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Specification for 11/0.433 kV Dist.

Transformers, Dry Type (Cast Resin)

EP-MS-P4/S4-035

EP-MS-P4/S4-035

Specification for
11/0.433 kV Distribution
Transformers, Dry Type
(Cast Resin), Ground Mounted
for Indoor Applications

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Specification for 11/0.433 kV Dist. Transformers, Dry Type (Cast Resin)

EP-MS-P4/S4-035

Document Control
Department

EP

Document Type

Document Title

Material
Specification
Standards

EP-MS-P4/S4-035
Specification for
11/0.433 kV Distribution
Transformers, Dry Type (Cast
Resin) Ground Mounted for
Indoor Applications

Issue Approval
Prepared By

Approved By

Materials Standards & Specification Engineer

Manager, EN Planning Dept.

Signature:

Signature:

Issue Record
Issue No.

Date

Reason for re-issuing Document

0.0

06.02.2005

First issue of Materials Specification Standards

1.0
2.0

05.02.2010

Review of Materials Specification Standards

16.10.2011

Review of Materials Specification Standards

3.0
4.0
5.0

Key Words

Specification for 11/0.433 kV Distribution Transformers,


Dry Type (Cast Resin) Ground Mounted for Indoor
Applications.

Review Frequency

Every 3 years

When this document is approved for publishing on the intranet, a copy of its Document Control page should be sent to
the QA section who is custodian of KM quality management system.

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Specification for 11/0.433 kV Dist. Transformers, Dry Type (Cast Resin)

EP-MS-P4/S4-035

INDEX
SL NO

DESCRIPTION

PAGE
NUMBER

1.

SCOPE

2.

ENVIRONMENTAL CONDITIONS

3.
4.

SYSTEM CONDITIONS

5/6

APPLICABLE STANDARDS

6/7

5.

GENERAL DESIGN FEATURES

6.

RATINGS & CHARACTERISTICS

Service conditions & Temperature rise limits

Ratings

Short Circuit ratings.

Tapping Range & Method

Magnetic core Material & Flux density

Thermal Insulation class of windings

Noise Levels

10

Climatic, Environmental & Fire behavior class

10

8/9

RATINGS, CONNECTION PLATE DETAILS & MARKING OF


TERMINALS

7
1.

Rating & Connection Plates.

2.

Marking of Terminals

8.

10/11
11

GENERAL CONSTRUCTION & FITTINGS


1.

Magnetic core & bus bars

11

2.

Windings

12

3.

Enclosure.

13

4.

Fittings and accessories

5.

Corrosion protection & painting

15

6.

Cable Boxes

16

9.

QUALITY CONTROL

16

10.

TESTS

16/17

11.

TASTING, INSPECTION & DELIVERY

17/18

12.

INFORMATION & DOCUMENTS TO BE SUBMITTED BY


BIDDERS

18/19

13.

WARRANTY

20

14

DEVIATIONS FROM THE TECHNICAL SPECIFICATION

20

15

RESTRICTIONS ON OUT-SOURCING

20

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Specification for 11/0.433 kV Dist. Transformers, Dry Type (Cast Resin)

EP-MS-P4/S4-035

APPENDICES
14

Appendix A- Transformer 11kV Cable Box for All Sizes

21

15

Appendix B -Transformer LV Cable Box for 500/1000kVA Sizes

22

16

Appendix C-Transformer LV Cable Box for 1600kVA Sizes.

23

17

TABLE-B1/ Details of Cable boxes

24

18

TABLE-B2/ Minimum Clearances in Cable boxes.

24

19

TABLE-B3/ No & Size of Cables in LV Cable Box

24

TABLES

ILLUSTRATIONS
20

STD-PRT-04 / Danger Plates

25

21

ED-04-035 Fig.4/ HV Cable box, for 11kV Transformer- All Sizes

26

22

ED-04-035 Fig.5/ LV Cable Box & Bushing assembly up to 1600KVA

27

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Specification for 11/0.433 kV Dist. Transformers, Dry Type (Cast Resin)

1)

2)

EP-MS-P4/S4-035

SCOPE

1)

This specification details about the requirements for design, manufacture, testing,
transporting, and delivery of 11/0.433KV Cast Resin (Dry Type) distribution
transformers, intended for use on public electric supply system in the State of Qatar.

2)

The transformers shall be two winding, cast resin, natural air cooled (without any forced
ventilation) with metallic enclosure, and connected through bushings in cable boxes.

3)

The transformers are intended to be installed in Indoor Applications, in non-air


conditioned rooms. These transformers need to withstand the harsh ambient and climatic
conditions prevailing in the state of Qatar, as specified in subsequent sections.

4)

The rated capacities of the transformers shall be 500KVA, 1000KVA & 1600KVA for
continuous service at 50 Hz to transform energy from 11kV (nominal) to
415/240V(nominal).

ENVIRONMENTAL CONDITIONS
The following conditions prevail throughout in the State of Qatar

3)

1)

Altitude - low lying, generally close to sea level, no part exceeding 100m above sea level.

2)

Maximum air temperature 50oC ( 46oC typical).

3)

Minimum air temperature 0oC ( 10oC typical)

4)

Mean maximum summer air temperature, 45oC typical.

5)

Mean maximum exposed sunlight temperature, 75oC

6)

Solar radiation- peak, 1030 Watts/sq.m.

7)

Humidity - 100% humidity is common throughout the year and may occur at air
temperature of 30oC or more.

8)

Rainfall - very low on average. The winter season may bring infrequent very heavy
rainfall.

9)

General atmospheric conditions: A hot atmosphere containing very fine, highly


penetrating dust particles. In parts the atmosphere contains a highly corrosive salt laden
sea mist. Prevailing winds generally from the north west, mostly light but occasionally
gusting in excess of 30 knots

SYSTEM CONDITIONS

The 11kV system has three phase, 3-wire system with star point earthed through
earthing transformer at 66/11KV primary sub-station.

Issue : 2

1)

Nominal Voltage ....................................................................11kV

2)

Maximum Voltage .................................................................12kV

3)

Maximum Symmetrical fault level ..............................................25KA/31.5kA (based


on location in the network)

4)

Limited earth fault current through earthing transformer....4.5KA


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Specification for 11/0.433 kV Dist. Transformers, Dry Type (Cast Resin)

EP-MS-P4/S4-035

5)

Impulse Voltage.....................................................................75kV

6)

Rated Frequency ...................................................................50 Hz


The LV System has 5 wires i.e. 3 Phase + Neutral + Earth. Neutral and earth is directly
shorted at the Distribution Substation end. A consumer earth terminal is provided.

7)

Nominal Voltage.................................................................. 415/240V

8)

Highest Symmetrical fault level............................................44kA

9)

The highest fuse rating(at LV Distribution Feeder Pillars).....400 A

Fault duration is limited by HRC fuses, Type-J to BS 88 (at LV Distribution Feeder Pillars).
4)

APPLICABLE STANDARDS

This Specification makes reference to the following documents:


Transformers
IEC 60076-11

Dry type Power Transformers.

IEC 60076

Power Transformers

IEC 60076-10

Power Transformers Determination of Sound Levels..

IEC 60905

Loading guide for Dry Type Power Transformers.

BS 2562

Specifications for Cable Boxes for Transformers, Flanges, Bushings

BS 6435

Un-filled enclosure for dry termination of HV Cables for transformers

Surface Preparation, Coating & painting Works


ISO 8501-1 to 4

Preparation of Steel Substrates before application of paints and related products.

ISO 8502-1 to 12

Preparation of Steel Substrates before application of paints and related products


Tests for assessment of surface cleanliness.

ISO 8503-1 to 5

Preparation of Steel Substrates before application of paints and related products Surface Roughness Characteristics of Blast-Cleaned Steel Substrates

ISO 8504-1 to 3

Preparation of Steel Substrates before application of paints and related products


Surface preparation methods.

ISO 12944-1 to 8

Corrosion Protection of Steel structures by protective paint systems

ISO 14713

Protection against Iron & Steel Structures Zinc and Al coatings Guide lines

BS 381C 1980

Specification for Colours for Identification, Coding, and Special Purposes.

BS EN ISO 1460

Hot Dip Galvanized Coatings on Ferrous metals Gravimetric determination

BS EN ISO 1461

Hot Dip Galvanized Coatings on Ferrous metals- Specification & test methods

ISO 2081

Electro-plated coatings of zinc with supplementary treatments on iron or steel

ISO 2063

Thermal spraying- Zinc, aluminum and their alloys

BS 2569-2

Sprayed Metal Coatings Protection of Iron & Steel against Corrosion

ISO 4628-1 to 5

Evaluation of Degradation of paint coatings

ISO 9227

Salt spray test

ISO 1519

Paints & Varnishes Bend test

ISO 2808

Paints & Varnishes Determination of film thickness

ISO 2409

Paints & Varnishes Cross cut test

ISO 1520

Paints & Varnishes Cupping test

ISO 6272

Paints & Varnishes Rapid deformation (Impact resistance) test

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Specification for 11/0.433 kV Dist. Transformers, Dry Type (Cast Resin)

EP-MS-P4/S4-035

ISO 6270

Paints & Varnishes Determination of resistance to humidity

ISO 11997

Paints & Varnishes Determination of resistance to cyclic corrosion conditions

ISO 7784

Paints & Varnishes Determination of resistance to abrasion

Other Common Standards


IEC 60529

Degrees of Protection Provided by Enclosures IP Code

IEC 62262

Degrees of Protection Provided by Enclosures IK Code

ISO 3864

Graphical symbols, Safety labels, Safety colours & Safety Signs

IEC 60502

XLPE Power Cables

Fasteners
BS 3692

ISO Metric Precision Hexagonal Bolts, Screws and Nuts.

BS 4190

ISO Metric Black Hexagonal Bolts, Screws and Nuts.

ISO 4042

Fasteners Electroplated coatings

ISO 888

Bolts, Screws and Studs - Nominal Lengths, and Thread Lengths for GP Bolts

5)

GENERAL DESIGN FEATURES


1)

The design, construction & testing of Cast-resin transformers shall be generally in


accordance with IEC 60076-11, unless other-wise specified. Cable boxes, mounting
flanges, bushings shall generally conform to the respective standards mentioned above,
unless other-wise specified.

2)

The transformer shall be fitted inside sheet steel enclosure having IP protection degree of
IP31 with natural air ventilation.

3)

The Transformer or its Enclosure shall not be fitted with any forced ventilation or
exhaust fans. Only the natural air ventilation available in the civil building room shall be
able to provide necessary ventilation needs.

4)

The manufacturer needs to provide necessary calculations for air flow requirements and
sizing details of indoor civil room construction for cooling of transformer with natural
ventilation.

5)

The transformers shall be capable of delivering full rated power continuously, under
specified service and ventilation conditions, without any thermal overloading. The
design & construction of transformer shall be such that, no de-rating factor shall need to
applied on account of specified temperature rise limits, enclosure IP protection, and
ventilation requirements.

6)

The no-load LV output voltage of the transformers shall be 433/250V, when HV side is
applied with 11kV at center tap. This is to provide consumers with a nominal supply
voltage of 415/240V (three phase 4 wire/Single phase 2 wire, 50Hz) on full load, after
permitted system voltage drops.

7) The sub-assemblies of the transformer shall be so designed that they should not un-duly
increase the vibrations or cause resonance. Anti-vibration mounts shall be incorporated to
reduce vibration & noise levels.

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Specification for 11/0.433 kV Dist. Transformers, Dry Type (Cast Resin)

6)

EP-MS-P4/S4-035

RATINGS & CHARACTERISTICS

1) Service conditions & maximum winding temperature rise limits


a) Average of hottest month temperature of cooling air outside enclosure is 350C
b) The maximum temperature of cooling air outside enclosure may exceed 500C any time
c) The relative Humidity surrounding the transformer may reach 100%
d) Frequent Condensation may occur during high humid conditions
e) The surrounding air may contain very fine, highly penetrating, sand dust with highly
corrosive salt laden sea mist.
f) The maximum temperature rises of the windings shall not exceed by 850K over an
ambient temperature of 500C, when fully loaded inside in the specified enclosure, without
forced ventilation.
2) Ratings
a) Rated Power of Transformers

: 500KVA/1000KVA/1600KVA

b) IP protection of Enclosure

: IP31

c) IK protection of Enclosure

: not less than IK7 (2.0 joules)

d) Ventilation

: Natural air cooling-AN (no forced ventilation)

e) Th. Insul. class of windings(HV/LV)

: Class F/F

f) Winding material (HV/LV)

: CU/CU

g) Voltage ratio

: 11000/433V

h) No. of phases

: 3-Phase

i) Connections

: Delta- Star, as per vector group Dyn11

j) Rated frequency

: 50HZ

k) Rated voltage (U)

: 11kV

l) Maximum flux density

: 1.6 Tesla at normal voltage and frequency

m) No-load current

: 1% of transformer rated current

n) Tapping range & steps

: +5% to -5%, in 4-steps each of 2.5%

o) Rated Insulation Levels

Issue : 2

Parameter Name

HV Side LV Side

Rated Voltage(U)

11KV

433/250V (at no load)

Rated Highest Withstand Voltage(Um)

12kV

1.1kV

Rated Lightening Impulse Withstand Voltage


(peak)

75kV

Rated Power frequency withstand voltage

28kV

3kV

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Specification for 11/0.433 kV Dist. Transformers, Dry Type (Cast Resin)

EP-MS-P4/S4-035

p) Guaranteed values of losses (load & no-load), percentage impedances measured at


principal tap and corrected to reference temperature of 750C shall be as mentioned
below.
KVA Rating

Max. No-load
losses*

Max. Load Losses*

% Impedance

500KVA

1050

5100

4.75 10%

1000KVA

1650

8800

5.45 10%

1600KVA

2200

12500

6.00 10%

*Note: The values specified for No-load & load losses are maximum values.
q) The climatic class of the transformers shall conform to: Class C1
r) The Environmental class of the transformer shall conform to: Class E2
s) The Fire behavior class of the transformer shall conform to: Class F1
t) Maximum dimensional limits of Enclosure: 2300 (L) x 1500 (W) x 2300 (H), mm
u) IP protection of HV & LV Cable boxes: IP43
3) Short Circuit Ratings
Verification of transformers ability to withstanding short-circuit conditions, shall be made
through type testing in accordance with IEC 60076-5, at reputed independent laboratories.
a) Thermal ability of the transformers to withstand short circuit current shall be verified for
a duration of 2 sec. The value of ambient temperature shall be considered as not less than
500C for calculation of initial winding temperature.
b) Ability to withstand dynamic effects of short circuit shall be verified by tests (not by
calculation method)
4)

Tapping Range & Tapping Method


a) Off-circuit tapping selection shall be made by the use of bolted links on the HV winding.
The tapping range shall be 5% in steps of 2.5% For total 5 tap positions.
b) Current carrying capacity of the bolted links for tapping shall be capable of withstanding
the rated short-circuits capacity.

5) Magnetic flux density


a) The flux density at any point of the magnetic circuit when the transformer is connected
on normal tap (3) and operating at normal voltage and frequency shall not be more than
1.6 Tesla, and well below the saturation level. Proof of this shall be submitted for
verification in the form of B/AT magnetizing curves of the magnetic core assembly
6)

Thermal insulation Class of windings & temperature rise limits


a) Thermal insulation class of HV & LV windings shall conform to the class-F/F
(Insulation system temperature - 1550C) as defined on IEC 60085.
b) The maximum temperature rises of the windings shall not exceed by 850K over an
ambient temperature of 500C, when fully loaded the transformer inside the specified sheet
steel enclosure with natural ventilation, without forced cooling.

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Specification for 11/0.433 kV Dist. Transformers, Dry Type (Cast Resin)

7)

EP-MS-P4/S4-035

Noise (Sound) Levels

a) Verification shall be done by conducting type test, through reputed independent


laboratory, for sound level measurements in accordance with IEC 60076-10 under
indoor conditions.

b) The maximum values of sound pressure and sound power levels, measured at a distance
of 1 meter from the principal radiating surface, are as mentioned below:
Parameter Details

Maximum values

Unit

500 KVA

8)

1000 KVA 1600KVA

Average A-weighted sound pressure level

LpA

dB(A)

54

57

60

Calculated A-weighted sound power level

LwA

dB(A)

67

71

75

Climatic, environmental and fire behavior classes


a) Special tests for climatic, environmental and fire behavior classes shall be carried out as
per the tests specified in clauses# 26, 27 and 28 of IEC 60076-11 in a reputed
independent testing laboratory.
b) A transformer is considered to be passed these tests, when all the prescribed tests are
conducted on same transformer in the sequence as given in table-5 of IEC 60076-11.
c) The climatic class of the transformers shall conform to: Class C1
d) The Environmental class of the transformer shall conform to: Class E2
e) The Fire behavior class of the transformer shall conform to: Class F1

7)

RATING AND CONNECTION PLATES - MARKING OF TERMINALS


1)

Rating and Connection Plates (as per IEC 60076-11/Cl-9)


Each Transformer, as well as the associated enclosure, shall be fitted with individual
rating plates of weather-proof materials, in a visible position, showing all the items
indicated below. The entries on the plate shall be indelibly marked (that is, by etching,
engraving, stamping, or by a photo-chemical process)
a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
k)
l)
m)
n)

Issue : 2

Dry-Type transformer
Compliance standards reference
Manufacturer Name
Manufacturers serial number
Month & Year of manufacture
KM Contact/Tender number
Insulation system temperature of each winding
Number of phases
Rated frequency
Rated voltage including tapping voltages
Rated current
Connection symbol
Short circuit impedance at 750C
Type of cooling

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Specification for 11/0.433 kV Dist. Transformers, Dry Type (Cast Resin)

o)
p)
q)
r)
s)
t)

2)

EP-MS-P4/S4-035

Insulation Levels
Degree of Protection
Environmental class
Climatic class
Fire behavior class
Total mass with and without enclosure

Marking of Terminals & start of windings


a) HV and LV Terminals shall be identified by characters of a type which cannot be
obliterated, marked on plates of durable and non-corrodible metal securely fixed to a
visible position. Stickers are not acceptable
b) The sequence of markings on HV terminals when read from left-to-right, facing HV
cable box, shall be as: A, B, C
c) The sequence of markings on LV terminals when read from left-to-right, facing LV cable
box, shall be as: c, b, a, n
d) Suitable markings to identify the start and end of windings shall be marked on each
physical winding.

8)

GENERAL CONSTRUCTION AND FITTINGS


1)

Magnetic Core & connecting bus bars


a) The magnetic core shall be constructed from high grade, low watt loss, cold rolled grain
oriented silicon steel sheets, having specific watt loss of not more than 0.95w/kg at 1.7T
and 50Hz, and conforming to IEC 60404-8-7:2008 and IEC 60404-1: 2000.(Note: 1.7T
is used only for the purpose of comparing the grade, but actual design of transformer
shall be made for 1.6T)
b) The construction of yoke and limbs shall be such that best space factor and highest
dimensional accuracy is achieved to ensure low core losses and nose levels.
c) The core shall be coated with high performance surface insulation material(s),
conforming to the requirements of IEC 60404-11, to obtain good insulation resistance
and anticorrosion protection.
d) The clamping structure shall not allow any bolt piercing the core lamination in order to
avoid circulating current in the core and local concentration of the flux in the yoke
e) The limb & yoke core joints shall be interleaved using modern step-lap technology to
achieve optimum conformity of magnetic flux pattern.
f) The core shall be pressed and banded and shall be clamped and bolted at the top and
bottom in such a manner as to ensure that no distortion shall take place when the
transformer is subjected to magneto motive forces equivalent to those which would be
present in the event of a total short circuit being applied across the low voltage terminal
with an infinite power supply at normal voltage and frequency available, at the high
voltage terminals.
e) All bus-bars shall be made of hard drawn high purity electrolytic copper with electro-tin
plating.

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Specification for 11/0.433 kV Dist. Transformers, Dry Type (Cast Resin)

2)

EP-MS-P4/S4-035

Windings
a) The HV windings of the transformers shall be made of high purity electrical grade
copper wire and shall be totally encapsulated in a glass-fiber reinforced resin-cast
insulation. The casting shall be made under vacuum in such a manner that all air shall be
totally evacuated from casting.
b) The casting shall be such that the composite structure shall have sufficient resilience
strength against stresses developed due to differences in co-efficient of thermal
expansions between insulation materials and copper.
c) Laying pattern of HV winding wires shall ensure to achieve superior linear lightening
voltage distribution characteristics.
d) LV windings shall be made of copper foil with impregnated type interlayer insulation.
The interlayer insulation shall be made of solid polyester foil with impregnated fiber
glass film which thermo-sets by curing, or by an equivalent process having same or
higher performance levels.
e) Sufficient numbers of cooling channels shall be provided in both the LV and HV
windings to restrict the temperature rise of the windings within the specified values and
thereby minimizing the damage due to hot spot. The cooling channels are arranged in a
vertical manner and all coils have even surface to minimize dust accumulation and to
give maximum cooling efficiency.
f) The completed winding stack assembly and connections shall have sufficient mechanical
rigidity to ensure no distortion or movement of any one winding, or to any other winding
or section of windings, shall take place when the transformers is subjected to the short
circuit stresses created by a total short circuit at the low voltage terminals with an
infinite power supply at normal voltage and frequency available for two seconds at the
high voltage terminals.
g) Sufficient barriers shall be provided between windings and core, and between HV and
LV windings.
h) The winding insulation shall be such that the transformer may be operated at 155 C
with no deterioration of the insulation properties as per IEC 60076-11 requirements. It
shall comply with the requirements of Class F/F insulating materials.
i) The high voltage and low voltage connections shall be brought out on opposite sides of
the transformer
j) The windings shall be connected Delta Star in accordance with Vector Group reference
Dyn11.
k) All leads or bars from windings to the termination points, shall be rigidly supported.
Stresses on coils and connections must be avoided.
l) The insulation materials used on windings and connections shall be shall be free using
any insulating compounds prone to shrinking or collapse during service life. Further,
there shall not be any joints either in the LV foil or insulation.

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Specification for 11/0.433 kV Dist. Transformers, Dry Type (Cast Resin)

3)

EP-MS-P4/S4-035

Enclosure
a) The Transformer shall be contained in a sheet steel ventilated enclosure suitable for
indoor service. The overall limiting dimensions of the enclosure and fittings attached
there-in shall not exceed the values specified below:
-

Length: 2300 mm
Width : 1500 mm (excluding cable boxes)
Height: 2300 mm.

b) The enclosure degree of protection shall not be less than IP 31 including its bottom
surface. If so desired, number of ventilation louvers may be increased to take care of
ventilation requirements.
c) All side panels (covers) and top of the enclosure shall be removable type using standard
metric spanners. No handles or other aids shall be employed for easy removal of panels.
All bolts & nuts shall be non-corrosive stainless steel/alloy steel.
4)

Fittings & Accessories:


The following accessories are required to be fitted on the transformer:
a) Earthing Terminal
Two stainless steel earthing flags, of size 63x63mm , and 6mm thick each, having hole
suitable for connecting M14 bolt, or an equivalent arrangement shall be provided at
bottom of the transformer frame work on either side. All exposed metallic conductive
non-live parts shall be connected to earth terminals by construction through full earth
fault rated conductors/braids.
b) Lifting Lugs on Total assembly
The transformer with enclosure assembly shall be fitted with two lifting lugs enabling
lifting of transformer and enclosure assembly. The position of the lugs facilitates easy
attachments of lifting slings. The transformer shall be suspended absolutely vertical
when it is lifted by means of the lifting hooks.
c) Lifting (hoist) eyelets on transformer (active part)
Four lifting (hoist) eyelets shall be provided on all four corners (one at each corner) of
upper press-beams/clamp-bars of the transformer, to facilitate lifting of transformer
alone (without enclosure) when required.
d) Haulage holes on under base
Four haulage holes shall be provided on all four corners of lower press-beam/clampingbar (one at each corner).
e) Bi-directional rollers at base
Four bi-directional flat rollers with blocking facilities (as mentioned below) are to be
fitted at base of the transformer, on to which entire load of transformer & enclose
assembly shall be transmitted.
f) Anti-vibration pads and Roller blocking devices
Anti-vibration pads made of polycarbonate material, having capability of carrying loads
of the transformer & enclosure, shall be provided at base to dampen the intensity of

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Specification for 11/0.433 kV Dist. Transformers, Dry Type (Cast Resin)

EP-MS-P4/S4-035

vibrations and avoid resonance. They should also serve as roller blocking devices to
arrest the movement of transformer unit after installation.
g) Rating & Connection Plate, and colour coding
Rating and connection diagram plates with details as described in clause # 5.1 shall be
provided both on transformer and enclosure. Colour coding (Red, Yellow & Blue), with
indelible markings, shall be provided at suitable locations on the frame of active part, to
identify phase of each core, and inside cable boxes to identify phases of HV & LV
terminals.
h) Danger Boards
Danger Boards, prepared as per KM specification # ED-01-400 (Drg # STD-PRT-04)
shall be fixed permanently on all four sides of the enclosure. [Note: Removable labels or
stickers are not acceptable]
i) Viewing Window
A transparent viewing window, of 6 inch x 4 inch size, with 5mm thick clear
polycarbonate sheet shall be fitted on enclosure at front, to view the tapping position of
transformer. This fixture shall have IP 65 protection with necessary gasket(s).
j) Chart of tap-changing link positions
A chart showing the combination of links positions for each tap position shall be
permanently fitted on enclosure at front. The details on the chart shall be indelibly
marked by etching, or engraving, or stamping, or by photo-chemical process (Note:
stickers are not acceptable)

k) Temperature monitoring unit for thermal protection

Issue : 2

1)

At least 2 sets of PT100 based, high accuracy, RTD type PTC Temperature sensors
shall be embedded into to each phase of LV winding.

2)

The sensors & its associated wiring shall be insulated, to avoid occurrence of any
short circuits with the transformer winding. The sensors shall be placed as close as
possible to the hottest spot in the winding.

3)

The insertion of sensors shall be made through capillary tube to enable them to be
replaced whenever necessary.

4)

The first set of the sensors shall be set to give alarm signal at 1400C, and the
second set shall be set to give trip signal at 1500C. These values shall be in
conformity with Class F insulation.

5)

The alarm and trip signals shall be in the form of voltage free relay output
contacts. Each output relay contacts shall have at least 2NO+2 NC and each rated
for 6A@240Vac.

6)

The temperature monitoring unit (i.e Electronic converter with relays and wiring
terminal block) shall be capable of operating in the specified local ambient
conditions. It shall be flush mounted on front side of the enclosure. The unit shall be
capable of operating on 240Vac @50Hz power supply.

7)

The monitoring unit shall have features of circuit-fault indication, storage of


maximum value of temperature, live voltage indication, status of relay positions
with different coloured light indications, reset facility, etc.

8)

The power supply for the monitoring unit shall be connected from transformer LV
output (240Vac, 1-Phase) through suitably rated terminal blocks. The terminal

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block shall have additional spare terminals, to facilitate connecting external power
source (auxiliary source), when required.
9)

All wiring, to and fro, from the temperature monitoring unit shall be routed through
properly clamped and insulated trunking-channels. No wires shall be left loose or
hanging inside the enclosure.

10) The monitoring units shall not cause any false tripping. It shall be sourced from
reputed brands and its source and technical details to be submitted along with
tendering information.
l) Thermometer.

5)

1)

In addition to the temperature monitoring unit as described above, a dial type


thermometer, having nominal dia of 100mm, with stainless steel bezel and casing,
shall be fitted on the transformer (not on enclosure) with suitable sensing element.
The thermometer shall indicate the temperature of the winding and maximum
temperature.

2)

Its dial shall be graduated in degrees Centigrade and cover the range 0C to 160C
with increment marks at not more than 5C intervals. The dial shall be fitted with
pointers to indicate the winding temperature, and maximum temperature value with
a RED pointer. The maximum temperature pointer shall be manually re-settable.
The thermometer shall be located in a safe and suitable place to have clear view.

Corrosion protection and Painting of Enclosure.


1) The definitive guideline documents are BS EN ISO 12944 Parts #1 to 8, & BS

EN ISO 14713. The painting procedure selected by the manufacturer should


clearly indicate its relationship to the appropriate parts and tables of BS EN ISO
12944 and BS EN ISO 14713
2) It is the responsibility of the manufacturer to assess environmental classification, select suitable
surface preparation process, protective paint system, execution and supervision process, in
accordance with above referred standards and requirements.

3) The painting work should render a service life of at least 20 years to the equipment,
withstanding local ambient climatic & environmental conditions.

4) The exact Specification & painting procedure going to be followed by the

manufacturer shall be submitted at time of tender.


5) The manufacturer should posses required laboratory testing equipment, in their

factory, to test the painting work samples in accordance with BS EN ISO 129446. The test reports should be submitted along with each consignment of delivery.
6) The paint work shall nee to pass following tests
a) Measurement of thickness of protective coating (ISO 2808)
b) Specular gloss factor at 60 deg (ISO 2813): 905%
c) Falling weight test (ISO 6272): 1kg/50cm
d) Cross cut test (ISO 2409): classification: 0
e) Cupping test (ISO 1520): 08mm
f) Bending test Cylindrical mandrel test (ISO 1519): 3.0mm
g) Salt spray (fog) test (ISO 7253): 1000hrs

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Specification for 11/0.433 kV Dist. Transformers, Dry Type (Cast Resin)

6)

EP-MS-P4/S4-035

Cable Boxes
1) Cable boxes shall be in accordance with the relevant Drawings no ED/04-035 Fig 1 and
Fig 2 generally comply with the requirements of BS 2562 and, where applicable BS
6435. The details are as explained in APPENDICES-A, B & C.
2) High Voltage and low voltage cable boxes shall be mounted on opposite sides of the
transformer.
3) HV & LV Cable boxes shall be suitable for vertical bottom entry of cables. However LV
cable box shall also have suitable facility (in addition to this bottom cable entry) for top
entry bus-bar connections, when required. [Note: Bus-connections shall be made through
cable box only, they should not be made through top of enclosure directly]

4) The bushing heights of HV and LV shall be 1320 mm from the enclosure base to
centre of bushings assembly.
5) The construction shall be such that the accumulation of water is avoided and the box is
effectively sealed against weather and insects

6) The minimum size of any fixing stud or bolt for securing a front cover plate shall be
M10 mild steel. All bolts used in assembly of cables boxes or enclosure shall be
electroplated for corrosion protection

7) Gaskets, where applicable shall be of nitrile rubber-bonded cork and shall not be less
than 5mm thick. [Note: Neoprene based cork gaskets are not to be used]
9)

QUALITY CONTROL
The manufacturer of the equipment specified shall possess certification, issued by a body
authorized to do so, which indicates that the manufacturing unit operates to a standard equivalent
to ISO 9001. Copies of valid ISO 9001 certificates need to be submitted along with tender
documents.

10)

TESTS
1) General
a) At the time of tender, manufacturers shall submit copies of test certificates, as prescribed
below, issued from reputed independent testing laboratories. All type tests & special
tests are to be carried out on representative specimen transformers essentially of the
same design & ratings.
b) KM reserves the right to verify the original test certificates & reports, if required.
c) Special tests for climatic, environmental and fire behavior classes shall be carried out as
per the tests specified in clauses# 26, 27 and 28 of IEC 60076-11. A transformer is
considered to be passed these tests, when all the prescribed tests are conducted on same
transformer in the sequence as given in table-5 of IEC 60076-11.
d) Each transformer shall be subjected to all routine tests prescribed below, and one set of
routine test report shall be attached with the body of transformer in a strong water-proof
envelope, at the time of delivery.

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2) Type Tests & Special Tests on Transformer.


a)
b)
c)
d)
e)
f)
g)
h)

Lightning Impulse test (type test) as per IEC 60076-3.


Temperature Rise test (type test) as per IEC 60076-2.
Partial discharge tests (routine & special tests) as per IEC 60076-11/Cl-22
Measurement of sound level (special test) as per IEC 60076-10
Short circuit test (special test) as per IEC 60076-5
Environmental test (special test)
Climatic test (special test)
Fire behavior test (special test)

3) Routine Tests on Transformer.


a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
k)
l)

Measurement of winding resistance.(IEC 60076-11/Cl-15)


Measurement of voltage ratio and check of phase displacement (IEC60076-11/Cl-16).
Measurement of short-circuit Impedance and load loss(IEC 60076-11/Cl-17)
Measurement of no load loss and current (IEC 60076-11/Cl-18)
Separate source AC withstand voltage test(IEC 60076-11/Cl-19)
Induced AC withstand voltage test(IEC 60076-11/Cl-20).
Routine partial discharge test (IEC 60076-11/Cl-22.4.1.1)
Transformer Noise level Test at 1meter distance.
Check of vector group by voltmeter method
Measurement of Insulation resistance of LV winding at 2500V, DC
Over-voltage test at 2000V, AC, for 60sec, on secondary wiring & equipment
Measurement of thickness of painting work

TESTING, INSPECTION & DELIVERY

11)

1)

Before commencing the production/manufacturing of 1st lot, against KM tenders, the


manufacturer is obliged to produce samples of Transformer with enclosure and inform
Kahramaa for inspection and acceptance through witnessing factory acceptance tests, and
routine tests.

2)

For every subsequent lot, the manufacturer is obliged to inform Kahramaa, at least 20 days
before dispatch, and obtain clearance for dispatch. KM Engineers have the option of
inspecting & witnessing all factory acceptance tests (FAT), including routine tests, at
manufacturers factory premises for each lot.

3)

Acceptance by KM Engineer(s)/Representative(s) of any Transformer shall not relieve the


manufacturer from any of their responsibilities, guarantees, or from other obligations, to
manufacture the product fully complying with KM specification.

4)

Type tests are to be carried out on specimen Transformer with enclosure, essentially of same
design and ratings, as being offered. Manufacturer is obliged to provide details of test
procedures being followed, to the KM inspection team before commencing factory accepting
tests.

5)

Each Transformer unit need to be subjected to all routine tests at factory before delivery.
Further, each unit may be subjected to inspection on receiving them at DOHA to verify its
healthiness and its conformity with the guaranteed design data.

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EP-MS-P4/S4-035

6)

All tests should be performed in accordance with the latest issue of relevant IEC standards

7)

Three sets (copies) of routine tests & FAT reports to be prepared. One set to be attached
with the body of transformer enclosure, in a strong water-proof envelope. Second copy to be
sent along with delivery note. Third copy to be sent to the end-user department.[This is
mandatory requirement]

8)

FAT report shall include copy of quality control report containing list of check points
verified/inspected at factory against each transformer.

9)

Each delivery note shall include the details of serial number and month/year of
production of each transformer.

10) Both the manufacturing date (i.e month/year) and delivery date should be shown on the
rating plate of each transformer, and the time difference between manufacturing date and
delivery date should not be more than 6-months.
12)

INFORMATION/DOCUMENTS TO BE SUBMITTED BY BIDDERS/MFRS


Each manufacturer/bidder shall submit following information/documents along with their offer
. At least two sets of documents with all details to be submitted.
1)

Technical data-sheets covering all the details as mentioned below.


a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
k)
l)
m)
n)
o)
p)
q)
r)
s)
t)
u)
v)

2)

The following drawings need to be submitted


a)

Issue : 2

Rated power
Rated Voltage ratio, Frequency, & number of phases
Rated insulation levels
IP protection class of enclosure
IK protection class of enclosure
Type of ventilation
Vector group
Thermal insulation class of HV/LV winding
Maximum flux density
No-load current and full load current values
Tapping range and number of steps
No-load and Load losses at 750C
Percentage impedance value at 750C
Winding material HV/LV
Guaranteed values of Winding temperature rise limits
Partial discharge levels
Noise levels
Climatic, Environmental & Fire behavior classes
Weights of transformer with and without enclosure and fittings
Overall sizes(WxHxD) of transformer with and without enclosure
Set values of alarm and trip in temperature monitoring unit.
Resistance values of HV & LV windings

Transformer general layout drawing with enclosure (all views plan, elevation, side
elevation) showing details of all components fitted and all dimensions.

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Specification for 11/0.433 kV Dist. Transformers, Dry Type (Cast Resin)

b)
c)
d)
e)
f)
g)
h)
i)
j)
3)

EP-MS-P4/S4-035

Transformer general layout drawing without enclosure (all views plan, elevation, side
elevation) showing details of all components fitted and all dimensions.
Separate HV cable box drawing with all views and dimensions
Separate LV cable box drawing with all views and dimensions
Separate HV bushing drawing with all views and dimensions
Separate LV cable box drawing with all views and dimensions
Connection diagram showing the sequence of HV & LV+ neutral terminals
Rating plate details
HV & LV terminal connection details
HV & LV cable boxes mounting flange drawings with dimensions

Other details and documents which need to be submitted


a) Original product catalogue (photocopy not acceptable) with all technical details
including all steps of manufacturing.
b) Original product catalogue of temperature monitoring unit (photo copy not acceptable)
c) Installation, Operation & Maintenance, and condition monitoring & trouble shooting
manuals, of transformer
d) Installation, Operation & Maintenance manuals of temperature monitoring unit
e) Ventilation calculations with room sizing and air flow requirements
f) FAT documents& check lists used for testing of transformers at factory

4)

Copies of test reports to be submitted


a)
b)
c)
d)
e)
f)
g)
h)
i)

Type test reports (full reports)


Lightning Impulse test
Temperature Rise test conducted along with enclosure
Partial discharge tests (routine & special tests)
Measurement of sound level (special test)
Short circuit test (special test)
Environmental test (special test)
Climatic test (special test)
Fire behavior test (special test)
Type testing report of HV bushing
Routine test reports

a)
b)
c)
d)
e)
f)
g)

Measurement of winding resistance.


Measurement of voltage ratio and check of phase displacement
Measurement of short-circuit Impedance and load loss
Measurement of no load loss and current
Separate source AC withstand voltage test
Induced AC withstand voltage test
Routine partial discharge test
Test reports of Enclosure painting work

a)
b)
c)
d)
Issue : 2

Measurement of thickness of protective coating (ISO 2808)


Specular gloss factor at 60 deg (ISO 2813): 905%
Falling weight test (ISO 6272): 1kg/50cm
Cross cut test (ISO 2409): classification: 0

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Specification for 11/0.433 kV Dist. Transformers, Dry Type (Cast Resin)

e)
f)
g)
5)

EP-MS-P4/S4-035

Cupping test (ISO 1520): 08mm


Bending test Cylindrical mandrel test (ISO 1519): 3.0mm
Salt spray (fog) test (ISO 7253): 1000hrs

Statement of Compliance / deviation


A statement of compliance or deviation against each clause of this specification
document needs to be submitted. This is very important document, without which the
offer documents shall not be considered.

13)

WARRANTY
Manufacturers need to provide a warranty of minimum 5 years from the date of delivery, or 4
years from the date of installation (whichever is earlier) against each unit supplied.
Any Transformer unit failed while in service, with-in the warranty period, need to be replaced
with new unit free of cost. Further, the manufacturer/supplier need to arrange for carrying-out
fault/abnormality analysis of any units(s) by reputed independent agencies, when required by
Kharamaa and respective abnormality and fault-analysis report(s) to be submitted

14)

DEVIATIONS FROM THE TECHNICAL SPECIFICATION


The bidders are required to attach a separate deviation list to their Technical Offer and include it
in the Technical Package if the offered equipments do not meet the requirements of any clause of
the Specification.
Offers without any deviation list attached to the Technical Offer and included in the Technical
Package shall mean that the offer meets the requirements of the Specifications on all the clauses.
Offers with deviations listed out shall mean that the offer meets the requirements of the
Specification on all the other clauses not included in the deviation list.

15)

RESTRICTIONS ON OUT-SOURCING
1) Out sourcing of any of main components (like magnetic core assembly, making winding
coils, casting of coils, fabrication of enclosure, paint work, etc) related to transformers, need
to be declared in the beginning it- self, before the transformer is pre-qualified or short listed
for tenders. In the event of out-sourcing any of these components, the transformer
manufacturer is responsible for quality of such components and paint work, and need to
produce all documentary evidences as to how they control quality of these components.
2) If any changes proposed by the manufacturer at later stage (after pre-qualification or shortlisting in tenders) in sourcing of these main components or accessories, shall need to be
informed to and obtain KM approval before the changes are made. Non-compliance of this
condition may lead to rejection of goods.

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APPENDIX A
High Voltage Cable Boxes for all Sizes of Transformers
1)

The high voltage cable box shall be in accordance with the requirements of Drawing No.
ED/04-035 Fig 4 and generally be in accordance with BS 2562:1979, and where applicable,
BS 6435.

2)

It shall be air filled and suitable for using heat-shrink terminations with cable entry from
bottom.

3)

The HV bushings shall be of the porcelain type of rating 250 Amps, in accordance with Fig
3 of BS 2562:1979. However similar rated bushings, made of porcelain material,
conforming to IEC 60137 is also permissible, provided its surface profile and terminal
connection shall be suitable for terminating with KM standard Right-Angled Boot type heat
shrinkable cable termination kits.

4)

A brass wiping gland shall be provided in accordance with Fig 32(Size-Y) of BS 2562:1979
suitable for terminating 3 core 70-120 sq.mm XLPE insulated PVC sheathed steel wire
armoured cable to IEC-60502. An armour clamp also shall be provided to fix armour wires
from cable.

5) The cable gland shall not be insulated from the cable box.

Issue : 2

6)

The cable box shall be designed for cables entering vertically from below, and to permit ease
of access for jointing and connecting the cable it shall be so constructed that the cable can
be introduced into the box without threading, with the cores cut to length and the gland and
plate located on the cable sheath. For this purpose, the bottom plate, with gland, shall be
detachable.

7)

IP protection class of the cable box shall be IP43. Two Breathing holes covered with wire
gauze shall be made in the cable box as shown, the degree of protection being IP43. The
same shall apply to a hole situated on the bottom plate of the box, the purpose of which is to
drain condensate.

8)

The HV cable box shall be mounted on enclosure wall through a flange facing "E" in
accordance with Fig 24 of BS 2562:1979.

9)

The minimum clearances of live metal in air shall be as follows:


Between Phases

-- 127 mm

Between Phases and earth

-- 127 mm

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EP-MS-P4/S4-035

APPENDIX B

Low Voltage
500/1000kVA

Cable Terminations and Cable Box for Transformers in the range

1)

The LV Cable Box shall be in general accordance with BS 2562:1979 and, in particular Fig
30 (unfilled boxes) and Fig 16 (cast resin bushings). The arrangement and dimensional
requirements of the attached Drawing ED-04-035 Fig-5 is mandatory.

2)

The box shall be un-filled type, air insulated, and suitable for connecting, a) bottom entry
cable termination, or b) top entry bus-bar connections. If necessary the box may be so
constructed that it may be made of two horizontally split boxes to meet this requirement.

3)

The cable box shall be of Shell Type 114, as defined in Table 11 of BS 2562 (except as may
be modified by Drawing ED-04-035 Fig 2) and its mounting on to the transformer enclosure
shall be through flange connection conforming to flange facing Type F of BS 2562.

4)

Three 12mm diameter breathing holes covered with fine wire gauze shall be made
equidistant along the stepped underside of the box. The degree of protection shall be IP43.
The same shall apply to a hole situated on the bottom plate of the box, the purpose of which
is to drain condensate.

5)

To accommodate bottom entry of the cables, removable bottom plate shall be provided. The
bottom plate shall have holes diameter for glands to be minimum 70 mm each.

6)

The cables will be single core, stranded compacted copper conductor, up to 630 sq. mm,
XLPE insulated, PVC Inner sheath, and copper wire armoured, PVC over-sheath to IEC
60502. There shall be two cables per phase. Terminations will be by heat shrink techniques.

7)

Seven numbers of Brass wiping glands conforming to size-X of BS 2662 shall be


fitted at bottom of the gland plate. Armour clamps shall be provided to each gland.

8)

The low voltage bushing shall be of the cast resin assembly type for use up to 1.1kV, as
shown in Fig 16 of BS 2562: 1979. The bus-bars shall be of high conductivity electrolytic
copper and all bus-bar lengths, including that of neutral shall be same.

9)

The cable cores shall be connected to the bushing bus-bars using 4 hole compression lugs as
per the cable size shown in Table B3.

10) The minimum clearances of live metal in air shall be:


Between Phases
Between Phase and earth

---

26mm
20mm

11) Drawings shall be submitted for approval at tender stage.

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APPENDIX C

Low Voltage Cable Terminations and Cable Box for 1600 KVA Transformers
1)

The low voltage Cable Box shall be in general accordance with BS 2562:1979 and, in
particular Fig 30 (unfilled boxes) and Fig 16 (cast resin bushings). The arrangement and
dimensional requirements of the attached Drawing ED-04-035 Fig-2 is mandatory

2)

The box shall be un-filled type, air insulated, and suitable for connecting, a) bottom entry
cable termination, or b) top entry bus-bar connections. If necessary the box may be so
constructed that it may be made of two horizontally split boxes to meet this requirement

3)

The cable box shall be of Shell Type 114, as defined in Table 11 of BS 2562 (except as may
be modified by Drawing ED-04-035 Fig 5) and its mounting on to the transformer enclosure
shall be through flange connection conforming to flange facing Type F of BS 2562

4)

Three 12mm diameter breathing holes covered with fine wire gauze shall be made
equidistant along the stepped underside of the box. The degree of protection shall be IP43.
The same shall apply to a hole situated on the bottom plate of the box, the purpose of which
is to drain condensate

5)

To accommodate bottom entry of the cables, removable bottom plate shall be provided. The
bottom plate shall have holes diameter for glands to be minimum 70 mm each.

6)

The cables will be single core, stranded compacted copper conductor, up to 800 sq. mm,
XLPE insulated , PVC Inner sheath, and copper wire armoured, PVC over-sheath to IEC
60502. There shall be two cables per phase. Terminations will be by heat shrink techniques

7)

Seven numbers of Brass wiping glands conforming to size-X of BS 2562 shall be fitted at
bottom of the gland plate. Armour clamps shall be provided to each gland

8)

The low voltage bushing shall be of the cast resin assembly type for use up to 1.1kV, as
shown in Fig 16 of BS 2562: 1979 (except as may be modified by Drawing ED-04-035 Fig
5, and the thickness of bus-bar shall be 20mm). The bus-bars shall be of high conductivity
copper and lengths of all bus-bars including that of neutral shall be same.

9)

The cable cores shall be connected to the bushing bus-bars using 4 hole compression lugs as
per the cable size shown in Table B3

10) The minimum clearances of live metal in air shall be:


Between Phases
Between Phase and earth

---

26mm
20mm

11) Drawings shall be submitted for approval at tender stage.

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EP-MS-P4/S4-035

TABLE B1 (Details of Cable boxes)

S.No

Description

HV Box

LV Box

12kV

1.1kV

Rated Voltage

No of Poles

No of Glands

Gland Size

Size-Y, BS: 2562

Size-X, BS: 2562

Size of Cables

3Cx70-120mm2

1Cx300 to 630mm2 up to 1000KVA


1Cx800mm2 for 1600KVA
1700A for 500/1000KVA

Bushing Assembly

250A - porcelain

Bushing Type

Porcelain as per Fig.3, BS: 2562

Cast resin assembly as per Fig.16 BS 2562

Type of Cable

CU/XLPE/SWA/PVC to IEC-60502

CU/XLPE/CWA/PVC to IEC-60502.

Type of Box

Dry type, un-filled using heat shrink


terminations.

Dry type, un-filled using heat shrink


terminations.

10

Cable entry

Vertically from below

Vertically from below

11

Mounting flange

Face flange- E

Face Flange -F

12

Box shell No

114

2500A for 1600KVA

TABLE-B2 (Minimum clearances in the cable boxes)

Voltage

Live metal to earth


Distance, mm

Phase to Phase Distance, mm

Distance to earth over surface of


bushing, mm

433V

20

26

26

11kV

127

127

76

TABLE-B3(No & Size of Cable in LV Cable Box)

Transformer Rating

No. of LV Cables

Size of LV Cables sq.mm

500 KVA

1Cx300 mm2

1000 KVA

1Cx630 mm2

1600 KVA

1Cx800 mm2

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