TECHNICAL SPECIFICATIONS

CAST RESIN MV/LV DISTRIBUTION TRANSFORMER

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Technical Specifications
Cast Resin MV/LV Distribution Transformer

TABLE OF CONTENTS
Section

Description

Part I General

1.1
1.2
1.3

Description

1.4
1.5
1.6

Submittals
Coordination
Product Delivery, Storage and Handling

Part II Products

2.1

General

2.2
2.3
2.4
2.5

General Requirements
Metal Enclosure
Accessories and Standard Equipment
Routine, Types and Special Tests

Part III Execution

3.1
3.2
3.3

Workmanship
Foundations and Supports
Equipment Erection

3.4

Equipment Testing and Commissioning

Applicable Codes and Standards

Quality Assurance

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VOLUME II, SECTION 4.15 - CAST RESIN MV/LV

DITRIBUTION TRANSFORMER
1

Part I General

1.1 Description
This section cover the manufacturer, furnish, install and test all
equipment, accessories and materials required for the installation of
cast resin distribution transformer in accordance with attached
specifications and drawings.
1.2

Applicable Codes and Standards

The work shall be carried out in accordance with this specification, the
contract drawings and the standards listed hereunder.
The following codes and standards provide an acceptable level of
quality for materials and products:
a. Local Electric Authority.
b. IEC 60076-1 Power transformers to 60076-5
c. IEC 60726

Dry type power transformers

d. IEC 60905

Loading guide for dry-type power transformers.

e. CENELEC Harmonization Documents:

1.3

HD 464 S1: 1988 / A4: 1995.

HD 538-2 S1: 1995.

HD 398-1 to 398-5.

Quality Assurance
a. All materials and products shall be new, sound and uniform in
quality, size, shape, color and texture and shall be free from defects.

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b. The contractor shall be responsible for ensuring that the required

standards of quality control as mentioned in relative sections are
maintained for the proposed transformer.
c. If requested by the client, the supplier shall provide proof of
application of a quality procedure complying with standards. This
means:
i). use of a quality manual approved and signed by a management
representative,
ii). regular updating of this manual so that it reflects the most recent
applicable quality control procedures,
iii). ISO 9002 certification.
d. The manufacturer must have a sound experience in the field of
transformers for not less than ten years, and should have a presentable
reference list of the already supplied equipment of the same type and
same make and that this equipment has been in satisfactory operation
in India for at least five years.
1.4

Submittals
a. Shop Drawings and Manufacturer's Data: The contractor shall submit
to the consultant/client representative for review, detailed
dimensioned shop drawings and manufacturer's literature where
deviations from the contract drawings or specification exist. Shop
drawings and/or data sheets shall be based on information stated in
the specifications and as shown on the contract drawings and shall
show all pertinent deviations and data for the fabrication and
complete installation.
Manufacturer's data sheets shall be submitted indicating the necessary
installation dimensions, weights, materials and performance
information. The above information may be provided by standard
catalogue sheets marked to indicate the specific items provided.
b. Operation and Maintenance Instructions: The contractor shall furnish
data covering model, type and serial numbers, capacities, maintenance
and operation of each major item of equipment or apparatus in
accordance with the requirements of the contract documents.
Operating instructions shall cover all phases of control.

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c. Test Reports:
The contractor shall submit test reports to the
client/client representative for review.
d. Recommended Spare Parts List:
The contractor shall submit
recommended spare parts list to the client/client representative for
review.
e. As Built Drawings: The contractor shall submit the as built drawings
to the client/client representative for review and approval.
1.5

Coordination
a. The contractor shall be held responsible for the proper coordination of
all phases of the work under this contract.
b. It shall be the responsibility of the contractor to coordinate the work
and equipment as specified herein with work to be performed and
equipment to be furnished under other sections of the specifications in
order to assure a complete and satisfactory installation.

1.6

Product Delivery, Storage And Handling

a. Deliver, store, protect and handle products to site as per
manufacturers instructions.
b. Store transformers in clean and dry space. Inspect for damage.
Maintain factory wrapping or provide an additional heavy canvas or
heavy plastic cover to protect units from dirt, water, construction
debris and traffic.
c. Lift only with lugs provided for the purpose. Handle carefully to
avoid damage to transformers internal components, enclosure and
finish.
2

Part II Production

2.1 General
a. The following specifications apply to three-phase transformers of cast
resin type, class F insulation system with natural (AN) cooling for
indoor installation, destined for use in three-phase MV/LV
distribution systems.

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b. If required, forced cooling (AF) can be used to increase the rated

power.
2.2

General Requirements
a. General:
i). The transformers shall be of climatic class C2 and of environmental
class E2 as defined in appendix B of HD 464 S1. C2 and E2 classes
shall be indicated on the rating plate.
ii). The transformers shall be of fire behavior class F1 as defined in
article B3 of CENELEC HD 464 S1. F1 class shall be indicated on the
rating plate.
b. Magnetic Core:
This shall be made from laminations of grain oriented silicon steel,
insulated with mineral oxide and shall be protected against corrosion
with a coat of varnish.
c. LV Windings:
i). These shall be made from aluminum or copper foil with class F
interlayer insulation by encapsulation (impregnation) with synthetic
alkyd resin or equivalent.
ii). At least the upper part of the LV coils shall be covered with a coat of
epoxy resin or equivalent and the foil shall be protected everywhere
with an insulation material even in the air ducts.
d. MV Windings:
i). At least the upper part of the LV coils shall be covered with a coat of
epoxy resin or equivalent and the foil shall be protected everywhere
with an insulation material even in the air ducts.
ii). The MV windings shall be vacuum cast in a class F fireproof epoxy
resin casting system composed of:

An epoxy resin

An anhydride hardener with a flexibilising additive

A flame-retardant filler.

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iii). The flame-retardant filler shall be thoroughly mixed with the resin
and hardener. It shall be composed of trihydrated alumina powder
(or aluminum hydroxide) or other flame-retardant products to be
specified, either mixed with silica or not.
iv). The casting system shall be of class F.
e. MV Connections:
i). The MV connections shall be made from above on the top of the
connection bars. Each bar shall be drilled with a 13-mm hole ready
for connection of cable lugs on terminal plates.
ii). The MV connection bars shall be in rigid copper bars protected by
heat shrinkable tubing.
iii). MV connections in cables are not allowed.
iv). The MV connections shall be copper.
f. LV Connection:
i). The LV connections shall be made from above onto bars located at
the top of the coils on the opposite side to the MV connections.
ii). Connection of the LV neutral shall be directly made to the LV
terminals between the LV phase bars.
iii). The LV connection bars shall be copper or tinned aluminum.
g. MV Tapping:
i). The tapping which act on the highest voltage adapting the
transformer to the real supply voltage value, shall be off-circuit
bolted links.
ii). Tapping with connection cables is not allowed.
iii). These bolted links shall be attached to the MV coils.
2.3

Metal Enclosure
If mentioned in the documents, the transformers shall be equipped
with a metal enclosure for indoor installation comprising an integral
IP 31 (except the base which may be IP 21) metal enclosure with:
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a. An anti-corrosion protection in the manufacturer's standard color.

b. Lifting lugs enabling the transformer and enclosure assembly to be
handled.
c. A bolted access panel on the enclosure front to allow access to the
MV connections and to the tapping. This shall be fitted with
handles; it shall have one "Danger Electricity" warning label, a
rating plate and a visible braid for earthing.
d. Blanked off holes for fitting key locks on the bolted access panel to
enable it to be locked.
e. 2 UN-drilled gland plates on the roof: one on the MV side, one on
the LV side.
f. 1 plate at the MV side on the bottom of the enclosure for the MV
cables for connections from the bottom.
2.4

Accessories and Standard Equipment

a. The transformers shall be equipped with:
i). 4 flat bi-directional rollers
ii). 4 lifting lugs
iii). Haulage holes on the under base
iv). 2 earthing terminals
v). 1 rating plate
vi). 1 "Danger Electricity" warning label
vii). 1 routine tests certificate
viii). 1 instruction manual
maintenance in English.

for

installation,

commissioning

and

b. THERMAL PROTECTION
i). The transformers shall be equipped with a thermal protection
device, which shall comprise:

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2 sets of 3 PTC sensors, one sensor for "Alarm 1", one for "Alarm
2" per phase, installed in the coils of the transformer. They shall
be placed in a tube to enable them to be replaced when ever
necessary.

An electronic converter with two independent monitoring

circuits equipped with a changeover switch, one for "Alarm 1"
and the other for "Alarm 2". The position of the relays shall be
indicated by 2 different colored indicator lights. A third indicator
light shall indicate the presence of voltage.

ii). The three indicator lights shall be on the front of the converter. The
electronic converter shall be installed away from the transformer.
iii). A plug-in terminal block shall be provided for connection of the PTC
sensors to the electronic converter.
iv). The PTC sensors shall be supplied assembled and wired to the
terminal block fixed on the upper part of the transformer. The
converter shall be supplied loose with the transformer, packaged
complete with its wiring diagram.
2.5

Routine, Types and Special Tests

a. Routine Tests: The following tests shall be carried out on all the
transformers after the manufacturing, enabling an official test
certificate to be produced for each one:
i). Measurement of windings resistance.
ii). Measurement of the transformation ratio and vector group
iii). Measurement of impedance voltage and load loss
iv). Measurement of no load loss and no load current
v). Applied voltage dielectric test
vi). Induced voltage dielectric test
vii). Measurement of partial discharges, partial discharges shall be less
than or equal to 10 pC at 1.10 Um.

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b. Type Tests: The following type-test certificates shall be submitted for

the transformers:
i). Temperature rise test carried out in accordance with the simulated
loading method as defined by the IEC 60726 standard.
ii). Lightning impulse test.
iii). Short circuit test.
iv). Noise level measurements in accordance with IEC 60551.
c. Special Tests: The following tests may be requested (if mentioned in
the other documents):
i). The environmental and climate tests shall be performed in
accordance with appendix ZA and ZB of CENELEC HD 464 S1.
ii). The fire behavior test shall be performed in accordance with
appendix ZC of CENELEC HD 464 S1.
d.

The manufacturer shall produce a test report from an official

laboratory on a transformer of the same design as those produced.

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Transformer Technical Data

For each requested transformer, the supplier shall give the following data :
Rated power ..............................................................................................................
Cooling................................ (as mentioned in the other documents) AN or AF
Rated frequency........................................................................................................
Primary voltage ........................................................................................................
Rated primary insulation level ...............................................................................
Power frequency withstand Voltage(rms) ...........................................................
Basic Insulation Level (BIL) or impulse withstand voltage (peak) ...................
Off-circuit tapping............................................................................................. +/Secondary voltage at no load
between phases ...........................................
phase to neutral...........................................
Vector group..............................................................................................................
No load losses ...........................................................................................................
Load losses at 75 C..................................................................................................
Load losses at 120 C................................................................................................
Rated impedance voltage at 120 C........................................................................
Acoustic power Lw(A).............................................................................................
Acoustic pressure at 1 meter Lp(A) .......................................................................
Maximum ambient temperature ............................................................................
Daily average ambient temperature ......................................................................
Yearly average ambient temperature ....................................................................
Maximum altitude....................................................................................................

W
W
W
%
dB(A)
dB(A)
C
C
C
m

MV winding temperature class ..............................................................................

LV winding temperature class................................................................................
Temperature of insulation system .........................................................................

Climatic classification (HD 464 S1) ........................................................................

Environmental classification (HD 464 S1)............................................................
Fire behavior classification (HD 464 S1)................................................................
Enclosure ...................................................................................................................
Protection degree......................................................................................................
Length ........................................................................................................................
Width..........................................................................................................................
Height.........................................................................................................................
Total weight...............................................................................................................
Measurement circuit supply voltage for the thermal protection electronic
Converter ...................................................................................................DC AC

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KVA
HZ
KV
KV
KV
KV
%
V
V

YES

NO
IP
mm
mm
mm
kg
V

Part III Execution

3.1 Workmanship
Materials, products and equipment furnished by the contractor, shall
be installed and all work shall be performed in a first-class
workmanship manner, in conformity with the best trade practices and
the printed directions of the applicable manufacturers; by skilled
workers equipped to produce satisfactory results; in a safe, substantial
manner so as to avoid undue stresses, rigid enough to prevent undue
movement, so as to present a neat, orderly appearance and to facilitate
operating, servicing, maintenance and repairing.
3.2

Foundations and Supports

The contractor shall provide concrete pedestals, anchor bolts, hangers,
channels, saddles, etc., for installation of equipment and apparatus
shown on the drawings and specified in the various sections.

3.3

Equipment Erection
a. All electrical equipment shall be installed in accordance with the
manufacturer's recommendations, good electrical engineering
practice, and the relevant drawings and specifications.
b. All metal surfaces to be bolted shall be thoroughly cleaned before
assembly. The connections shall be tightened with manual torque
wrenches to the manufacturer's erection instructions.

3.4

Equipment Testing and Commissioning

a. After the installation is complete and properly adjusted, the contractor
shall conduct operating tests. The various equipment and systems
shall be demonstrated to operate in accordance with the requirements
of the contract documents. Tests shall be performed in the presence of
the client/client representative. The contractor shall provide electric
power, instruments and personnel necessary for performing the
various tests.
b. The testing of all electrical equipment shall include, but not be limited
to, the items below. This shall be in addition to testing specified
elsewhere in this specification.

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i). General equipment check.

ii). Field wiring and ground system verification.
iii). Equipment adjustment.

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