low voltage KV
06. Guaranteed wet withstand voltage KV
i) Low voltage
07. Guaranteed puncture voltage
i) High voltage KV
ii) Low voltage KV

Sl. F. ON / COOLING EQUIPMENT

No. Particulars 15MVA Transformer
01. On rating of transformer with specified KVA
temperature raise with one radiator cut off
02. On rating of transformer with all radiator in KVA
service
03. Type of radiators coolers
04. Number of radiator units

Sl. G. WEIGHT
No. Particulars 15MVA Transformer
01. Net weight of core KGS
02. Net weight of copper in
i) LV winding KGS
ii) HV winding KGS
03. Net untanking weight of core frame and coils KGS
04. Net weight of insulating oil KGS
05. Total weight of radiators KGS
06. Shipping weight of transformer package with KGS
i) Transformers under oil
ii) Transformers under inert gas
07. Volume of insulating oil Ltr.
08. Total shipping weight of ancillary equipment KGS