Professional Documents
Culture Documents
VOLUME II
PART-6
Technical Book Serial No.
MPPTCL/TECH/PROC/06/July13
Description
Technical Book
Serial No.
Part-1
MPPTCL/TECH/
Part-2
Part-3
Part-4
Part-5
Part-6
Part-7
Part-8
PROC/01/JULY13
MPPTCL/TECH/
PROC/02/JULY13
MPPTCL/TECH/
PROC/03/JULY13
MPPTCL/TECH/
PROC/04/JULY13
MPPTCL/TECH/
PROC/05/JULY13
MPPTCL/TECH/
PROC/06/JULY13
MPPTCL/TECH/
PROC/07/JULY13
MPPTCL/TECH/
PROC/08/JULY13
MPPTCL/TECH/
PROC/09/JULY13
MPPTCL/TECH/
PROC/10/JULY13
PART-6
TECHNICAL SPECIFICATION FOR 132/33 KV, 63 MVA
POWER TRANSFORMERS
Please note that the modifications in technical specifications
are indicated in Appendix-1, enclosed in Volume-I of the
Tender document.
Contents
Description of document
Technical specification for transformer
Page No.
1-67
Annexure II
Schedule of Inspection
Windows
Annexure V
Schedule of Valves
68-70
71-75
76-78
79
80-81
82-84
85
Annexure VII
- Calculations required to be
furnished
86-89
Annexure VIII -
Annexure IX
95
Annexure X
96
Annexure XI
Appendix I
Appendix II -
Technical particulars to be
filled-in by bidder
90-94
97-100
101-102
103
104-105
SCOPE
1.1
This specification covers design, engineering, manufacture,
assembly, stage inspections and testing before
supply
and delivery
including unloading on plinth at our substation sites located anywhere in
the state of Madhya Pradesh, of the 132/33KV, 63 MVA three phase
transformers complete with all fittings, accessories, associated equipment
including oil for first filling including wastage & 10% extra of that quantity
specified herein which are required for efficient and trouble free operation
as specified hereunder.
1.2
It is not the intent to specify completely herein all the details of
the design and construction of equipment. However, the equipment shall
conform in all respects to high standards of engineering, design and
workmanship and shall be capable of performing the duties specified
herein. The offered transformers shall be complete with all components
necessary for their effective and trouble free operation. Such components
shall be deemed to be within the scope of Bidders supply irrespective of
whether those are specifically brought out in this specification or not. The
transformers should be free from Polychlorinated Biphenyls
(PVB/PCB).
1.3
The Purchaser will interpret the meanings of drawings and
specification and shall have the power to reject any work or material
which,
in
his judgment is not in accordance therewith. The offered
transformers shall be complete with all components necessary for their
effective and trouble free operation. Such, components shall be deemed to
be within the scope of Bidders supply irrespective of whether those are
specifically brought out in this specification and/or the commercial order or
not.
2.0
STANDARDS
2.1
The transformers and associated accessories shall conform to
the latest issues/amendments of standards as given below, and report of
the committee for standardization of the parameters and specification of class
132 KV equipment, except to the extent explicitly
modified
in
this
specification. Transformers conforming to any other authoritative standards
meeting better quality and ensuring better performance are also acceptable.
Bidder shall specifically indicate deviations if any from the INDIAN
STANDARDS.
MPPTCL/TECH/PROC/06/JULY13
Page 1 of 105
Volume-II, Part-4
THE APPLICABLE INDIAN/INTERNATIONAL STANDARDS FOR POWER
TRANSFORMERS AND ASSOCIATED ACCESSORIES ETC.
INDIAN
STANDARD
NUMBER
TITLE
IS-2026
Power Transformers
(Part 1 to 5 )
CBIP PubliManual on Power Transformers
cation
No.295
IS-335
Insulating oil for transformers
IS1866Electrical maintenance and Supervision
2000
of mineral insulating oil in equipment.
IS-2099
Bushings for alternating Voltage above
1000V.
IS-2312
Fans (Cooler fans)
IS-2705.
Current Transformers.
IS-325.
Three phase Induction motors.
IS-375 &
Marking & arrangements for switch
IS-996
gear, bus bars, main connections &
auxiliary wiring.
IS-3637.
Gas & oil operated relays.
IS-10028
Code of practice for installation and
(Part 1to3)
maintenance of transformers.
IS-2147.
Degree of protection provided by
enclosures for low voltage switch gear
and control.
IS-5.
Colours for ready mix paints.
IS-6272
Industrial cooling fans.
DOC.ETD16
Draft standard by BIS for revision of IS(3703)
6600 for Guide for loading of oil
immersed transformers.
OLTC
IS 8478
Application Guide for OLTC
IS 10561
Application
Guide
for
Power
Transformer.
IS 13964
Method of measurement of Transformer
Sound levels.
IS 2071
Methods of High Voltage Testing
(Part 1 to 3)
IS 6209
Methods
for
Partial
Discharge
Measurements
IS 2165
Insulation Coordination
IS 5561
Terminal connectors
MPPTCL/TECH/PROC/06/JULY13
INTERNATIONAL
AND
INTERNATIONALLY
RECOGNISIED
STANDARD
IEC-60076(Part I to
5)
IEC-296,BS-148.
IEC-60137(2008)
IEC 60044
IEC-34.
IEC 60529,IEC60947
IEC 60354
IEC 60214
IEC 60542
IEC 60076-8
NEMA-TR1
IEC 60060
IEC 60270
IEC 60071
Page 2 of 105
Volume-II, Part-4
INDIAN
STANDARD
NUMBER
IS-5553
IS:335
IS -1886
INTERNATIONAL
AND
INTERNATIONALLY
TITLE
RECOGNISIED
STANDARD
Short Circuit Current calculation of IEC 865(part I & II)
effects
Shunt
Reactors,
Neutral/Earthing IEC 60289
Reactor and Arc Suppression Coil
Insulating oils for transformers and IEC:60296, BS:223
switchgears
Code of practice for installation and
maintenance of transformers.
Supervision and Maintenance guide for IEC 60422
Mineral Insulating Oil in Electrical
Equipment
Method of Sampling of Liquid dielectrics
IEC 60475
Guide for the Sampling of Gases and of IEC 60567
Oil from Oil-filled Electrical Equipment
for the Analysis of Free and Dissolved
Gases
Digital Recorders and Software for High IEC 61083
Voltage Impulse testing
Specification for radio disturbance and CISPR 16
immunity measuring apparatus
Guidelines for conducting design reviews Cigre Publication 202
for transformers 100 MVA and 123 kV
and above.
Metal oxide surge arrestors without
IEC 99-4
gaps
Selection and application
IEC 99-5
recommendation
Indian Electricity Rule 1956
2.2
In case equipment conforms to other International standards which
ensure equivalent or better performance than specified under cl 2.1 then
the English version of such standards or the relevant extracts of same shall
be forwarded with the bid and the salient features of comparison shall be
brought out separately.
2.3
The electrical installation shall meet requirements of Indian
Electricity Rules, 1956 and IS-1886,"Code of practice for installation &
maintenance of Transformers" as amended till date.
2.4
It has been experienced that the weight of core lamination, weight of
copper, weight of steel, weight of Transformer Tank along with Fittings and
Accessories and quantity of oil for first filling including wastage & 10% extra
of that quantity, total weight of core + winding after assembly and total
weight of transformer are indicated in the technical bid by the manufacturers
MPPTCL/TECH/PROC/06/JULY13
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Volume-II, Part-4
on tentative basis and at the time
of submission of drawing, wide
variations in these quantities take place. This is not in order and it will
be obligatory
on the part of the Manufacturer to ensure that all these
details are worked out carefully and only correct figures after proper design
are offered in the technical bid. It may be noted that at the time of
submission of final drawings, variation in these weights beyond the limits of
(+) 5% shall not be permitted.
2.5
It will also be obligatory on the part of the manufacturer to furnish
details of calculations for quantity (weight & size) of core material, quantity
(weight & size) of copper material, calculations for thermal and dynamic
short
circuit withstand capability of transformer, calculations for pressure
relief valve, adequacy of size of AIRCELL Bag, volume of oil for adequate
cooling with calculations of size of conservator and other details as called
for in the specification. Furnishing of these calculations along-with technical
bid is a must. All the data should be supported with calculation details. In
addition, calculations for no. of thermosyphon filter and their adequacy be
furnished.
2.6
Interconnection : The transformers are meant for service as
interconnecting transformers and shall be capable of being energized either
from 132 KV side or 33 KV side. The power transformer shall be capable of
being loaded at rated power on the 132 KV and 33 KV sides at its full rating
(lagging or leading or mixed load). On Load Tap Changer shall be suitable for
such operation. The OLTC shall be suitable for bidirectional flow of power.
3.0
SERVICE CONDITIONS
3.1
Climatic Conditions : The transformers and its accessories to be
supplied against this specification shall be suitable
for satisfactory
continuous operation under the following tropical conditions.
1.
Location
2.
3.
4.
5.
6.
7.
8.
9.
Volume-II, Part-4
Moderately hot and humid tropical climate, conducive to rust and
fungus growth. Tropical Protection Shall conform to IS:3202 titled climate
proofing of electrical equipments and BS: 1014 : titled protection of
electrical power equipments against the climatic condition.
The
transformer tank fittings and radiators including all accessories shall be
designed to withstand seismic acceleration equivalent to 0.3 g. Special
precautions shall be taken to prevent mal-operation of Buchholz relay under
such condition.
3.2
Auxiliary Power Supply : Auxiliary electrical equipment shall be
suitable for operation on the following supply system.
a.
Power Devices
(like drive motors)
b.
DC
Alarm, 110volts DC, ungrounded 2wire .
control
&
protective
devices
c.
Lighting.
AC supply
ii)
DC supply
4.1
Duty Requirements
a)
shall
perform
The transformers and all its accessories like CTs etc., shall
be designed to withstand without injury, the thermal and
mechanical effects of any external short circuit to earth and of
short circuits at the terminals considering infinite bus
arrangement of values specified as under :
132KV 33KV -
b)
supply
MPPTCL/TECH/PROC/06/JULY13
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Volume-II, Part-4
basis without exceeding the temperature limits specified in
clause 6.0.
The transformer shall be capable of being operated without
danger on each tapping at the rated KVA with specified
voltage variation
corresponding
to the voltage of
that
tapping with normal temperature rise. The design adopted to
achieve this shall be indicated in detail in the Bid.
Transformer shall be capable of operating under the
natural cooled condition up to the specified load i.e. as ONAN
rating. The forced air cooling equipment shall come into
operation by pre-set contacts of winding temperature
indicator and the transformer shall operate as a forced air
cooled unit i.e. as ONAF. Cooling shall be so designed that
during total failure of power supply to cooling fans the
transformer shall be able to operate at full load for Ten(10)
minutes without the calculated winding hot spot temperature
exceeding 140 deg.C. Also stopping of two cooling fans should
not have any effect on the cooling system. Transformers fitted
with two coolers (cooling banks) each capable of dissipating
50 per cent of the loss at continuous maximum rating shall be
capable of operating for 20 minutes in the event of failure of
the blowers
associated
with one
cooler, without the
calculated winding hot spot temperature exceeding 140oC at
continuous maximum rating.
c)
4.2
4.2.1
The transformers shall be designed with particular attention for
suppression of maximum harmonic voltage especially the third and fifth so
as
to eliminate wave form distortion
and minimize interference with
communication circuits.
4.2.2
The
noise
level, when energized at
normal
voltage
and
frequency with fans running shall not exceed, when measured under standard
conditions, the values specified in NEMA,TR-I.
4.3
Stresses : Transformer shall be capable of withstanding Electrical,
thermal and mechanical stresses on any winding caused by forces due to
symmetrical or asymmetrical external fault on any winding .
4.4
4.4.1
The transformers shall be suitable for continuous operation for a
frequency variation of (+) plus (-) minus 4% from normal 50Hz without
exceeding the specified temperature rise. For considerations
of over
MPPTCL/TECH/PROC/06/JULY13
Page 6 of 105
Volume-II, Part-4
fluxing, the transformer shall be suitable for
values of over fluxing factor up to 1.1.
V
FN
The over fluxing factor being { -x -- }
VN
F
continuous operation
for
4.4.2
The working flux density shall not exceed 1.65 Tesla for offered no
load losses and the maximum flux density in any part of core and yoke at
110% rated voltage combined with (-) 4% frequency variation
shall
preferably not exceed the value of 1.90 Tesla as per CBIP manual no 295.
For manufacturing of Power transformer, core laminations
of various
specifications are available and therefore while selecting the working flux
density, the Bidders will have to comply with the requirements of cl.4.4.1 &
4.4.3.
4.4.3
For the selected flux density, the transformer shall have
minimum of following over fluxing capabilities , such that while meeting
the above requirement saturation of transformer core shall not take place
under any circumstances.
Transformer shall accept, without injurious
heating, combined voltage & frequency fluctuation, which produces the
following over fluxing conditions :
Over Fluxing
Factor
1.50
1.40
1.25
1.10
Period
Less than 2 seconds
5.0 seconds
60 seconds
Continuous
The Bidder shall also indicate 160% & 170% over voltage/over
fluxing withstand capability period. Over fluxing withstand characteristics up
to 170% shall be submitted along with the bid.
4.4.4
Detailed calculations for maximum flux density and magnetizing
current for core material
shall
be furnished to
substantiate
the
above requirement. The Bidder shall enclose details of Core Material with
thickness of lamination, type designation and source of raw material and its
characteristic curves. All characteristic curves of material including Voltage Vs
Flux Density and Loss per Kg Vs Flux Density are to be enclosed with Bid
clearly indicating Flux Density selected for calculation of core losses (No load
loss). On the basis of these data, for the Flux Density and core material
chosen verification of Saturation Flux Density shall be done
by the
purchaser, to know the margin considered in operating Flux Density .
4.4.5
The maximum current density for design of power transformers
within specified limits of transformer losses shall not exceed the limits of 300
amps per sq.cm.
4.4.6
All other requirement of magnetic circuit shall be as per latest issue
of CBIP Manual no 295.
MPPTCL/TECH/PROC/06/JULY13
Page 7 of 105
Volume-II, Part-4
4.4.7
The
transformers shall be either core type
or
shell
type
construction, oil immersed, ONAN/ONAF with external heat exchangers
and shall be suitable for outdoor service as inter connecting and/or stepdown transformers suitable
for
parallel operation
with
the existing
transformer having tertiary winding already in service at the EHV substation
where these transformers are to be commissioned. The rating and electrical
characteristics of the transformers shall be strictly as specified in this
specification. For matching the parameters required for parallel operation with
existing unit, details shall be intimated to successful Bidder.
4.5
All the transformers shall be suitable for continuous operation with
frequency variation of +/- 4% from normal 50 Hz . Combined voltage &
frequency variation should not exceed the rated V/f ratio by 10 %.
5.
INSULATION
5.1
Impulse & Power Frequency Voltage Withstand Values : For
rated system voltage of 33KV & 132KV following minimum power frequency
and impulse withstand voltage should be offered for the windings.
System
Voltage
Highest
System
Voltage
Power Frequency
Withstand
Voltages
Impulse
Withstand
Voltage
33KV
36KV
95KV rms
250KVp
132KV
145KV
230KV rms
550KVp
5.2
The HV winding of the transformers shall have graded
insulation. The insulation class of the neutral end of the winding
shall be graded to 95 KV. The 33KV winding shall have full insulation
for 33KV i.e. 250 KVp impulse and 95KVrms power frequency.
6.0
TEMPERATURE RISE : Each transformer shall be capable of
operating continuously at its normal rating & 10% over load condition
without exceeding temperature limits as specified below. The maximum
ambient temperature shall be taken as 50 degree C and type of cooling be
suitably adopted to limit the temperature rise within the safe limit of
operation.
Type Of Cooling
Temperature-Rise
Windings
o
Oil
50 C
45oC
50oC
45oC.
7.0
FREQUENCY : All the transformers shall be suitable for continuous
operation with a frequency variation of + 4% to -4% from normal 50 Hz
without exceeding the specified temperature rise.
MPPTCL/TECH/PROC/06/JULY13
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Volume-II, Part-4
8.0
IMPEDANCE : The percentage impedance of the power transformer
shall be 10% on 63 MVA base. Bidders shall indicate the
guaranteed
impedance, tolerances and also the impedance on all taps for the offered
transformers. Impedance shall include positive and zero sequence and shall
be expressed in terms of the branches of the star connected equivalent
diagrams on all the specified MVA base and the range shall be given for each
branch of the equivalent circuit turn. It may be noted that if required the
percentage impedance should be designed identical to the existing
transformer of any make in case parallel operation is desired. The
IS
tolerance on all matching taps are acceptable. Confirmation regarding
requirement of parallel operation should be given in the Bid.
It may be noted by the Bidders that for the purpose of matching
impedance of transformer, included in scope of this Bid, between 132KV &
33KV windings,
the Bidders
are not permitted to use reactor or
reactor/capacitor assembly. The design of the main winding should take care
of the requirement of impedances as specified in this Bid document and for
this purpose, no reactor or reactor/capacitor should be used.
9.0
MAXIMUM LOSSES:
9.1
Maximum Losses : While the Bidders may offer their own design, it
may be noted that the transformer losses at 75 deg. C. at rated output,
rated Voltage and rated frequency should not exceed the following maximum
limits which include tolerances as per IS :
a)
25 KW
Page 9 of 105
Volume-II, Part-4
11.0
CONSTRUCTION DETAILS : The features and construction details
of power transformer shall be in accordance with the requirements stated
hereunder
11.1
Tank
(A) As required in CBIP specification, the tank shall be of Bell type
construction for 63 MVA transformers covered under this
specification. Top cover of Bell type construction shall be
welded to the tank body
(B) Tank shall be of welded construction and fabricated from
tested quality low carbon steel suitable for welding & of
following minimum sheet thickness.
Tank cover - 20 mm, sides including inspection covers - 10
mm , Base - 20 mm.
(C) All seams and those joints not required to be opened at site
shall be factory welded and wherever possible they shall
be double welded. After completion of tank construction and
before painting, 'Dye Penetration Test' shall be carried out on
welded parts of jacking bosses, lifting lugs and all load
bearing members.
(D) Tank stiffeners shall be provided for general rigidity and these
shall be designed to prevent retention of water.
(E)
(ii)
torr
in
transformer
(G) The shields shall be such that no magnetic fields shall exist
outside the tank. They shall be of magnetically permeable
material. If required impermeable shields shall be provided
at the coil ends. Tank shield shall not resonate when excited at
the natural frequency of the equipment.
(H) The tank shall be provided with :
(i)
MPPTCL/TECH/PROC/06/JULY13
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Volume-II, Part-4
(ii)
(J)
(i)
(ii)
The design of the tank, lifting lugs shall be such that the
complete transformer assembly filled with oil can be lifted with
the use of these lugs without any damage or distortions.
MPPTCL/TECH/PROC/06/JULY13
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Volume-II, Part-4
(M) For the complete transformer we have clearly brought out our
requirement of various types of valves in Annexure V
enclosed brings out details of type, size and quantity of valves
which are to
be provided at various locations. This
requirement has to be confirmed by the Bidders without any
deviation.
(N) It may be noted that all gasketted joints shall be grooved one
using O rings of nitrile rubber or better, such as the joints
between bushing turret and bushing flange, inspection covers
of inspection windows and all other openings provided for the
purpose of inspection of internal parts of the transformer etc.
The main bell tank gasket between upper tank and bottom
tank shall be single piece O ring cord/gasket of nitrile rubber
or material of better quality. The gasketting arrangement shall
be grooved one with proper stopper to avoid over
compression. It is to be noted that one additional set of
gaskets shall be delivered by the tenderer alongwith
transformer
to replace the used gaskets at the time of
erection of the unit.
(O) One detachable bolted type mild steel (MS) ladder with anticlimbing arrangement shall be provided. Ladder for climbing
up to & over top cover of power transformers shall be
mechanically sturdy enough to bear the load of healthy
maintenance staff without any shake/jerks. The arrangement
shall not be detached after erection and commissioning of the
unit, hence shall be provided with padlock locking arrangement
for anti-climbing device. On the upper top of the ladder,
provision for support shall be
made. However, the
arrangement of the ladder shall be to purchasers approval.
Collapsible ladder shall not be acceptable to us.
(P)
11.2
Tank Cover
(a)
rain
(b)
Inspection cover/man
Annexure-IV.
per
(c)
(d)
Bushings,
turrets,
covers
of
inspection
openings,
thermometer, pockets etc., shall be designed to prevent
ingress of water into or leakages of oil from the tank.
MPPTCL/TECH/PROC/06/JULY13
holes
shall
be
provided
as
Page 12 of 105
Volume-II, Part-4
11.3
11.4
(e)
(f)
Undercarriage
(a)
(b)
(c)
(d)
The transformers are to be provided with flanged bidirectional wheels and axles. These shall be so designed as
not to deflect excessively to interfere with the movement of
the transformer. Wheels shall be provided with suitable
bearings which shall be rust and corrosion resistant.
Fittings for lubrication shall also be provided.
(b)
(c)
(d)
MPPTCL/TECH/PROC/06/JULY13
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Volume-II, Part-4
11.5
11.6
To
prevent
transformer movement during earthquake,
clamping device shall be provided for fixing transformer to the
foundation. The Bidder shall supply necessary bolts for
embedding in the concrete foundation. The arrangements
shall be such that the transformer can be fixed
to or
unfastened from these bolts as desired. The fixing of the
transformers
to the foundations shall be designed
to
withstand seismic events to the extent that a static co-efficient
of 0.3g. applied in the direction of least resistance to that
loading will not cause the transformer or clamping devices as
well as bolts to be over stressed.
(b)
Conservator Tank
(a)
(b)
(c)
(d)
(e)
(f)
to
MPPTCL/TECH/PROC/06/JULY13
Page 14 of 105
Volume-II, Part-4
(i)
11.7
Tank Earthing Arrangement : Two earthing pads complete with
two number tapped holes M10 bolts plain and spring washer suitable for
connection to 50X8 mm GI flat shall be provided each at position close to
two diagonally opposite bottom corners of tank. Earthing strips up to the
ground level and its connection with station earth pit shall be provided by the
Bidder.
11.8
Pressure Relief Device : A minimum of 3 (three) number
of pressure relief devices of reputed make and reliable quality shall
be provided on each transformer and these shall be mounted
preferably on the tank cover above each phase winding. Bidders must
submit calculations to prove that the no and capacity of pressure relief device
with location of each PRV provided on the transformer will adequately meet
our requirement. The quantity of three numbers is on the basis that two
numbers will be required as per design calculation and one number additional
PRD shall be provided from the point of view of additional safety.
Constructional and design details of pressure relief device must be furnished
and it should be proved by calculation that the size and operating pressure
setting of pressure relief device is adequate, considering the rating of the
transformer and quantity of oil
in the transformer. Furnishing of this
information is a must. These PRD's shall be of sufficient size for rapid
release of any pressure that may be generated in the tank and which may
result in damage to the equipment. The device shall operate at a static
pressure of less than the hydraulic test pressure of transformer tank. It
shall be mounted directly on the tank. One set of electrically insulated
contacts
shall be
provided
for
alarm & tripping along-with the
recommendations.
11.9
Relays
11.9.1
Buchholz Relay : A double float type Buchholz relay along with
suitable moulded type cover to avoid ingress of moisture/ rain water shall be
provided. All the gases evolved in the transformer shall collect in this relay.
The relay shall be provided with a test cock suitable for a flexible pipe
connection for checking its operation and for taking gas sample. A copper
or stainless steel tube, shall be connected from the gas collector to a
valve located about 1200mm above ground level to facilitate sampling of
gas while the transformer is in service. The device shall be provided with
two electrically independent ungrounded contacts, one for alarm on gas
accumulation and the other for tripping on sudden rise of pressure. The
contacts of relay shall be properly housed, sealed and gasketted to make the
arrangement water proof. Entry of moisture/water in the contact chamber
needs to be eliminated. Cable entry to terminal box of buchholz relay should
be made through bottom of relay.
11.9.2
Oil Surge Relay (OSR) : From our past experience, it is found
that undesired tripping of Power Transformers is occurring on oil surge relay
MPPTCL/TECH/PROC/06/JULY13
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Volume-II, Part-4
(OSR)and Buchholz relay operation actuating due to accumulation of water
inside relay pockets. The water accumulation takes place through entry
point of cable gland. In view of above, the design and placement of Alarm &
trip contact assembly of OSR and Buchholz Relay should be improved to
take care of the following requirements:
(a)
(b)
Temperature Indicator
(ii)
Image coil.
Calibration device.
MPPTCL/TECH/PROC/06/JULY13
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Volume-II, Part-4
Note
11.11
(b)
(c)
(d)
(e)
(f)
(b)
(c)
to
all
(d) The core shall be provided with lugs suitable for lifting complete
core & coil assembly of transformer.
(e)
MPPTCL/TECH/PROC/06/JULY13
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Volume-II, Part-4
during
transport, installation, service
and
adequate
provision shall be made to prevent movement of core &
winding relative to tank during these
conditions. The
location,
size and material of belting shall
be
clearly
indicated in drawing which shall be submitted with Bid.
Bolted type core construction shall not be acceptable.
(f)
be
(g)
(h)
(i)
The maximum flux density in any part of the core and yoke at
rated MVA, 110% voltage and (-) 4% frequency at any tap
shall not exceed 1.90 Tesla. The Bidder shall
provide
saturation curve of the core material proposed to be used
and calculations to demonstrate that the core is not over
fluxed under stringent condition of transformer operation.
(j)
(k)
(l)
from the
marketing
Page 18 of 105
Volume-II, Part-4
(n)
11.12
Windings
(a)
(b)
(c)
(d)
(e)
(f)
(g)
(h)
MPPTCL/TECH/PROC/06/JULY13
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Volume-II, Part-4
develop the full electrical strength of the winding. All materials
used in the insulation and assembly of the winding shall be
insoluble, non-catalytic and chemically inactive in the hot
transformer oil and shall not soften or otherwise be adversely
affected under the operating conditions.
(i)
(j)
(k)
MPPTCL/TECH/PROC/06/JULY13
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Volume-II, Part-4
v) Bill of entry certificate by customs.
(l)
(m)
(o)
11.13
Bushings
(a)
(b)
(c)
MPPTCL/TECH/PROC/06/JULY13
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Volume-II, Part-4
the full flashover strength will be utilized
adequate phase clearance shall be realized.
S.
N
o
1
2
and
the
(d)
(e)
(f)
(i)
(g)
All bushings shall have puncture strength greater than the dry
flashover value.
(h)
(i)
Nomin
al
Syste
m
Voltag
e
132KV
33KV
Voltage
Class
Of
Bushing
Curre
nt
Rating
Impulse
Withsta
nd
Voltage
(Kvp)
145KV
72.5KV
1250A
2000A
650
325
1min.Po
wer Frequency
Withstan
d Voltage
Kv(rms)
275
140
Creepa
ge
Distanc
e
in mm
3625
1813
Clearance
in mm
Ph to
Ph.
Ph to
E
1430
700
1270
660
(k)
MPPTCL/TECH/PROC/06/JULY13
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Volume-II, Part-4
to
decide
the
actual
gap
setting.
recommendations are also invited in this respect.
(l)
Bidder's
(ii)
(p)
(q)
(r)
(s)
(t)
MPPTCL/TECH/PROC/06/JULY13
for
Page 23 of 105
Volume-II, Part-4
size of the LV winding lug shall be of suitable rating to match
with the maximum load current of the transformer to be fed
through extreme tap of OLTC meeting requirements of IS6600. In this regard, the clamping arrangement of LV
winding with two lugs having two holes with two hole
terminals on counter part of the bushing pad are not
acceptable. In case of such arrangement, it will have to
be ensured that the counter part of winding lead/lug i.e.
bushing terminal is with four holes or vice versa.
11.14
(b)
(c)
(d)
(e)
11.15
Terminal Marking
: The terminal marking and their
position shall be in accordance with IS:2026.
physical
11.16
The positioning of HV & LV bushings shall be such that skew
jumpering is avoided. The middle phase primary & secondary bushing center
line shall be parallel to side axis of the transformer body.
12.0
EARTHING ARRANGEMENT
12.1
NEUTRAL EARTHING ARRANGEMENT
: The neutral terminal
of the star connected HV / LV winding shall be brought up to the ground
level through two tinned copper flat strips of size 50x6mm which shall be
supported on transformer tank horizontal/vertical by porcelain insulators of
adequate voltage class. The number of insulators shall be sufficient to
provide a mechanically sturdy arrangement. Necessary mechanical supports
on the tank for mounting of the insulators shall be made. The KV class rating
of insulators shall commensurate with the rating /KV class of neutral design.
It may be ensured that connection of the neutral strips to neutral bushings at
one end shall be made using a terminal connector suitable for connection to
the neutral bushing terminal and to receive 2x50x6 mm tinned copper strips
on the other side. The connection between the bushing and transformers
MPPTCL/TECH/PROC/06/JULY13
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Volume-II, Part-4
earth pit shall be through 2x50x6 mm tinned copper strips single run without
any joint connection/brazing/ welding etc. In case of problem in availability of
single run tinned copper strips, it may be accepted with single joint. However,
joint to be provided shall be subject to approval of purchaser. The other end
of the earth connection to the earth pit shall also be through terminal
connector suitable to receive 2x50x6 mm copper strips at one end and to
receive MS flat and /or twin ACSR zebra conductor on the other end. The
length of the copper strips shall be suitable for providing a joint less
connection between transformer neutral and earth pit and details in this
regard shall be intimated to the successful bidder based on
transformer/substation layout design. A typical arrangement is shown in drg.
No: MPPTCL/63MVA/02 of this specification for neutral earthing.
12.2
CORE EARTHING ARRANGEMENT : The bidder should note our
requirement in this regard very clearly. It is required to bring out leads from
core, end frame and tank to the top of the transformer through only
three insulated bushings. The arrangement shall be housed in a box at the top
cover of transformer tank with provision for interconnection between the studs
of bushings. The bushing housing shall have a suitable cover with gasket to
make the arrangement waterproof. A clear marking (engraved/punched)
shall be made to indicate that the housing contains core/end frame/ tank
earthing arrangement. Please note that stickers/flags/tags/painted marking for
identification shall not be accepted. A typical sketch of general arrangement
needed by purchaser is shown in drawing no. MPPTCL/63MVA/03 of this
specification. Arrangement shall be
such that even after removal of
connections, oil shall not leak. Removable shorting strips between the three
bushing shall be provided. It may be noted that internal earthing of any
nature between core and End frame should not be provided. Earthing at
site shall be done by interconnecting the three bushings through shorting
strips. This arrangement is to facilitate checking of multiple core earthing
in the transformer.
It may be noted that :
a)
b)
MPPTCL/TECH/PROC/06/JULY13
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Volume-II, Part-4
13.1
Duplicate (Two) auxiliary power supplies of 0.4 KV, three phase,
four(4) wire shall be provided by the purchaser at cooler control cabinet and
for OLTC drive.
13.2
All loads shall be fed by one of the two feeders through an
electrically interlocked automatic transfer switch housed in the cooler control
cabinet , for tap changer control and cooler control circuits.
13.3
normal
ii)
iii)
iv)
Automatic
re-transfers to normal source
without
intentional time delay following re-energisation on
normal source.
v)
any
the
13.4 AC feeder shall be brought to the OLTC cabinet (Cooler Control Cabinet)
by the Bidder, after suitable selection at cooler control cabinet. The
Bidder
shall derive AC power for control circuit from the AC feeder as mentioned
above by using appropriately rated dry type transformers. If the control
circuit is operated by DC supply then suitable converters to be provided by
the Bidder to be operated from AC Power source.
13.5 Necessary isolating switches and HRC fuses shall be provided at suitable
points as per approved scheme of purchaser.
14.0 TAP CHANGING EQUIPMENT
14.1: GENERAL REQUIREMENT
a) OLTC gear shall be motor operated for local as well as remote
operation. An external hand wheel/handle shall be provided for local
manual operation. This hand wheel/handle shall be easily operable by a
man standing at ground level.
(b) Arrangement shall be made for securing and padlocking the tap changer
wheel in any of the working positions and it shall not be possible for
setting or padlocking the wheel in any intermediate position. The
arrangement shall be such that no padlock key can be inserted unless
all contacts are correctly engaged and switch set in a position where no
MPPTCL/TECH/PROC/06/JULY13
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Volume-II, Part-4
open or short circuit is possible. An indicating device shall be provided to
show the tap in use.
(c) The design of OLTC shall be on the principle of Constant Flux Design
(CFVV) wherein HV (132KV ) voltage would be varied in the range of (+)5
% to (-)15 % in steps of 1.25 % so as to provide constant voltage of 33
KV on LV side. While through current rating of OLTC shall be based on
cl.2.3.2 of IS 8478,the purchaser desires to obtain OLTC with higher
voltage and current rating from the point of view of better performance. In
view of this, the bidder shall offer OLTC for 63 MVA transformer suitable
for rated voltage and rated current as mentioned in the following table :
Rating of OLTC
Transformer
Rating
OLTC on
Winding
(HV)
Voltage
Rating
Minimum
Current
Rating
Tap Range
(In steps of
1.25%)
132 KV, 63
MVA
132KV
66KV/132KV*
500 Amp.
(+)5% to (-)15%
MPPTCL/TECH/PROC/06/JULY13
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Volume-II, Part-4
an oil surge relay. For accommodating oil expansion of OLTC a separate
conservator tank shall be provided.
(f) The diverter switch or arcing switch shall be designed so as to ensure that
its operation once commenced shall be completed independently of the
control relays or switches, failure of auxiliary supplies etc. To meet any
contingency which may result in incomplete operation of the diverter
switch, adequate means shall be provided to safeguard the transformer
and its ancillary equipments.
(g) Drive mechanism chamber 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.
(h) The control feature shall provide the following :
i)
ii)
iii)
iv)
v)
vi)
MPPTCL/TECH/PROC/06/JULY13
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Volume-II, Part-4
transformer. Complete mounting details shall be included
approved diagram.
with
viii) Transformer load tap changer shall be equipped with a fixed resistor
network capable of providing discrete voltage steps for input to the
supervisory system. Any other approved / established design for
remote indication of tap position shall also be acceptable.
(i) Limit switches shall be provided to prevent overrunning
of the
mechanism and in addition, a mechanical stop shall be provided to
prevent over-running of the mechanism under any condition.
(j) Limit switches may be connected in the control circuit of the operating
motor provided that a mechanical-de-clutching mechanism is
incorporated.
(k) Thermal device or other means shall be provided to protect the motor
and control circuit. All relays, switches, fuses etc. shall be mounted in the
drive mechanism chamber and shall be clearly marked for the purpose
of identification.
(l) A permanently legible lubrication chart shall be fitted within the driving
mechanism chamber.
(m) Any "DROP DOWN" tank associated with the tap changing apparatus
shall be fitted with guide rod to control the movements during lifting or
lowering.
(n) A five digit counter shall be fitted to the tap changing equipment to
indicate the number of operations performed.
(o) All relays and operating devices shall operate correctly at any voltage
between the limits specified.
(p) It shall not be possible to operate the electric drive
operating gear is in use.
(q) It shall not be possible for any two controls to be in operation at the
same time.
(r) The equipment shall be suitable for supervisory control and indication
with make before break multi-way switch, having one potential free
contact for each tap position. This switch shall be provided in addition
to any other switch/switches which may be required for remote tap
position.
(s) Operation from the local or remote control switch shall cause one tap
movement only until the control switch is returned to the off position
between successive operations.
(t) All electrical control switches and the local operating gear shall be clearly
labeled in a suitable manner to indicate the direction of tap changing.
(u) Transfer of source failure of one AC supply shall not affect tap changing
operation.
MPPTCL/TECH/PROC/06/JULY13
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Volume-II, Part-4
(v) For the
purpose of operation of OLTC, based on
design
of
manufacturer, transition resistor could be used. However, no component
of OLTC including transition resistor shall be housed inside main
transformer tank. The design of the transition resisters should be liberal
to ensure suitability during tap change operation at rated current
including over loading capability and system short circuits.
(w) The location and design of OLTC shall be such that in the event of any
repair / maintenance , it should be possible to take out various parts
from the OLTC and other accessories and fittings mounted on the
transformer particularly equalizing pipes etc do not infringe /obstruct.
14.3
MANUAL CONTROL : The cranking device for manual operation of
the OLTC gear shall be removable and suitable for operation by a man
standing on ground level. The mechanism shall be complete with the
following :
i)
ii)
iii)
iv)
(ii)
(iii) Step-by-step operation ensuring only one tap change from each tap
changing impulse and lock-out of the mechanism if the control switch (or
push button) remains in the "Operate Position".
(iv) An interlock to cut-out electrical control when it tends to operate the
gear beyond either of the extreme tap positions.
(v)
MPPTCL/TECH/PROC/06/JULY13
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Volume-II, Part-4
Suitable interlocks shall be provided to prevent operation of OLTC
beyond extreme tap with a mechanical/electrical lockable switch.
(vi) Protection apparatus, considered essential by the
specification.
Bidder according to
(ii)
14.6
LOCAL OLTC CONTROL CUBICLE The Auxiliary devices for electrical
control of the OLTC shall be housed in a weather proof cubicle. It shall be
complete with the following :
i)
devices for
to
the OLTC
Page 31 of 105
Volume-II, Part-4
i)
ii)
iii) Signal lamps for Tap changer in progress and Tap changer out of
step.
iv) Auxiliary devices for remote electric group control of OLTC.
v)
vi)
1.
2.
3.
4.
5.
MPPTCL/TECH/PROC/06/JULY13
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Volume-II, Part-4
6.
7.
8.
9.
10.
11.
12.
13.
14.
Terminal blocks.
15.
Cubicle lamp.
16.
Door switch.
17.
HRC cartridge fuse holder with link for cubicle illumination circuit.
18.
Neutral link.
19.
Earth bus.
20.
21.
22.
HRC cartridge fuse holder with link for RWTI and ROTI circuit.
23.
24.
25.
28.
29.
15.0
MPPTCL/TECH/PROC/06/JULY13
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Volume-II, Part-4
15.1
b)
Each radiator bank / block shall have its own set of cooling
fans, shut off valves, lifting lugs, top and bottom oil filling
valves, air release plugs, drain valves and if considered
necessary based on design thermometer pocket fitted with
captive screw cap on the inlet and outlet, in line with valve
schedule as per Annexure-V.
c)
d)
e)
f)
g)
h)
i)
j)
k)
MPPTCL/TECH/PROC/06/JULY13
to
meet
overloading
on
directed
oil pipe
Page 34 of 105
Volume-II, Part-4
15.2
15.3
l)
m)
n)
b)
c)
shall
be
Indicating devices
-
One potential free initiating contact for all the above indications shall be
wired independently to the terminal block of cooler control cabinet exclusively
for purchasers use.
16.0
MPPTCL/TECH/PROC/06/JULY13
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Volume-II, Part-4
mounted on the transformer. The thickness of front panel,
door frame etc. shall be 3mm (10 SWG),while
doors
&
side panels may be 2 mm (14 SWG) and gland plate shall be of
minimum thickness 4 mm.
b)
(c)
d)
e)
f)
all
necessary
ii)
iii)
MPPTCL/TECH/PROC/06/JULY13
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Volume-II, Part-4
iv)
v)
16.1
2147.
The degree
IS-
16.2
The temperature indicators shall be so mounted that the
dials are not above 1600mm from ground level. Glazed door of suitable
size shall be provided for convenience of reading.
16.3
A space heater and cubicle lighting with ON-OFF switch shall
provided.
16.4
be
Terminal Blocks
a)
b)
c)
d)
e)
MPPTCL/TECH/PROC/06/JULY13
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Volume-II, Part-4
f)
g)
16.5
One Cooler Control Cabinet and OLTC local control cabinet shall be
tested for IP-55 protection in accordance with IS-2147.
16.6
17.0
PAINTING
17.1
It has been observed that certain units received in the past
by us are not having good quality painting on inside & out side and
with passage of time peeling of flakes of paint takes place. In view of
this the Bidders are requested to furnish in a separate sheet painting
procedure adopted by them for internal & external surfaces of the
tank. This is an essential requirement and details should be confirmed
by the Bidders in their offer. The internal and external surfaces including
oil filled chambers and structural steel work to be painted shall be shot or
sand blasted to remove all rust and scale of foreign adhering matter or
grease. All steel surfaces in contact with insulating oil shall be painted with
two coats of heat resistant, oil insulating varnish.
17.2
All steel surfaces exposed to weather shall be given a primary
coat of zinc chromate, second coat of oil and weather resistant varnish of
a colour distinct from primary and final two coats of glossy oil and Epoxy light
gray paint in accordance with shade no.631 of IS-5.For each transformer oil
paints should be obtained from same source to ensure compatibility & proper
finish.
17.3
All paints shall be carefully selected to withstand extremes of
weather. The paint shall not scale off or crinkle or be removed by abrasion
due to normal handling. The process of painting should be clearly described.
17.4
The minimum thickness of each coat of outside painting of tank
shall be 20 microns and the total thickness shall be minimum 80 microns.
17.5
Bolts & Nuts :All bolts and nuts exposed to weather shall be hot
dipped galvanised/cadmium plated.
18.0
MPPTCL/TECH/PROC/06/JULY13
Page 38 of 105
Volume-II, Part-4
(a)
: 1100volts
grade
PVC
insulated
armoured
aluminum cable .
: 1100volts
insulated
stranded
cable .
grade
PVC
7/0.737mm
armoured copper
the
(b)
for
(c)
(d)
(e)
(f)
(g)
(h)
be
provided
MPPTCL/TECH/PROC/06/JULY13
Page 39 of 105
Volume-II, Part-4
19.1
Terminal connectors for HV & LV side bushings shall be suitable
for single/double Zebra ACSR (28.62mm) conductor and suitable for
horizontal and /or vertical take off arrangement i.e. universal type.
19.2
Bushing terminals shall be provided with terminal connectors of
approved type and size for connection to external parts. Terminal connectors
offered must have been successfully type tested as per IS-5561.
19.3
All terminal connectors shall be manufactured out of gravity dye
casting process only and shall be free from blow holes, surface blisters,
cracks and cavities. All sharp edges and corners shall be blurred and
rounded off. The aluminum alloy castings, if used, shall conform to
relevant IS.
19.4
19.5
19.6
For
bimetallic clamps , bimetallic strip of not less than 2 mm
thickness shall be provided.
19.7
sheets.
19.8
Size of terminal (bushing stud)/conductor ( ACSR Zebra ) for which
the clamp is designed and also rated current under site conditions shall be
embossed/ punched on each part of the clamp, except hardware.
19.9
All current carrying parts shall be designed and
have minimum contact resistance.
19.10
manufactured to
19.11
The nominal current rating and short time current rating of terminal
connectors shall match the corresponding rating of respective bushings.
20.0
20.1
Transformer oil shall be supplied by the Bidder. The offered Price
of
transformers therefore, should
include first filling of oil( including
wastage) & 10% extra of that quantity. The quantity of oil for first filling
including wastage and 10% extra of that quantity should be indicated by the
Bidder in kilo-liters and in kg. The design of the transformer shall be based
on the characteristic of EHV transformer oil as per relevant IS.
20.2
Although oil for the transformer is included in the scope of supply,
but it may be noted that the transformer shall be supplied duly N2 gas filled
with suitable arrangement to ensure that the pressure of gas is regularly
maintained during transit and upto the date of filling of oil. For this
purpose, necessary gas cylinders with regulator shall be supplied on non
returnable basis. Additional gas cylinders required recouping and
MPPTCL/TECH/PROC/06/JULY13
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Volume-II, Part-4
maintaining of positive Nitrogen pressure upto filling of oil should be
supplied by the manufacturer of Transformers and the offered price
should take into account this requirement.
20.3
The quality of the oil supplied with transformer shall conform to the
oil parameters specified in this clause. No inhibitors shall be used in the oil.
The oil samples of transformer will be drawn for the oil used at factory &
site as follows.
i.
Prior to filling
ii.
Before and after heat run test / pre-commissioning test.
iii. Before energizing.
All tests as per IS:335 (latest revision) shall be conducted on oil
samples.
20.4
Sufficient quantity of oil necessary for first filling of main tank,
coolers, radiators and conservators etc. upto the proper level plus anticipated
quantity of wastage of oil during first filling shall be supplied in tankers. Please
note, wastage means quantity of oil absorbed during initial filling at works for
testing. In addition to the oil needed for first filling, 10% extra quantity of oil
for topping up in future, shall be supplied in non-returnable containers
suitable for outdoor storage. Therefore, total quantity of oil required for first
filling shall be measured at works at the time of testing on unit subjected to
heat run test.
20.5
The supplier shall dispatch the transformer in an atmosphere of
pressurised Nitrogen.
In this case, necessary arrangement shall be ensured
by the supplier to take care of pressure drop of nitrogen during transit and
storage till completion of oil filling during erection. A gas pressure testing
valve with necessary pressure gauge and adapter valve shall be provided.
20.6
The supplier shall warrant and confirm that oil to be used for the
transformer testing at Works & oil to be supplied for the transformer is free
from Polychlorinated Biphenyls (PVB/PCB). The transformer oil to be used
and supplied by the bidder for first filling at site shall be new oil of EHV GradeI having technical specification mentioned hereunder . Hence Oil to be used
by the manufacturers at factory for the purpose of testing at their
works shall be of similar or better quality having parameters matching
with the parameters specified in the specification. Specific approval of
oil test results of oil proposed to be used for testing of transformer in
factory shall be obtained by the manufacturer from the purchaser
before first filling in the unit. MPPTCL shall not accept any other oil for
testing purposes having lower parameters than those specified in the
Bid. Bidders should specifically confirm this requirement in their offer.
Sl.
No
Characteristics
Requirement
Method of Test
1.
2.
3.
4.
MPPTCL/TECH/PROC/06/JULY13
Page 41 of 105
Volume-II, Part-4
Sl.
No
Characteristics
Requirement
Method of Test
1.
2.
3.
4.
1.
Appearance
A
representative
sample of oil shall be
examined in a 100
mm thick layer at
ambient
temperature.
2.
Density at 29.5oC
(maximum)
0.89 gm/cm3
IS:1448
3.
Kinematics viscosity at
27oC (miximum).
27 CST
IS:1448
4.
Interfacial tension at
27oC (minimum).
0.04 N/m
IS:6104
5.
Flashpoint Pensky
Marten (closed)
(minimum).
140oC
IS:1448
6.
-6 oC
IS:1448
7.
Neutralization value
(Total acidity maximum)
0.01 mg KOH/g
IS:335 Appendix `A
8.
Corrosive Sulphur
Non-corrosive
IS:335 Appendix `B
9.
Electric strength
(breakdown voltage)
Minimum.
a. New unfiltered oil (as 40 KV (rms)
received condition).
b. After filtration
60 KV (rms)
IS:6792
10.
Dielectric
dissipation 0.002
factor (tan delta) at
90oc Maximum.
IS:6262
11.
Specific resistance
(resistivity)
a. at 90oC Minimum.
b. at 27oC Minimum.
100x1012 ohm.cm
1500X1012 ohm.cm
12.
Oxidation stability
a. Neutralisation value 0.20 mg KOH/g
after
oxidation,
maximum.
0.02 percent by
b. Total sludge, after weight
oxidation Maximum
13.
Presence
inhibitor
of
MPPTCL/TECH/PROC/06/JULY13
IS:6103
IS:335
Appendix `D
Page 42 of 105
Volume-II, Part-4
Sl.
No
Characteristics
Requirement
Method of Test
1.
2.
3.
4.
14.
SK value
6% maximum
IS:335
15.
Water content,
maximum.
10 ppm
IS:2362
16.
Ageing
characteristics
after accelerated ageing
(open Breaker method
with copper catalyst)
a) Resistivity
i. 27oc
ii. 90oc
b) Tan delta at 90oc
c) Total acidity
d) Sludge content
by weight
17.
18
As per ASTM-D
1934/ IS 12177
2.5x1012 ohm.cm
(min.)
0.2x1012 ohm.cm
(min.)
0.15 (max.)
0.05 mg
KOH/gm(max.)
0.05% (max)
Tested in accordance
with IS :335
20.7
AIR CELL : Our technical specification calls for supply of power
transformers with air cell type oil preservation system of PRONOL, make
only. It is obligatory on the part of the Bidders to clearly submit complete
constructional and technical details of sealing arrangement, duly supported
MPPTCL/TECH/PROC/06/JULY13
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Volume-II, Part-4
with technical details, pamphlets and dimensional drawings. While
furnishing details for the above sealing arrangement the Bidders must
confirm clearly that the size and capacity of sealing arrangement is
adequate for the transformer and for the quantity of oil required for the
transformers. Necessary calculation/documentary proof shall be furnished.
20.8
Air cell type oil preservation system included with each transformer
shall ensure as under:
(a)
The
Bidder
shall clearly
indicate in the manual the
procedure
for installation of COPS and precautions to be
taken at the time of first oil filling under vacuum in the
transformer.
Silica Gel
Breathers each of 100% breathing capacity are required and the same shall
be provided. Size of breather and its pipe connection is to be indicated.
However, each breather of minimum capacity of 8 Kg having its pipe
connection of minimum size of one inch dia shall be preferable. Suitable
arrangement for parallel mounting of breathers shall be made for connecting
both the Silica Gel Breather to the main conservator.The passage of air should
be through dual filter & Silica Gel. Silica Gel shall be isolated from atmosphere
MPPTCL/TECH/PROC/06/JULY13
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Volume-II, Part-4
by an oil seal. Adequate supports are required to be provided for pipe
connection to avoid any swing in air.
The capacity of silicagel breather shall be adequate to ensure supply of dry air
only for the volumetric expansion/contraction of oil keeping in view the total
quantity of oil in the unit.
The container of the breather shall be made of
metal with glass enclosure along its periphery to ensure that the transparency
(to verify the colour of dehydrating agent) is maintained during operation
directly under sunlight (ultra violet rays) for long life. The quantity of the
dehydrating agent shall be sufficient keeping in view the climatic condition
specified and that the breather will be maintained generally two times in a
year. This applies to all the breathers provided with the transformer.
20.11
TRANSPORTATION
CONFIGURATION
OF
POWER
TRANSFORMER : In order to conduct low voltage field testing on power
transformers before
unloading/commissioning at site to determine the
internal condition, the transformer shall be transported with :
a) Small bushing (12 KV) may be installed on the bushing cover plate to
represent the actual bushing.
b) Winding leads may be routed, secured and electrically isolated from the
tank walls and active part.
c) Temporarily tests leads may be used to connect the winding leads by
the small bushings (which will be removed before erection of the main
bushings).
The details of arrangement for transport configuration of Power Transformer (
which shall be adopted by Manufacturer) shall be submitted by the
Manufacturer to the Purchaser for approval. The price quoted by the Bidder
should take into account this requirement.
21.0 FITTINGS & ACCESSORIES FOR THE POWER TRANSFORMERS
21.1
The Bidders submit a specific confirmation that the transformers
will be supplied complete with all fittings and accessories exactly in line with
various requirements indicated in Annexure II in this technical specification.
The basic offered cost must take into consideration cost of all fittings and
accessories as under and indicated elsewhere in this specification.
21.2
The
equipments and accessories furnished
with
the
transformer shall be suitably mounted on the transformer for ease of
operation, inspection and maintenance and the mounting details shall be
subject to the approval of the purchaser. All valves shall be provided either
with blind companion flanges or with pipe plugs for protection.
21.3
Indication, alarm and relay equipment shall have contacts suitable
for operation with 110V DC supply. Any other accessories or
appliances
recommended by the manufacturer for the satisfactory operation of the
transformer shall also have 110V DC as input.
a)
OLTC
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b)
All
cabinets
& panels shall
stipulations under Clause-16 .
be
conforming
to
c)
21.4.
Equalizing pipes for maintaining equal pressure between main tank
and OLTC and at various other locations as per design shall be provided.
These equalizing pipes shall be routed such as not to create any obstruction.
21.5
Accessories,which are necessary for satisfactory operation of
Transformer shall be deemed to have been included in the accepted price
without any extra cost to the Purchaser.
21.6
It may be noted that all the name plates/rating plates/diagram
plates on transformer shall be engraved type/anodized type and shall be fixed
using rivets/spot welding method. The method of printing of letters on the
R&D plate shall be such that inscriptions shall not fade by ultra violet rays and
other adverse weather conditions under which the same is subject to during
service life of transformers.
(a)
(b)
Valve Schedule Plate: In the valve schedule plate, at least two views
should be inscribed so that location of all the valves provided on the
transformer could be indicated/visualised. In the table of valve
schedule plate, details of valves viz. type of valve, material of valve,
size of valve & position of valve during transportation and after
commissioning shall be clearly indicated. The size of the letter shall be
such that the same be visible clearly to a person standing away at a
distance of one meter from the respective vertical face of the
transformer.
(c)
Instruction Plate For Oil Filling in the Conservator with Air Cell:
An instruction plate shall be provided for oil filling in the conservator
having air cell type breathing arrangement. In addition to the
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instructions for oil filling on this plate, a diagram indicating mounting
details of MOLG, oil level gauges, air cell inside the conservator with a
pictorial view of conservator including make, type & size of air cell shall
also be inscribed. The location of plate should be such that same is
visible to operating personal from a distance as mentioned in (b)
above.
22.0 CENTRE OF GRAVITY : The centre of gravity of the assembled
transformer shall be low and as near to the vertical centre line as possible.
The transformer shall be stable with or without oil. If the centre of gravity is
eccentric relative to track gauge either with or without oil, its location shall
be shown on the outline drawing.
23.0
PACKING
23.1
The packing may be in accordance with the Bidder's standard
practice but Bidder should give full particulars of packing for the approval of
the purchaser. Special arrangements should be made to facilitate handling
and to protect the projecting connections for damage in transit.
23.2
The transformer shall be transported filled with inert gas preferably
Nitrogen gas. The Bidder shall ensure that adequate pressure of gas is
maintained inside the tank throughout during transportation by sending
escorts and required apparatus and equipment with the transformers.
23.3
All parts shall be adequately marked to facilitate field erection.
Boxes and crates shall be marked with the contract number and shall have
a packing list enclosed showing the parts contained therein. however the
verification of accessories shall be done in presence of suppliers
representative.
24.0
TESTS
24.1
The manufacturer shall carryout routine test ,additional routine
tests and type tests on the transformers as per the relevant Indian
Standard IS-2026 with latest amendments , IEC 60076,CBIP Publication No
295,IEEE or any equivalent International Standard .The details of tests are
specified hereunder. It should be specifically noted by the Bidder that testing
of each & every transformer included in this Bid specification shall be carried
out at the manufacturers works in fully assembled condition complete with all
fittings & accessories.
24.2 ROUTINE TESTS AND ADDITIONAL ROUTINE TESTS: All routine
tests and additional routine Tests detailed under clauses 24.2.1 & 24.2.2
herein under will be carried out on each transformer on "free of cost" basis, in
accordance with IS:2026 part-I.
24.2.1
ROUTINE TESTS
a)
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and of all the three phases and values be recorded in
respective test certificates.
b)
c)
d)
e)
f)
g)
h)
i)
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when air cell is provided) shall
be subjected to a
pressure corresponding to twice the normal head of oil or to
normal pressure plus 35 kN/ m.sq. whichever is
lower
measured at the base of the tank and will be maintained
for 12 hours during which time no leakage shall occur. Before
conducting the pressure test, the following are to be taken
care of :
(i)
(ii)
are
to
be
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i.
ii.
iii.
iv.
a
b
On
HV
side
On LV side
(J)
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to despatch. Temperature, pressure and dew point at the time
of gas filling (reading taken after stabilisation) shall be taken
and painted on the transformer tank. The minimum
permissible value of dew point shall be ()25oC at normal
temperature and pressure.
(L)
24.3
TYPE TESTS :
Following Type Tests shall be conducted on
one transformer of each manufacturer (if there are more than one
manufacturer) as per IS:2026 Part I, CBIP publication no 295 :
(A) Temperature Rise Test : This test as per cl. 16.8 of IS:2026(PartII) shall be conducted at the lowest voltage tap having maximum
current with 10% over load condition. The supplier before carrying
out such tests, shall submit detailed calculations showing the
alternatives possible, on various taps and for different ratings
(ONAN/ONAF), of the transformer and shall recommend the
combination that results in highest temperature rise, for the test.
Gas chromatographic analysis of oil shall be conducted before and
after heat run test and the values shall be recorded in the test
report. The sampling shall be in accordance with IEC-567. For the
evaluation of the gas analysis in temperature rise test, a method
will be proposed which is based on the rate of increase of
particular gases and the permissible limits of minimum detectable
value of gases and the maximum limit will be mutually discussed
and agreed upon between the Purchaser and Supplier. This shall be
treated as reference during maintenance of transformer in future.
The calibration of OTI and WTI shall be done by Transformer
Manufacturer and these calibrated OTI,WTI shall be used during
testing of transformer. The Sr.No. of WTI,OTI shall be recorded
during testing of transformer and these indicators only shall be
supplied with the transformer. During test the manufacturer
selects suitable tap from CT based on gradient between the reading
of WTI & OTI . This tap position is to be clearly recorded on test
report so that selection of correct tap could be done at site to avoid
discrepancy in temperature gradient recorded during factory test and
the value recorded at site.
(B) Impulse Test on line terminals as per IS 2026 part III, on one
transformer of Bid
(C) Tank tests : Following Vacuum and Pressure tests shall be carried
out on one transformer tank.
(a)
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kN/m.sq. (25 mm of Hg) for one hour i.e. 760-25=735 mm of
Hg at sea level and (Barometric reading -25mm Hg) at other
location. The permanent deflection of flat plates after vacuum
has been released shall not exceed the values specified
below:
Horizontal Length of flat plate (in
mm)
Up to and including 750
751 to 1250
1251 to 1750
1751 to 2000
2001 to 2250
11
2251 to 2500
12.5
2501 to 3000
16
Above 3000
19
(b)
24.4
SPECIAL TESTS
: Following special tests other than type and
routine tests shall also be carried out as per IS:2026 Part-I
on one
transformer of each manufacturer (if there are more than one manufacturer):
a) Measurement of zero seq. impedance as per CL.16.10 of IS:2026 PartI.
b) Measurement of acoustic noise level as per CL.16.12 of IS:2026
Part-I,NEMA TR1 & IEC 60076-10. Detailed calculations & conditions
outlined in the IEEE standard C 57.12.12.90 shall be followed.
c) Measurement of power taken by fans as per cl.16.14 of IS:2026
Part-I.
d) Measurement of harmonic level of no load current and total harmonic
distortion of voltage & current as per CL.16.13 of IS:2026 Part-I.
Details of rms voltage applied & print out of Harmonic Analyser shall be
enclosed with report.
e) One Cooler Control Cabinet and OLTC cabinet of each type
of
transformer shall be tested for IP:55 protection in accordance
with IS:2147.
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f)
24.5
Special tests
24.7
Tests at site
On One unit of
Bid
On
each
unit
included in Bid
Note :
It is to be noted that after complete final testing of the unit ,
it should be kept charge at rated voltage for adequate time to ensure
proper demagnetization of core i.e. demagnetization of core shall be
ensured prior to dispatch of the unit.
24.6
Oil to be used by manufacturers at factory for the purpose of
testing at their works shall be of similar or better quality having
parameters matching with the parameters specified in the
specification. Specific approval of oil test results of oil proposed to be
used for testing of transformer in factory shall be obtained by the
manufacturer from the purchaser before first filling in the unit.
MPPTCL shall not accept any other oil for testing purposes having
lower parameters than those specified in the Bid. Bidders should
specifically confirm this requirement in their offer.
25 TESTS AT SITE :On delivery /receipt, after erection at site, the
transformer shall be subject to the following tests, in presence
of
supplier's engineer.
(i)
ii)
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iii)
iv)
v)
OLTC operational test at each tap for lower and raise operation
of tap changer.
vi)
Magnetic
current.
& moisture
xii) Leakage current between core & tank, core & end frame , end
frame & tank and between short circuited links & neutral in
grounded and un grounded conditions. DGA
of oil and
Dielectric, Tan-Delta, resistivity & moisture content test of oil
xiii)
Check
completed
transformer
against approved
out line
drawing, provision for all fittings, finish level etc.
Jacking test on the assembled Transformer.
Measurement and recording of temperature and drying time during
vacuum treatment.
Check
for completeness of drying by measuring IR values & Tan
Delta.
Certification of all test results.
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b)
Buchholz relay
Excessive winding temperature
Excessive oil temperature
Low oil flow
Low oil level indication
g)
27 TEST REPORTS : After all tests have been completed seven certified
copies of each test report shall be furnished. Each report shall supply the
following information :i)
ii)
Method
of
application, where applied,
duration
and
interpretation of results for each test. Complete diagram of
test circuits and details of test equipments including auxiliary
transformer, Instrument transformer shall be furnished.
iii)
iv)
Test certificates
inspections.
of
all
including serial
the
accessories
number of
and
the
stage
28.
TOOLS : The transformer shall be supplied with a full outfit of tools,
spanners, special tools for assembling and dismantling transformers with a
rack for holding them as per Annexure IX. All spanners shall be double ended
& case hardened. The quantity of each item of tools shall be indicated by the
Bidder in Bid.
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29.0 DRAWINGS & INSTRUCTION MANUALS
29.1
SPECIFIC REQUIREMENT FOR GENERAL ARRANGEMENT
DRAWING: For our 132 KV switch yard, the bay width adopted is 9.6
metres. Following points shall be kept in view while finalizing General
Arrangement drawing of the transformer.
i.
ii.
29.2
The drawings for each items of transformer and its accessories to
be submitted with the Bid shall be indicated in schedule IV.
29.3 As
soon as
possible after the award of
the
contract
the
manufacturer shall
supply Instruction Manual. This Instruction Manual
shall be hard bound manual shall contain set of all approved drawings,
instruction books, manufacturers catalogue of all bought items & fittings,
operation & maintenance manuals , spare part bulletin.
(a)
(b)
30.0
The offered price shall include cost of drawing / manuals as
detailed out in Annexure VII.
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31.0
DESIGN CALCULATIONS & DESIGN DATA TO BE ENCLOSED
WITH BID : All the important data of the transformer i.e. Net weight of bare
copper in each winding , Weight of core without clamping fixtures , Weight of
core and windings, Cross section of the core, Flux density calculations ,
Calculations for short circuit current and its duration , Current density during
short circuit , Calculations showing withstand capability of windings for
thermal & mechanical stresses during short circuit conditions , Mechanical
Design of transformer tank etc should be invariably submitted by the Bidder .
After placement of detailed contract the final design calculations shall be
submitted for our verification and records .
Submission of design calculations and data with technical bid is a
necessary requirement
and
those Bids will be rejected wherein
these data & calculations is not found . It may be noted by the Bidders
that no correspondence with the bidder in this regard shall be made
after opening of technical & commercial offer. All responsibility for
Submission of design calculations and data with the Bid is therefore
of the Bidder & non furnishing of same may run the risk of rejection
/non responsiveness of the Bid.
31.1 SHORT CIRCUIT WITHSTAND CAPABILITIES :
31.1.1 The
calculations
to prove
dynamic and thermal short circuit
withstand capability of transformer shall be submitted by the Bidder for the
fault level indicated as under
132 KV 40 KA for 3 secs.
33KV 31.5KA for 3 secs.
It may be noted by the Bidders that calculations for short circuit withstand
capability
for two winding transformer shall be submitted. Results of
calculations shall be submitted with the Bid . The design of winding assembly ,
which is to be furnished in the drawing as per Sr. No. (e) of Annexure
VII should
be commensurating with these calculations. The details of
clamping ring shall be indicated in the drawing .
31.1.2 Design of Tank : Complete mechanical design of transformer tank
including details of stiffeners shall be submitted . The tank shall be designed
to withstand the following without permanent distortion.
(i)
(ii)
The calculations for tank stiffeners shall be submitted with the Bid to prove
no. & size of stiffeners are adequate to withstand full vacuum & pressure .
Drawing of tank shall be submitted indicating stiffners .
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31.1.3 Design of Static End Rings (SER) and Magnetic Shunts : Details
of Static End Rings (SER) and magnetic shunts , if provided , shall be
submitted with the Bid with calculations . A drawing indicating locations , size
,material of SER and magnetic shunts shall be submitted with the Bid .
31.1.4 Overfluxing Capability: A curve to prove suitability of transformer
to withstand various Overfluxing conditions for the duration indicated in clause
4.4.1 to 4.4.3 without core saturation shall be furnished with the Bid .
31.1.5
Cooling Calculations : Calculations of tank surface for heat
dissipation, details of radiators , fans for ONAN & ONAF `cooling shall be
provided with the Bid.
31.2 DESIGN DATA : On the basis of offered flux density and current
density, the Bidder shall furnish following design calculations & data. :
31.2.1 Core Data: Details of core material i.e Name of Manufacturer,
Manufacturers type designation for core , thickness of core, curve for Loss Vs
Flux density, No of steps of Core & No of limbs, gross core area , stacking
factor , Net core area ,height & width of core window, center to center
distance of limb, voltage per turn, wt. of core material, working flux density ,
core loss in watts per kg marked on graph for grade of core material &
selected flux density, building factor
and calculated no load loss in watts,
guaranteed no load loss.
Design data for core shall be submitted with the Bid . A drawing indicating
details of core i.e. limbed construction, step width & thickness , core belting,
top & bottom yoke plate etc shall be submitted with the Bid .
31.2.2 Winding Data : wt. of copper for windings ie. for HV, LV, tap, cross
sectional area ,current density, type of coil, ID/OD/mean dia of coils, size of
winding conductor including parallels, no. of turns per phase, no of spacers,
length of mean turn, weight of copper without paper covering, resistance per
phase of winding at 75 deg C,I2R loss at 75 deg C & normal tap, eddy current
& stray loss at 75 deg C , total copper loss at 75 deg C , guaranteed
transformer losses at 75 deg C.
Complete details of Insulation components i.e. Top & Bottom clamping rings,
washers , Pressboard blocks & cylinders, Pressboard spacers & Phase barriers,
Pressboard segments etc shall be submitted indicating qty , thickness in mm,
width & height , wt. Design data for winding as per clause 31.2.2 shall be
submitted with the Bid .
Dimensioned drawings indicating details of winding , ducts, insulation , take
off arrangement, clamping ring , pressure points etc shall be submitted with
the Bid .
31.3 QUANTITY OF OIL : Complete calculations of oil quantity to be utilized
in transformer for first filling shall be submitted with the Bid. The calculations
shall indicate
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(i) Volume of tank including turrets, conservator main & OLTC ,volume
of headers & Radiators, oil quantity in OLTC & thermosyphon filter.
(ii) Oil displacement by Active parts i.e. core - coil assembly,
31.4
CAPACITY OF CONSERVATOR & SIZE OF AIR CELL : While
furnishing details of conservator & air cell type sealing arrangement, the
Bidder shall submit details & calculations for adequacy of size and capacity of
Pronal make air cell for the rating of the power transformer and also for the
quantity of oil required with the Bid. Catalogue of Pronal should be enclosed
with the Bid clearly marking type designation of selected size of Air cell. A
drawing indicating complete details of conservator with Air cell shall be
submitted .
31.5 CAPACITY OF PRESSURE RELIEF DEVICE : Our specification calls
for supply of pressure relief device for all power transformers. Bidders
must submit
calculation with the Bid to prove that the capacity/rating of
pressure relief device and locations of the same for the transformer will
adequately meet our requirement. Constructional and design details of
pressure relief device must be furnished and it should be proved by
calculation that the size
and setting of pressure relief device
is
adequate considering the rating of the transformer and quantity of oil in the
transformer.
A drawing indicating complete details of PRDs & their locations on tank shall
be submitted .
31.6
LIMITS OF TEMPERATURE RISE & HOT SPOT WINDING
TEMPERATURE : The limits of temperature rise for windings, oil and hot spot
have been specified. Temperature rise calculations at rated full load, 110%
load and 125% load considering 100% cooler banks, 50% cooler banks and
without coolers shall be furnished as indicated below :
(a)
(b)
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- 50 % cooler bank
- without cooler bank
The calculations shall indicate temperature gradient (for all windings i.e.
HV,LV,tap), load losses at lowest tap for all windings , Eddy current & stray
losses, thermal Constant Value & calculations with parameters affecting the
values for above conditions for top oil temperature & winding hot spot
temperature .
The Calculations for Hot Spot winding Temperature and Calculations for
Temperature Rise shall be submitted with the Bid.
31.7
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established by calculations and also by test reports. The above Calculations
for OLTC shall be submitted with the Bid.
31.9 Capacity of Nitrogen Cylinder, pressure in Nitrogen Cylinder to be used
during transportation of transformer shall be submitted with the Bid.
31.10
The Bidder shall carry out optimization of Dielectric design of
insulation including electromagnetic design, overload & short circuit withstand
capabilities. During design , transformer modeling shall be done & finite
element software (FEM) may be used.
31.11
Please note that submission of above calculations with
technical bid is a must and in absence of the above, the Bid will
be treated as non responsive and rejected. It is assured that these data
will be kept strictly confidential by MPPTCL.
32.0 QUALITY ASSURANCE PROGRAMME : The Bidders must establish
that a proper quality assurance program is being followed by them for
manufacture of power transformers. In order to ensure this, suitable QAP
should form a part of the technical bid, which will be submitted
against this Bid specification. The quality Assurance Program must have
a structure as detailed in the following paragraphs.
32.1 Customers Specifications And Contract Review : The quality
assurance and failure prevention starts with careful study and scrutiny of
our technical specifications and requirements. The supplier shall carefully
study all the technical parameters and other particulars & the supplier shall
categorically give his confirmation that these requirements shall be met
in a satisfactory manner.
32.2 Design Control : The supplier shall furnish the checks exercised in
design calculations particularly in respect of short circuit forces and method
of clamping end coil to show the healthiness of the design. The salient
features of design together with the certificates of design engineers will have
to be made available to the Purchaser.
32.3
Engineering Documents :The supplier shall give complete
information regarding copper conductor, insulating paper, core materials,
tap changer, gaskets etc. bringing out
the
detailed description and
specification of these items with explanation as to how our requirements are
being met in this respect.
32.4
Procurement Document Control & Purchased Material &
Services
:
The supplier shall indicate the various sources of the items namely
copper conductor, insulating paper, core material, tap changer and other
items such as gaskets etc. are being procured. The type of checks,
quantum of checks and acceptance norms shall be intimated and random
test and check results should be made available for inspection whenever
so desired. The vendor list for various bought out items shall be submitted
with the Bid and the same shall be subject to purchasers approval. However,
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no change in vendor list shall be acceptable after placement of order and list
of vendors shall be freezed at the time of placement of order. Furnishing
of following certificates is essential ;
i)
ii)
33.1
Inspection
33.1.1
The Purchaser shall have access at all times to the works and all
other places of manufacture where the transformers are being manufactured
and the Bidder shall provide all facilities for unrestricted inspection of the
Bidders works, raw materials, manufacture of all the accessories and for
conducting necessary tests as detailed herein.
33.1.2
The successful Bidder shall keep the Purchaser informed in advance
of the time of starting and of the progress
of manufacture
of
equipment at its various stages of manufacturing, so that arrangements
could be made for inspection.
33.1.3
No material shall be dispatched from its point of manufacture
unless the material has been satisfactorily inspected and tested.
33.1.4
The acceptance of any quantity of Transformer & its accessories
shall in no way relieve the successful Bidder of his responsibility for
meeting all the requirement of this specification and shall not prevent
subsequent rejection if such equipments are later found to be defective.
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Acceptance of condition regarding stage inspection at various stages which
will be intimated to successful Bidders shall be the essence of the contract to
be placed against this Bid.
33.2.
Inspection Programme :The Bidder shall chalk out a detailed
inspection and testing program for manufacturing activities for the various
components. An indicative program of inspection as envisaged by the
Purchaser is given in Annexure-VIII. The Purchaser reserves the right to get
carried out any tests by a third party. All Cost of inspection/tests shall be
borne by the Bidder.
33.3
Stage Inspections
33.3.1
The supplier shall indicate the inspections and checks carried out
at various stages of the manufacture of the transformers. A complete
record of stage inspection would be kept by the supplier and this record
should be made available for inspection by the representative of the
Purchaser. The supplier should indicate the manufacturing program and
the Purchaser will have a right to depute its inspecting officers during
the manufacture. Some of the inspecting stages are tank during fabrication,
coil winding , core building, assembly of coil on core, the condition of the coil
and core after the treatment in vacuum chamber, assembly within the
transformer tank together with application of tap changer.
33.3.2
It may be noted that stage inspection for first unit or all the units
,at our discretion , shall be done by us at the following stages.
(a)
(b)
(c)
(d)
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(e)
Final Assembly of Transformer after boxing in of active
material
Apart from the above, the Purchaser also reserves the right to carry out stage
inspections at
other stages also, for which advance intimation shall be
given and all necessary cooperation shall be rendered by the manufacturer.
33.4
33.4.1
At the time of final inspection, the supplier shall identify each
and every item/accessories/fittings
of the particular transformer under
testing. Unless all the items are identified, the manufacture will not be
treated as complete. Serial number of bushings, serial number of tap changer
and other accessories shall be entered into the test report to ensure that the
same are supplied with the transformer. Various
tests
stipulated in IS
shall be performed in the presence of purchasers engineers or when the
inspection waiver has been given, in such a case, the testing shall be
done at the manufacturer's works as per IS stipulations and same should
be confirmed by documentary evidence by way of Test Certificate which
shall be got approved by the purchaser.
33.4.2 The WTI & OTI shall be calibrated during testing of transformer
and Serial Nos. of these instruments shall be recorded in test reports.
The WTI & OTI used during testing shall be dispatched with the transformer
so that installation of same OTI & WTI on transformer is done which are
utilized during testing of transformer at suppliers works. The Bushings
and Radiators on Transformer (if heat run test is conducted ) during testing
of transformer at manufacturers works are required to be supplied with the
same transformer to avoid any mismatch / misalignment etc. during
assembly of transformer. This should be noted for strict compliance and
confirmed specifically.
33.4.3
Whenever inspection call for a particular transformer is given, the
letter of inspection call will accompany the following:
a.
List of various fittings and accessories which are ready at the works
and will be offered for inspection. The Inspecting Officer will carry
the list and check the items declared to have been offered for
inspection
b.
c.
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Purchaser will reserve the right to recover the complete cost of
deputation of inspecting team to the works of the manufacturer.
34.0
STORAGE, HANDLING & SHIPPING : When the transformer is
declared ready, the manufacturer has to identify each and every item
associated with this unit and a `Complete Packing List shall be prepared in
advance. The equipments shall be stored and handled properly in
shipping depot, while the
same
is
under process
of dispatch. The
manufacturer should ensure dispatch of all the related items and accessories
with a particular unit of transformer along with tank.
Tap changer, bushing, radiators and other accessories of the
transformer should not be withheld for use subsequently on units for testing
purposes. If there are any items procured from sub-contractors which are to
be directly installed like instrumentation, panels, control gear etc. test and
inspection report for the same shall be kept separately and made available to
purchasers inspecting officers.
It may be noted that NO CHANGE in any accessory or
associated equipments after passing all the test successfully shall be
allowed and if this is subsequently detected it shall be binding on the Bidder
to replace with the same item with which the initial test were conducted at
his part failing which the entire test shall become null and void. The
Purchaser at his discretion may consider for rejection of the units thus
supplied. The entire cost, for replacement of such rejected units thus
supplied and for repeating acceptance test, shall be borne by the Bidder.
35.0
MPPTCL/TECH/PROC/06/JULY13
Page 65 of 105
Volume-II, Part-4
35.4
It may be noted that in case of damages/shortages due to
improper packing or any other negligence ,replenishment shall be arranged
within 45 days of being noticed by the purchaser. If this is not done, date of
delivery of such accessory will be treated as date of delivery of main
equipment and full penalty shall be recoverable from the Bidder on total
cost of the equipment. This should be confirmed.
35.5
For bought out items, responsibility for guarantee and obtaining
immediate replacement in case any defects are noticed and in case defective
supply of any item is reported will rest on the Bidder.
35.6
In case for attending to defect in any accessory or inspection/
replacement of the accessory, which may be bought out item
for the
Bidder; services of engineer of original manufacturer is required, the same will
be organized on immediate basis by the Bidder at his cost.
35.7
The bidders are required to furnish in their bid, the following details
of packages for supply of complete quantity of materials/one complete
equipment:
i.
Total number of packages
ii.
Dimensional details of each package.
iii. Weight of each package.
iv.
Nature of content (i.e. fragile or non-fragile)
In addition, the bidder from outside India offering CIF prices shall
also indicate the port of entry in India.
36.0
For all power transformer included in the
Bid specification ,
provisions and stipulations as per CBIP Manual on Transformers in regard to
the following except as modified in this document should be strictly adopted
a)
b)
Galvanising.
c)
Labels.
d)
e)
f)
Prevention of acidity.
g)
h)
i)
j)
k)
Suppressions of harmonics.
l)
m)
n)
Earthing arrangements.
MPPTCL/TECH/PROC/06/JULY13
Page 66 of 105
Volume-II, Part-4
o)
p)
q)
r)
s)
t)
u)
MPPTCL/TECH/PROC/06/JULY13
Page 67 of 105
Volume-II, Part-4
ANNEXURE I
PRINCIPAL PARAMETERS FOR 132/33 KV, 63 MVA
POWER TRANSFORMER
The transformers shall conform to the following specific parameters described
here under :transformer/ Two winding, Three phase suitable for
out door installation
Mounted on rails
Centre to centre distance 1676 mm +
Rail width on both direction
i.e
longitudinal and transverse.
Type of power
installation
Type of mounting
3
4
5
6
7
50 Hz
132/33 KV
Three
Two
ONAN/ONAF
50 MVA
63 MVA
Method of connection
HV - Star
LV - Star
10
Ynyno
11
System earthing
12
13
14
15
MPPTCL/TECH/PROC/06/JULY13
10%
ON LOAD
Taps on HV for variation of HV voltage
to provide constant 33 KV Voltage.
Page 68 of 105
Volume-II, Part-4
iii.
iv.
v.
Tap range
Tap step
Voltage and current rating
(-)15% to (+)5%.
1.25%
66KV/132 KV(Suitable for132KV
neutral end), 500Amp.(Min.)
16
17
18
19
Flux Density
a.
Working Flux density in 1.65
any part of core and yoke at
rated MVA,
frequency and
normal voltage .
21
HV/LV
550/250
230/95
Graded
Full
22
23
24
25
MPPTCL/TECH/PROC/06/JULY13
PHASE TO PHASE
GROUND
PHASE TO
Page 69 of 105
Volume-II, Part-4
b. LV ( 33)
26
27
28
29
30
Terminals : (Bushings)
a. HV winding line end
b. HV/LV winding Neutral end
c. LV winding
Max. Radio Interference voltage
level at 1 MHz. & 266 kV rms
phase to ground voltage for HV
winding
Cooling Equipments :
a. Number of banks
b. Number of Fans
Bushings :
a. Voltage Rating ( KVrms )
b Current Rating (Amps)
c. Insulation level
i. Lightning impulse
withstand(KVp)
ii. One minute power
frequency withstand
voltage (KV rms)
iii. Creepage distance (mm)
1430
700
1270
660
HV
LV
a) Bushing Current Transformer
for purchasers use
Single phase ring type turret mounted
i. Type
400/1
1200/1
ii. Current Ratio HV:LV(A/A)
3 nos
3 nos
iii. Quantity
1000V
1000V
iv. Knee point voltage (V)
PS
PS
v. Accuracy class
vi. Secondary resistance (Ohms) As per requirement or < one ohm
One
One
vii. No. of cores
HVN
LVN
b) Neutral
side
C.T.
for
Purchasers
use
(for
restricted E/F protection):
i. Type
Single phase ring type turret mounted
ii. Quantity
1 no
1 no
iii. No. of cores
One
One
iv. Current Ratio (A/A)
400/1
1200/1
v. Class of accuracy
PS
PS
Max.
secondary
winding As per requirement or < 1.5 ohm
resistance
MPPTCL/TECH/PROC/06/JULY13
Page 70 of 105
Volume-II, Part-4
ANNEXURE - II
LIST OF FITTINGS AND ACCESSORIES TO BE PROVIDED WITH EACH
POWER TRANSFORMERS.
1.
ii
iii
RWTI
: These shall be as per cl.11.10 of Section-I. A
precision potentiometer mounted inside the case shall function
as a transmitter to operate a repeater for RWTI. For HV
winding the transmitter shall be directly connected to the
repeater. For the LV winding the transmitter shall be
connected to a Resistance Transducer, which will supply DC
for operating repeater.
iv
One magnetic type oil level gauge with low level alarm
contacts and dial showing minimum, maximum and normal oil
levels.
One plain oil level gauge of over lapped type on either side of
the conservator shall also be provided.
vi
vii
MPPTCL/TECH/PROC/06/JULY13
Page 71 of 105
Volume-II, Part-4
viii
A set of air release valves on the top and on the radiators and
also at appropriate places.
ix
One thermometer
thermometer.
xi
xii
a.
b.
for
mercury
in
glass
type
xiii
xiv
xv
xvi
xvii
at
diagonally
opposite
a.
b.
Required no of cooling
fans
(Industrial
duty
of
adequate voltage & rpm) be provided in each bank to
ensure 100% ONAF rating of the transformer. As per
our specification, for each bank 20% additional cooling
fan is to be included which will be duly wired-up.
xviii
xix
xx
xxi
xxii
MPPTCL/TECH/PROC/06/JULY13
as
per
coil
Page 72 of 105
Volume-II, Part-4
xxiii
xxiv
xxv
xxvi
xxvii
MPPTCL/TECH/PROC/06/JULY13
Page 73 of 105
Volume-II, Part-4
be brought out on to a terminal box with cover. Arrangement
for inter connecting these terminals in the terminal box shall also
be provided. This arrangement shall facilitate verification of
core, end frame and tank insulation.
xxviii
xxix
2.
The equipments and accessories furnished with the transformer
shall be suitably mounted on the transformer for ease of operation, inspection
and maintenance and the mounting details shall be subject to the approval
of the purchaser. All valves shall be provided either with blind companion
flanges or with pipe plugs for protection.
3.
Indication, alarm and relay equipment shall have contacts suitable for
operation with 110V DC supply. Any other accessories or appliances
recommended by the manufacturer for the satisfactory operation of the
transformer shall also have 110V DC as input.
4.
a.
b.
All
cabinets
& panels shall
be
conforming
to
stipulations under Clause-16 of Section -I of specifications.
c.
5.
Provision for Measurement of Degree of Polymerisation of
Insulation of Winding of Transformer :- To assess the life of paper
insulation of winding , a provision is to be made inside the transformer . For
this purpose, a container of insulating material of good electrical, mechanical
& chemical properties having free circulation of oil through it shall be provided
at suitable location where maximum oil temperature is expected. In the
container, atleast 10-12 spools of paper having size not more than one cm be
placed . The container shall be closed and there should not be any possibility
of spools coming out from the container due to natural circulation as well
turbulence of oil during fault etc.
Location of the container shall be selected such that spools may be
removed from the container as and when required by the purchaser during
service of transformer for the purpose of testing of insulating material for
Degree of Polymerisation (DP test).
MPPTCL/TECH/PROC/06/JULY13
Page 74 of 105
Volume-II, Part-4
6.
Accessories, Which
Are Not
Included In The Above
Annexure But Details Of Which Are Given In Bid Specification And
Which Are Necessary For Satisfactory Operation Of Transformer Shall
Be Deemed To Have Been Included In The Accepted Price Without
Any Extra Cost To The Purchaser.
MPPTCL/TECH/PROC/06/JULY13
Page 75 of 105
Volume-II, Part-4
ANNEXURE -III
LIST OF TRANSFORMER ACCESSORIES AND THEIR TESTCERTIFICATES
TO BE SUBMITTED BY MANUFACTURERS/APPROVED VENDORS
S.
No.
Accessory
Condenser
Bushing
2.
Pronol
Ref. Std.
Test-certificates required
IS2099,
IEC60137
IEC
1.
2.
3.
OLTC
4.
Winding
IS 2026
part I,
IEC 60214
IS
MPPTCL/TECH/PROC/06/JULY13
Dimensional check,
inflation/Deflation at 10
inflation/Deflation at 10 KPa
Pressure test at 10 KPa for 24 Hr.
Volume-II, Part-4
S.
No.
Accessory
Ref. Std.
Temp
Indicator &
Oil Temp
Indicator
Test-certificates required
2. Dielectric test at 2 kV for one minute.
3. Accuracy test for indication and switch
setting scales.
4. Test for adjustability of switch setting
5. Test for switch rating
6. Measurement of temperature rise with
respect to the heater coil current.
5.
Pressure
Relief valve
IS13947
6.
Cooling Fan
and motor
assembly
IS 2312
7.
Buchholz
Relay
IS:3407
8.
Oil Level
gauge
including
MOG
IS
9.
Pressed Steel
IS: 513
MPPTCL/TECH/PROC/06/JULY13
dimensional
Page 77 of 105
Volume-II, Part-4
S.
No.
Accessory
Ref. Std.
Radiators
Test-certificates required
check.
2. Air pressure test at
water for 15 minutes
2 kg/cm2 under
10.
OLTC Control
cubical/Cooler
Control
cubicle
IS
11.
Bushing
Current
Transformers
IS: 2705
12.
Terminal
connector
IS5561
13
Silica Gel
Breather
IS
MPPTCL/TECH/PROC/06/JULY13
1.Pressure tests
2. Visual & dimension tests
3. Operation test
4. silica gel test
5. Oil compatibility test
Page 78 of 105
Volume-II, Part-4
ANNEXURE-IV
SCHEDULE OF INSPECTION COVER/ACCESS WINDOWS
No.
Particulars
Size
(Length x
Width)
(mm x mm)
Qty.
(Nos.)
450x900
400x500
500x500
500x500
500x500
MPPTCL/TECH/PROC/06/JULY13
Page 79 of 105
Volume-II, Part-4
ANNEXURE-V
Item
SCHEDULE OF VALVES
Description of Valves
Size
Qty
Type
(Design)
200NB
Gate valve
200NB
Gate valve
50NB
Gate valve
50NB
Gate valve
15NB
Globe valve
15NB
Globe valve
25NB
100NB
Butterfly valve
100NB
Gate valve
10
100NB
11
Bsp
12
Bsp
13
14
50NB
Globe valve
Bsp
--
15
Bsp
16
Bsp
17
Bsp
18
15NB
19
150NB
20
25NB
Gate valve
21
15NB
Globe valve
22
50NB
Gate valve
23
Bsp
24
Bsp
25
100NB
Butterfly valve
26
25NB
Globe valve
27
15NB
Gate valve
28
25NB
Globe valve
29
15NB
Globe valve
30
80NB
Gate valve
31
25NB
Gate valve
32
Bsp
Gate valve
MPPTCL/TECH/PROC/06/JULY13
Gate valve
Page 80 of 105
Volume-II, Part-4
Item
Description of Valves
Size
Qty
Type
(Design)
33
50NB
Gate valve
34
25NB
Gate valve
35
25NB
Gate valve
* NOTE: 1. All valves shall have position indicators to indicate the status i.e. valves
are in open or shut position.
2. All valves shall be made of gun metal (GM); cast iron valves are not
acceptable.
3. All plugs shall be made of cast iron (CI)/GM
NB- Normal Bore mm.
MPPTCL/TECH/PROC/06/JULY13
Page 81 of 105
Volume-II, Part-4
ANNEXURE VI (A)
DRAWINGS AND DATA TO BE FURNISHED BY THE BIDDER.
The following drawings and data for each items are to be submitted
with the Bid
(a)
(b)
Drawing of
transformer tank with location of inspection windows,
thickness of side/bottom/top of tank, details of stiffener.
(c)
(d)
(e)
(f)
(g)
(h)
(i)
(j)
MPPTCL/TECH/PROC/06/JULY13
of the
ducts,
screws,
should
you for
Page 82 of 105
Volume-II, Part-4
(k)
(l)
(m)
(n)
Drawing
including
(o)
(p)
Oil filling instruction plate for conservator fitted with Air cell breather
arrangement including equalizing arrangement if any required at
the time of taking full Vacuum at site.
(q)
(r)
(s)
(t)
(u)
(v)
(w)
Detailed drawing
transformer tank.
(x)
Drawing
of Thermosyphon filter with fixing arrangement
transformer tank.
(y)
(z)
(aa)
(ab)
(ac)
indicating plate
MPPTCL/TECH/PROC/06/JULY13
with
Page 83 of 105
Volume-II, Part-4
(ad)
(ae)
(af)
(ag)
(ah)
(ai)
(aj)
(ak)
Internal drawing & design of Core & Winding indicating all attachment
with identification numbers, description including take-off arrangement
of lead connection for Core & End frame and related Bill of Material
(al)
Locking arrangement drawing for tank top cover, core & winding with
complete dimension & details.
(am) Plan view of the bottom of Bell Tank for complete details of core coil
resting arrangement, indicating clearly dimensional details, material of
insulation, clamping arrangement with details of nuts/ bolts, clearance
from all sides provided at bottom.
(an)
(ao)
(ap)
As soon as possible after the award of the contract the manufacturer shall
supply four (4) copies of the drawings as listed out above, which will
describe the equipment in details for approval and shall subsequently
provide ten complete sets of final drawings, one of which shall be autopositive suitable for taking blue prints. Ten sets of instruction books,
operation and maintenance manuals and spare part bulletin, shall be
supplied. In addition to above two sets of manuals and drawings with test
certificates for each unit to be despatched as per despatch instructions.
MPPTCL/TECH/PROC/06/JULY13
Page 84 of 105
Volume-II, Part-4
ANNEXURE VI (B)
LIST OF DRAWINGS TO BE FURNISHED ALONGWITH BID AND
DETAILS TO BE SUBMITTED WITH THE BID
S.No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
Particulars
OGA drawing of transformer
List of fittings & accessories for OGA
Drawing for HV,LV , OIP Condenser bushings
Makes of various accessories and source of raw material
Universal type bimetallic terminal connector for HV,LV, Neutral
Conservator with air cell breathing arrangement
Thermosyphon filter assembly with pump & without pump
Internal clearances detailed drawing
Dimensional details for transportation of transformer.
Radiator arrangement
Core earthing arrangement box
Yoke binding details
Neutral earthing arrangement
Foundation details
List of tools & tackles
Bottom locking & insulating arrangement
Core insulation details
MS Ladder
Sealing arrangement between top & bottom shell.
OLTC Conservator with breather arrangement
Drawings for various types of valves.
Core shunt fixing arrangement
Rating & diagram plate
Valve schedule plate
Oil filling instruction plate for conservator with air cell.
Roller assembly with anit-earthquake arrangement
Coil clamping arrangement
Oil flow diagram
Winding details arrangement with dimension
Core details with design data
Over fluxing curve
Drawing for tank stiffener & magnetic shunt inside transformer with
calculation.
Schematic drawings for OLTC, FCC & RTCC .
Cooler control cubicle cum marshalling box with schematic
RTCC panel drawing
Drawing for static end ring
Complete dimensioned details of bottom tank
MPPTCL/TECH/PROC/06/JULY13
Page 85 of 105
Volume-II, Part-4
ANNEXURE VII
CALCULATIONS REQUIRED TO BE ENCLOSED WITH
THE BID FOR POWER TRANSFORMER
It should be specifically noted by the Bidders that submission of
following Design Calculations & Design Data with the offer is
necessary and bids wherein these calculations are not found enclosed
shall run risk of rejection.
(1) SHORT CIRCUIT WITHSTAND CAPABILITIES : The calculations to
prove dynamic and thermal short circuit withstand capability of transformer
as per clause 31.1.1 shall be submitted for the fault level indicated as
under:
132KV
33KV
40 KA for 3 secs.
31.5KA for 3 secs.
Results of calculations shall be submitted with the Bid . The design of winding
assembly , which is to be furnished in the drawing as per Sr. No. (e) of
Annexure VI should be commensurating with these calculations. The details
of clamping ring shall be indicated in the drawing .
(2) DESIGN DATA OF CORE & WINDING : On the basis of offered flux
density and current density, the Bidders shall furnish furnish following
design calculations & data. Calculations regarding wt. of core & copper and
also calculations for losses will
be brought out to justify the offered
transformer losses. :
(A) Core Data: Details of core material i.e Name of Manufacturer,
Manufacturers type designation for core , thickness of core, curve for
Loss Vs Flux density, No of steps of Core & No of limbs, gross core area
, stacking factor , Net core area ,height & width of core window, center
to center distance of limb, voltage per turn, wt. of core material,
working flux density , core loss in watts per kg marked on graph for
grade of core material & selected flux density, building factor
and
calculated no load loss in watts, guaranteed no load loss. Design data for
core as per clause 31.2.1 shall be submitted with the Bid. A drawing
indicating details of core i.e. limbed construction, step width & thickness
, core belting, top & bottom yoke plate etc shall be submitted with the
Bid .
(B)
Winding Data: wt. of copper for windings ie. for HV, LV, tap, cross
sectional area , current density, type of coil, ID/OD/mean dia of coils,
size of winding conductor including parallels, no. of turns per phase, no
of spacers, length of mean turn, weight of copper without paper
covering, resistance per phase of winding at 750C, I2R loss at 750C &
normal tap, eddy current & stray loss at 750C , total copper loss at 750C ,
guaranteed transformer losses at 750C.
MPPTCL/TECH/PROC/06/JULY13
Page 86 of 105
Volume-II, Part-4
Complete details of Insulation components i.e. Top & Bottom clamping
rings, washers , Pressboard blocks & cylinders, Pressboard spacers &
Phase barriers, Pressboard segments etc shall be submitted indicating
qty , thickness in mm, width & height , wt. Design data for winding as
per clause 31.2.2 shall be submitted with the Bid .
Dimensioned drawings indicating details of winding , ducts, insulation ,
take off arrangement, clamping ring , pressure points etc shall be
submitted with the Bid .
(3) DESIGN OF TANK : Complete mechanical design of transformer tank
including details of stiffeners as per clause 31.1.2 shall be submitted . The
tank shall be designed to withstand the following
without permanent
distortion.
(i)
(ii)
The calculations for tank stiffeners shall be submitted with the Bid to prove
no. & size of stiffeners are adequate to withstand full vacuum & pressure .
Drawing of tank shall be submitted indicating stiffners .
(4) DESIGN OF STATIC END RINGS (SER) AND MAGNETIC SHUNTS :
Details of Static End Rings (SER) and magnetic shunts , if provided , with
calculations as per clause 31.1.3 shall be submitted with the Bid . A drawing
indicating locations , size ,material of SER and magnetic shunts shall be
submitted with the Bid .
(5) QUANTITY OF OIL : Complete calculations of oil quantity to be utilized
in transformer for first filling shall be submitted
with the Bid . The
calculations shall indicate
(i) Volume of tank including turrets, conservator main & OLTC ,volume
of headers & Radiators, oil quantity in OLTC & thermosyphon filter.
(ii) Oil displacement by Active parts i.e. core - coil assembly,
(6) CAPACITY OF CONSERVATOR & SIZE OF AIR CELL : While furnishing
details of conservator & air cell type sealing arrangement, the Bidder shall
submit details & calculations for adequacy of size and capacity of Pronal
make air cell for the rating of the power transformer and also for the
quantity of oil required with the Bid. Catalogue of Pronal should be enclosed
with the Bid clearly marking type designation of selected size of Air cell. A
drawing indicating complete details of conservator with Air cell shall be
submitted .
MPPTCL/TECH/PROC/06/JULY13
Page 87 of 105
Volume-II, Part-4
(7) CAPACITY OF PRESSURE RELIEF DEVICE : Bidders must submit
calculation with the Bid to prove that the capacity/rating of pressure relief
device and locations of the same for the transformer will adequately meet our
requirement. Constructional and design details of pressure relief device must
be furnished and it should be proved by calculation that the size
and
setting of pressure relief device is adequate considering the rating of the
transformer and quantity of oil in the transformer. A drawing indicating
complete details of PRDs & their locations on tank shall be submitted .
(8) CALCULATIONS FOR TEMPERATURE RISE & HOT SPOT WINDING
TEMPERATURE : The limits of temperature rise for windings, oil and hot spot
have been specified in Volume II . Temperature rise calculations at rated full
load, 110% load and 125% load considering 100% cooler banks, 50% cooler
banks and without coolers shall be furnished as indicated below :
(a)
(b)
(c)
The calculations shall indicate temperature gradient (for all windings i.e.
HV,LV,tap), load losses at lowest tap for all windings , Eddy current & stray
losses, thermal Constant Value & calculations with parameters affecting the
values for above conditions for top oil temperature & winding hot spot
temperature. The Calculations for Hot Spot winding Temperature and
Temperature Rise shall be submitted with the bid.
(9)
COOLING CALCULATIONS : Calculations of tank surface for heat
dissipation, details of radiators , fans for ONAN & ONAF cooling shall be
provided with the bid.
(10)
OVERFLUXING CAPABILITY: A curve to prove suitability of
transformer to withstand various Overfluxing conditions for the duration
indicated in clause 4.4.1 to 4.4.3 without core saturation shall be furnished
with the Bid .
(11)
(A)
MPPTCL/TECH/PROC/06/JULY13
Page 88 of 105
Volume-II, Part-4
capacity of thermosyphon filter for the oil quantity in the power
transformer. While furnishing details of thermosyphon filter
arrangements, the Bidder must confirm clearly the
number of
thermosyphon filter, its size and capacity is adequate for the rating of
power transformer. The Bidder shall submit details & calculation to
prove for adequacy of size and capacity of thermosyphon filter with the
bid.
(B)
Capacity of Silica Gel Breather : The Bidder shall submit details &
calculations for adequacy of size and capacity of silica gel breather
for the oil quantity in the power transformer with the bid.
MPPTCL/TECH/PROC/06/JULY13
Page 89 of 105
Volume-II, Part-4
ANNEXURE VIII
DETAILS OF INSPECTION PROGRAMME
1.
INSPECTION
PROGRAMME :
STAGE INSPECTIONS :
2.2.1 Manufacturer shall indicate the inspections and checks carried out at
various stages of the manufacture of the transformer. A complete record of
stage inspection shall be kept by Manufacturer and this record shall be made
available for inspection by the representative of the MPPTCL. Manufacturer
shall indicate the manufacturing programme and the MPPTCL will have a right
to depute its inspecting officers during the manufacture. The inspecting stages
shall be Fabrication of Tank & Conservator, core building, coil winding ,
assembly of coil on core, the condition of the coil and core after the
treatment in vacuum chamber, assembly within the transformer tank
together with application of tap changer etc .
2.2.2 It may be noted that stage inspections for all the units shall be done
by us at the following stages as per the different formats enclosed :
(i) STAGE I : Stage Inspection of Transformer Tank and Conservator
after fabrication. After fabrication, tank & conservator shall be inspected for
measurement of its dimensions, thickness of sheets used and leakage test by
applying requisite pressure.
In this stage following shall be measured ,recorded & checked in Format I
(A,B,C) .
(A) Format I (A) : Inspection of Tank & Conservator
a) Certification of chemical composition and mechanical properties
of plates.
b) Welder's and weld procedure qualification.
c) Testing of electrodes for quality of base materials as per ASME.
d) Dimensional check and visual Inspection of weld .
e) Crack detection, of
major strength weld seams by dye
penetration test.
f) Measurement of film thickness of inside and outside of X'mer tank
and conservator
i) Oil insoluble varnish
ii) Zinc chromate paint
iii) Light grey paint
g)
Check correct dimensions between wheels, rotation of wheels
through 90 deg.
h) Check for physical properties of materials for lifting lugs, jacking
pads, etc.
All load bearing welds including lifting lug and jacking
parts shall be subjected to DP test.
MPPTCL/TECH/PROC/06/JULY13
Page 90 of 105
Volume-II, Part-4
i)
j)
k)
l)
(B)
(C)
(B)
(C)
MPPTCL/TECH/PROC/06/JULY13
Page 91 of 105
Volume-II, Part-4
a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
(iii)
STAGE III : Stage Inspection of Winding after their preparation
: Once the coils are prepared but before the same are
fitted on to
the core, stage inspection shall be done to take various measurements
and also for weighment of total weight of coil of each voltage class.
Measurement of winding resistance shall be also done. A small piece of
conductor for each type of winding shall be made available by the
manufacturer to our representative.
During this stage, following documents shall be verified by MPPTCL
inspector as a proof towards use of prime copper and insulating material
for manufacturer of transformer ordered by us :
i)
ii)
iii)
iv)
v)
Page 92 of 105
Volume-II, Part-4
(A)
Winding:
a)
Insulating Material:
a)
b)
c)
d)
e)
MPPTCL/TECH/PROC/06/JULY13
Page 93 of 105
Volume-II, Part-4
(v)
Check
completed
transformer
against approved
drawing, provision for all fittings, finish level etc.
Jacking test on all the assembled Transformers.
out line
MPPTCL/TECH/PROC/06/JULY13
Page 94 of 105
Volume-II, Part-4
ANNEXURE IX
LIST OF HAND TOOLS FOR SUPPLY
ALONG WITH EACH 132 KV, 63 MVA TRANSFORMER
(A)
1.
SPANNERS
a)
Square
drive
inch
inch
1-7 Kg mtr
7-35 Kg mtr
4.
30mm
32mm
Head
depth
45 mm
55mm
5.
Head width
(mm
)
3,0
4,0
5,5
6,0
8,0
9,0
Length of
steel (mm)
75
100
125
150
175
200
Total length of
Screw
Driver(mm)
155
190
225
250
285
310
6. GASKET PUNCH : 1 set comprising of size 8, 10, 12, 14, 16, 18,
20, 22, 24, 25mm.
MPPTCL/TECH/PROC/06/JULY13
Page 95 of 105
Volume-II, Part-4
ANNEXURE -X
DESCRIPTION OF EQUIPMENT FOR SCHEDULE OF RATES & PRICES
For this Bid which includes 132 KV 40 MVA transformers, description of main
equipments and other items should be brought out exactly as per details
furnished herein and accordingly schedule of price should be enclosed with
the Bid.
Item
Nos
Description
Particulars
Supply
of
63MVA
132/33KV,
Three
phase
ONAN/ONAF cooled transformer fitted with Pronol
air-cell, and all accessories/ fittings as described
under annexure II , duly passed all routine additional
routine and acceptance tests as per IS-2026 with
one set of tools as per annexure IX complete with
first filling of oil including wastage & 10% extra of
that quantity & meeting all technical requirement
as
per Part-2 of Volume II & annexure I. The
offered cost includes cost of all tests as per clause
24.5 and conforming to all requirements as described
in bid document. The transformers shall be supplied
fitted with Impact Recorder (on returnable basis)
during transportation of Transformers and Vehicle
tracking system (GPRS/ GPS/ GSM based) to track
the exact position of the vehicle during transportation
of Transformers as per clause no. 37.0.
As per price
Schedule.
2.
SIGNATURE
WITH SEAL OF BIDDER
MPPTCL/TECH/PROC/06/JULY13
Page 96 of 105
Volume-II, Part-4
ANNEXURE XI
LIST OF VENDORS FOR MAJOR ITEMS OF TRANSFORMER
The vendors of various major items from whom procurement was made by
various suppliers of transformers and quality of which was found acceptable
are listed below. However, Major items/inputs in transformers have to
conform to highest quality standards and these items/inputs procured from
any vendors meeting the required specification would be acceptable.
No.
1.
2.
(a)
Name of Item
Supplier
CRGO
MPPTCL/TECH/PROC/06/JULY13
Page 97 of 105
Volume-II, Part-4
No.
M/s
M/s
M/s
M/s
Supplier
Lacroix and Kress (GMBH) germany
Pirellicavi Italy
Shree Cable & Conductors
Chandra Metals,allahabad
CTC Conductor
M/s
M/s
M/s
M/s
M/s
3.
Precompressed
press Board & press
Board components
M/s
M/s
M/s
M/s
H. Weidmann, Switzerland
Fige Holms Brruk, Swedan
Senapathy Whiteley, Banglore
Raman Board, Mysore
4.
Insulating Material
M/s
M/s
M/s
M/s
M/s
M/s
Dupont, USA
Senapathy Whiteley, Banglore
H. Weidmann, Switzerland
Munksio
Amotfors, Sweden
Krammerer
5.
Air Cell
M/s PRONAL,
M/s PRONAL, Asia manufacturing SDN BHD
Malaysia
6.
Gaskets
M/s
M/s
M/s
M/s
M/s
M/s
M/s
M/s
M/s
Talbros, Faridabad
Cortica, Chennai
Packing & Jointing, Chennai
Indian Rubber Products, Haridwar
Bombay Oil Seal Mfg. Mumbai
MGM Rubber Kolkata
Bharat Corrub Industries, Vadodara.
Indian Cork Industries,Bahadarpur
Nucork, Gurgaon
7.
OIP Condensor
bushing
M/s
M/s
M/s
M/s
M/s
BHEL
CGL
TELK
ASEA-MICAFIL
Passonivilla
8.
Terminal Connector
M/s
M/s
M/s
M/s
M/s
(b)
Name of Item
MPPTCL/TECH/PROC/06/JULY13
Page 98 of 105
Volume-II, Part-4
No.
9.
Name of Item
Supplier
M/s Vinayak and Co., Mumbai
M/s Megha Engg. Enterprises, Chennai
M/s Klemmen Engg. Corporation , Chennai
OTI/WTI with
repeater
10.
11.
M/s
M/s
M/s
M/s
M/s
12.
Pressure Relief
Device
M/s
M/s
M/s
M/s
Qualtrol, USA
GE, USA;
Sukrut Udyog, Pune
ATVUS Industries, Kolkatta
13.
14.
Un-impregnated
Densified laminated
wood
M/s
M/s
M/s
M/s
M/s
15.
Valves
M/s
M/s
M/s
M/s
M/s
M/s
M/s
M/s
M/s
M/s
M/s
Leader
Bombay Metal & Alloys
Audco
Petson
Manixon
Creseant
Precision Engg. Kottayam,
Eapen Joseph, Kottayam
Apex Piping Systems, Jalandhar
Liberty Engg., Mumbai
Niton Valves, Mumbai
MPPTCL/TECH/PROC/06/JULY13
Page 99 of 105
Volume-II, Part-4
No.
Name of Item
Supplier
M/s Eapen Joseph & co., Coimbatore
M/s GG Valves ,Udaipur
16.
MCB
Ms Siemans
M/s MDS
M/s S&S
M/s Havell's
17.
Fuse
18.
Tank Steel
M/s SAIL
M/s Essar
19.
OLTC Complete
M/s BHEL
M/s TELK
M/s Easun, Madras
20.
Terminal Blocks
M/S ELMEX
M/S Technoplast,
M/S Tosha
21.
22.
Transformer oil
23.
Radiator
M/s
M/s
M/s
M/s
M/s
24.
MPPTCL/TECH/PROC/06/JULY13
Volume-II, Part-4
APPENDIX I
Calculation for Hot Spot winding temperature for EHV transformers
Overloading capability of the transformer and also the loading
capability of transformer with and without cooling fans (coolers) for a
short period of 10/20 minutes with out exceeding temperature rise of
winding beyond specified limits have been indicated in the technical
specification. In this regard following calculation based on maximum
ambient air temperature as 50 degree centigrade and maximum
yearly average weighted air temperature as 32 degree centigrade
using the under mentioned formulae or any other authentic formulae
shall be furnished.
-t/
c = a +
b0
+ ( b- bo) ( 1- e
2
b =
br
( 1+dk )
------------- ( 1+d) x
2y
) + ( c - b ) k
Where
a
cr
cr
bo
br
br
MPPTCL/TECH/PROC/06/JULY13
S /Sr
Volume-II, Part-4
K1
= S1 /Sr
K1
K2
SIGNATURE
WITH SEAL OF
BIDDER
MPPTCL/TECH/PROC/06/JULY13
Volume-II, Part-4
APPENDIX II
TECHNICAL PARTICULARS TO BE FILLED-IN BY BIDDER
S. No.
Particulars
Values
Losses
a. No load Losses (KW)
b. Load Losses including stray losses
(KW)
c. Auxiliary losses (KW)
10
Quantity of oil
a. For first filling including
(KL/Kg)
b. 10% extra of a (KL/Kg)
11
12
wastage
SIGNATURE
WITH SEAL OF BIDDER
MPPTCL/TECH/PROC/06/JULY13
Volume-II, Part-4
OLTC
OIP
DL type
COPS
RTCC
Cl
IEEMA
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
KV
KW
IV
LV
VPD
ONAN
ONAF
OFAF
CBIP
OTI
WTI
KA
TC
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
V
f
VN
FN
CT
PT
Xmer
PRD
PRV
MOLG
OSR
Isc
V
Zt
Zs
1
0
J
t
Iph
Zpu
Rdc
MPPTCL/TECH/PROC/06/JULY13
Volume-II, Part-4
48.
49.
50.
51.
52.
53.
54.
55.
56.
Hw
N
Dmi
Bi
E
Sn
Pu
Fa
Ai
57.
Ao
58.
59.
60.
61.
62.
63.
64.
65.
66.
67.
68.
69.
70.
71.
72.
73.
bo
Dmo
Ao
F
D
b
t
n
mA
kg
kl
temp.
max.
min.
vol.
height of winding in cm
no of turns per phase of winding
mean diameter of inside winding ,cm
thickness of inside winding conductor ,cm
modulus of elasticity of conductor, cm
rated KVA
per unit impedance
axial imbalance force, Kg
(no of spacers x length x width ) for inner
winding
(no of spacers x length x width ) for outer
winding
no of conductors in the radial direction= no of
turns x no of parallel conductor
thickness of outer winding conductor, cm
mean diameter of outer winding, cm
supported area of outer radial spacers
total axial force in MT
mean diameter of clamping ring ,cm
width of clamping ring ,cm
thickness of clamping ring ,cm
no of jacking or clamping points
milli ampere
kilogram
kilolitre
temperature
maximum
minimum
volume
MPPTCL/TECH/PROC/06/JULY13
ANNEXURE 1(A)
LIST OF VENDORS FOR MAJOR ITEMS OF TRANSFORMER
The vendors of various major items from whom procurement was made by various
suppliers of transformers and quality of which was found acceptable are listed
below. However, Major items/inputs in transformers have to conform to highest
quality standards and these items/inputs procured from any vendors meeting the
required specification would be acceptable.
No.
1.
2.
(a)
Name of Item
Supplier
CRGO
No.
(b)
Name of Item
Supplier
M/s Chandra Metals,allahabad
CTC Conductor
M/s
M/s
M/s
M/s
3.
Precompressed
press Board & press
Board components
M/s
M/s
M/s
M/s
H. Weidmann, Switzerland
Fige Holms Brruk, Swedan
Senapathy Whiteley, Banglore
Raman Board, Mysore
4.
Insulating Material
M/s
M/s
M/s
M/s
M/s
M/s
Dupont, USA
Senapathy Whiteley, Banglore
H. Weidmann, Switzerland
Munksio
Amotfors, Sweden
Krammerer
5.
Air Cell
6.
Gaskets
M/s
M/s
M/s
M/s
M/s
M/s
M/s
M/s
Talbros, Faridabad
Cortica, Chennai
Packing & Jointing, Chennai
Indian Rubber Products, Haridwar
Bombay Oil Seal Mfg. Mumbai
MGM Rubber Kolkata
Bharat Corrub Industries, Vadodara.
Indian Cork Industries,Bahadarpur
7.
OIP Condensor
bushing
M/s
M/s
M/s
M/s
M/s
BHEL
CGL
TELK
ASEA-MICAFIL
Passonivilla
8.
Terminal Connector
M/s
M/s
M/s
M/s
M/s
M/s
M/s
M/s
No.
9.
Name of Item
Supplier
OTI/WTI with
repeater
10.
11.
M/s
M/s
M/s
M/s
M/s
12.
Pressure Relief
Device
13.
M/s
M/s
M/s
M/s
Areva(Alstom) ,Calcutta
CGL, Mumbai
Khaitan,Calcutta.
EPC, Calcutta
14.
Un-impregnated
Densified laminated
wood
M/s
M/s
M/s
M/s
M/s
15.
Valves
M/s
M/s
M/s
M/s
M/s
M/s
M/s
M/s
M/s
M/s
M/s
M/s
M/s
Leader
Bombay Metal & Alloys
Audco
Petson
Manixon
Creseant
Precision Engg. Kottayam,
Eapen Joseph, Kottayam
Apex Piping Systems, Jalandhar
Liberty Engg., Mumbai
Niton Valves, Mumbai
Eapen Joseph & co., Coimbatore
GG Valves ,Udaipur
No.
Name of Item
Supplier
16.
MCB
Ms Siemans
M/s MDS
M/s S&S
M/s Havell's
17.
Fuse
18.
Tank Steel
M/s SAIL
M/s Essar
19.
OLTC Complete
M/s BHEL
M/s TELK
M/s Easun, Madras
20.
Terminal Blocks
M/S ELMEX
M/S Technoplast,
M/S Tosha
21.
22.
Transformer oil
23.
Radiator
M/s
M/s
M/s
M/s
M/s
24.
On Line Monitoring
Device
M/s Kelman, UK
25.