CIGRE Brochure 528 Transformer Specifications

528
GUIDE FOR
PREPARATION OF SPECIFICATIONS
FOR POWER TRANSFORMERS
Working Group
A2.36
April 2013
GUIDE FOR
PREPARATION OF SPECIFICATIONS
FOR POWER TRANSFORMERS
WORKING GROUP A2.36

Task Force 1
Replaces TB 156
Convenor: T. Breckenridge (UK)

Task Force Leader: M. Lamb (USA)
Members
N. Buthelezi (SA), A. Cancino (MX), L. Cornelissen (BE), E. de Groot (NL),

M. Figura (PL), T. Fogelberg (SE), T.Gradnik (SI), AC Hall (UK),
J. Lackey (CA), A. Manga (CA), A. Mjelve (NO), M. Oliva (SP), V. Podobnik (HR),
S. Ryder (UK), K. Ryen (NO), C.Swinderman (USA), J.Velek (CZ), M. Zouiti (FR).
Copyright 2013
Ownership of a CIGRE publication, whether in paper form or on electronic support only

infers right of use for personal purposes. Unless explicitly agreed by CIGRE in writing,
total or partial reproduction of the publication and/or transfer to a third party is prohibited
other than for personal use by CIGRE Individual Members or for use within CIGRE
Collective Member organisations. Circulation on any intranet or other company network
is forbidden for all persons. As an exception, CIGRE Collective Members only are
allowed to reproduce the publication.
Disclaimer notice
CIGR gives no warranty or assurance about the contents of this publication, nor does
it accept any responsibility, as to the accuracy or exhaustiveness of the information. All
implied warranties and conditions are excluded to the maximum extent permitted by
law.
ISBN: 978-2-85873-222-7
WG A2-36 Guide for preparation of specifications for power transformers
Contents
FOREWORD ................................................................................................................................. 1
1 SCOPE AND STANDARDS .................................................................................................. 4

1.1 Scope ............................................................................................................................ 4
1.2 Standards ...................................................................................................................... 4
2 DEFINITIONS ........................................................................................................................ 5
3 EXTENT OF SUPPLY ........................................................................................................... 6

3.1 General ......................................................................................................................... 6
3.2 Additional Requirements ............................................................................................... 6
3.3 Exclusions ..................................................................................................................... 6
3.4 Alternative offers ........................................................................................................... 6
3.5 Transfer of liability/ownership ....................................................................................... 7
4 PURPOSE OF THE EQUIPMENT ........................................................................................ 7

4.1 Some Examples ............................................................................................................ 7
5 SYSTEM OPERATING CONDITIONS .................................................................................. 7

5.1 General Description of Network .................................................................................... 7
5.2 Insulation Co-ordination ................................................................................................ 8
5.2.1 Method of System Earthing ....................................................................................... 8
5.2.2 Unusual Operating Conditions .................................................................................. 8
5.3 Short-Circuit Withstand ................................................................................................. 8
5.4 Over-Excitation.............................................................................................................. 9
5.5 DC Magnetisation........................................................................................................ 10
5.6 Harmonics ................................................................................................................... 10
5.7 Loading ....................................................................................................................... 10
5.8 Neutral Point Loading ................................................................................................. 11
6 SITE INFORMATION .......................................................................................................... 11
7 CONTRACT WORKS .......................................................................................................... 11

7.1 Installation Details ....................................................................................................... 11
7.2 Documentation Requirements .................................................................................... 11
7.3 Details of Additional Requirements ............................................................................. 12
7.4 Details of Requirements for Interfacing with Other Equipment, or to Achieve
Interchangeability or Permit Parallel Operation .......................................................... 12
8 ENVIRONMENTAL CONSIDERATIONS ............................................................................ 12

8.1 General ...................................................................................................................... 12
8.2 Audible Sound ............................................................................................................. 13
8.3 Losses ......................................................................................................................... 13
8.4 Oil pollution ................................................................................................................. 14
8.5 Explosion or blast hazards .......................................................................................... 14
8.6 Fire hazards ................................................................................................................ 14
8.7 Visual impact ............................................................................................................... 15
8.8 Seismic impact ............................................................................................................ 15
9 TRANSPORT ...................................................................................................................... 15
9.1 General ....................................................................................................................... 16
9.2 Design for transport .................................................................................................... 16
9.3 Impact recorders ......................................................................................................... 17
9.4 Transportation with or without oil ................................................................................ 17
9.5 Loose equipment......................................................................................................... 18
9.6 Inventory ..................................................................................................................... 18
9.7 Handling and markings ............................................................................................... 18
9.8 Documentation ............................................................................................................ 18
i
9.9 Storage ........................................................................................................................ 19

9.10 Storage without oil ...................................................................................................... 19
9.11 Storage with oil............................................................................................................ 20
10 SAFE WORKING SYSTEMS ......................................................................................... 20
11 TECHNICAL REQUIREMENTS ..................................................................................... 21

11.1 General ....................................................................................................................... 21
11.2 Normal and Abnormal Operating Conditions .............................................................. 21
11.2.1 Gas and Oil Actuated relays ............................................................................... 21
11.2.2 Overloads ............................................................................................................ 21
11.2.3 Geomagnetic Induced Current (GIC) Effects ...................................................... 22
11.3 Design Requirements ................................................................................................. 22
11.3.1 Flux density ......................................................................................................... 22
11.3.2 Voltage regulation ............................................................................................... 22
11.3.3 Cooling ................................................................................................................ 23
11.3.4 Control detail ....................................................................................................... 23
11.3.5 System Earthing .................................................................................................. 23
11.4 Core ............................................................................................................................ 23
11.5 Tank ............................................................................................................................ 24
11.5.1 Handling facilities ................................................................................................ 24
11.5.2 Cover ................................................................................................................... 24
11.5.3 Oil-tight Joints ..................................................................................................... 24
11.5.4 Vacuum and pressure requirements ................................................................... 25
11.5.5 Valves ................................................................................................................. 25
11.5.6 Circulating and eddy-currents ............................................................................. 26
11.5.7 Access Openings ................................................................................................ 26
11.5.8 Conservator Tanks .............................................................................................. 26
11.5.9 Tank Earthing ...................................................................................................... 26
11.5.10 Pressure relief ..................................................................................................... 27
11.6 Insulating Fluid ............................................................................................................ 27
11.7 Bushings ..................................................................................................................... 27
11.8 Secondary Wiring and Control Cabinets ..................................................................... 28
11.9 Fittings ......................................................................................................................... 28
11.10 Tap Changers ......................................................................................................... 29
11.11 Monitoring ............................................................................................................... 31
11.12 Interchangeability ......................................................................................................... 31
11.13 Standardisation ....................................................................................................... 31
11.14 Exclusions ............................................................................................................... 32
12 MANAGING QUALITY ................................................................................................... 32

12.1 Quality Inspection and Test Plan (QITP) .................................................................... 33
12.2 Quality Inspection and Test Plan (Outline) ................................................................. 33
12.3 Quality Assurance Plan ............................................................................................... 35
12.4 Quality Assurance Manuals ........................................................................................ 35
12.5 Final Quality File ......................................................................................................... 35
13 FACTORY ACCEPTANCE TESTS AND FINAL INSPECTIONS .................................. 37

13.1 General ....................................................................................................................... 38
13.2 Standards and testing specifications .......................................................................... 38
13.3 Testing environment ................................................................................................... 38
13.4 Measurement accuracy ............................................................................................... 38
13.5 Tolerances .................................................................................................................. 39
13.6 Summary of tests ........................................................................................................ 39
13.6.1 Routine tests ............................................................................................................ 39
13.6.2 Type tests .......................................................................................................... 40
13.6.3 Special tests ........................................................................................................... 40
13.6.4 Additional tests .................................................................................................... 41
13.7 Test sequence............................................................................................................. 41
13.8 Test results and test reports ....................................................................................... 42
13.9 Site acceptance tests - erection tests ......................................................................... 42
ii
13.9.1 General ............................................................................................................... 42

13.9.2 Required tests ..................................................................................................... 43
13.9.3 Commissioning tests ........................................................................................... 43
13.10 Energisation ............................................................................................................ 44
13.11 Trial operation ......................................................................................................... 44
13.12 Special tests ............................................................................................................ 44
13.13 Site test reports ....................................................................................................... 45
14 LIST OF GUARANTEES AND WARRANTIES .............................................................. 45

14.1 Guaranteed performances .......................................................................................... 45
14.2 Other types of guarantee ............................................................................................ 45
15 CONTRACT DOCUMENTATION ................................................................................... 46

15.1 An Enquiry document should include the following details, where applicable: ........... 46
15.2 A Tender should include: ............................................................................................ 46
15.3 A manufacturer should provide the following documents as part of a Contract: ........ 46
16 EXAMPLES OF TECHNICAL AND OTHER INFORMATION SCHEDULES RELATING

TO A TRANSFORMER SPECIFICATION ..................................................................... 47
APPENDIX A - Loss evaluation, penalties, bonuses and rejection ................................... 63
iii
FOREWORD
CIGR Technical Brochure 156 was first published under the auspices of CIGR
Study Committee 12 in 2000. This first revision of the original document has been
prepared by CIGR WG A2-36 Transformer Procurement Process and directly
replaces Technical Brochure 156.
The original document was produced by Working Group 12.15 and published in April
2000. The members of the original Working Group 12.15 were:
A. C. Hall (UK) Convener,
A. Alvarez (ES), S. Bhumiwat (TH), G. Cannavale (IT), A. Carlson (SE), V.M.
Chornogotsky (UA), J. Elovaara (FI), G. Gomez (ES), A. Higgins (IR), J. Kulikowski
(PL), R. De Lhorbe (CA), Z. Luspay (HU), T.L. Machado (BR), G. Moore (IR), K.
Newman (UK), H.J. Klein Nibbelink (NL), J-O. Persson (SE), A Petersen (AU), J-F.
Ravot (CH), Y Shafir (UE), C.M. Sharma (IN), V. Sokolov (UA), J-P. Taisne (FR), E.
Troyan (UA), J-P. Uehlinger (CH).
This document is a general update from the existing CIGR Technical Brochure 156
and introduces additional sections based on current market issues such as
transportation. References to IEC standards have been updated to reflect the current
documents many of which have be brought under the IEC 60076-X umbrella since the
original publication date.
The title of the previous guide restricted the application to above 123 kV and above
100 MVA. The principles in this document are equally applicable at lower voltages and
lower rated power where purchasers often require more support than larger user and
so the limitations in the title have been removed to widen the scope of application.
This document has been prepared as an aid to purchasers and manufacturers of
power transformers in the preparation of specifications for purchasing transformers. A
typical guide has been produced under the headline of transformer procurement
process and is one of a number of key steps in the process. A typical procurement
process is shown in figure 1 and clearly shows where this guide fits into the whole
procurement process with various quality factors other than just the cost.
It should be borne in mind when preparing transformer specifications that this
document will determine all of the future operating characteristics of the unit and it is
where many future problems in terms of reliability of the transformer ultimately begin.
It is of vital importance for the specification to be correct in order that the manufacturer
can deliver the transformer the purchaser really needs. The key word is
communication and the specification is the foundation of the technical communication.
Getting the specification right is the first step, and ensuring the requirements are
communicated and understood by the manufacturer is also important, but that is where
the design review comes into play. With the globalisation of the transformer market
place since the original issue of this guide, specifications are often written in a
language which is foreign to the potential manufacturer; therefore the purchaser needs
to consider carefully the wording of the document. Complicated language can often be
misinterpreted by a non-native speaker, so it is extremely important to try and use
simple internationally understood language wherever possible.
The aim of the document is to highlight some of the important topics that should be
considered for inclusion in an enquiry document. Wherever possible, guidance and
other practical information about such topics is provided to explain their purpose and
significance in transformer enquiries. Clearly it is not possible to address all the issues
that may arise. Neither is the document in any way intended to be a complete and
1
applicable specification.
It is strongly recommended that purchasers use recognised standards and application
guides on which to base their specifications. This document refers principally to
standards and guides published by the International Electrotechnical Commission
(IEC), but other regional or national relevant standards and guides may be used. In
addition, purchasers can refer to manufacturers and other specialist providers for
assistance in preparing specifications. This can be especially important if the technical
features of the required equipment are outside the purchasers previous scope and
experience.
The format and content of technical specifications are not constant. They vary
according to particular equipment needs and also to other factors such as purchasers
purchasing, economic and operating policies as well as technology innovations by
manufacturers and material suppliers. Significant changes are often necessary as the
result of experience of previous purchases, either during manufacture or in service or
both. In other words, it is both customary and necessary to review specifications often
to ensure that they are up to date with purchasers requirements and obligations and
able to utilise the best manufacturing and operating practices.
Purchasers should also remember that the constantly changing legislative and
regulatory environment in which power system operators find themselves often
requires changes in policy or solutions being purchased and this should be reflected in
the specification.
Certain sections of this specification include a Preface. This is used solely to draw
the purchasers attention to some particular aspects of the section or to explain its
purpose. Additional information may also be obtained from application guides and
codes of practice.
Because the document is advisory and not purchase or site specific, or intended for
use directly as a purchasing specification, words such as should, may and could are
used throughout the document. Purchasers should therefore, strengthen the wording
of appropriate clauses in their specifications by using words such as shall and must
to indicate mandatory requirements.
2
Identify Prepare and Assess Tender

Determine List of Pre Contract
Transformer Issue Technical Issue Tender Returns Place Contract
Tenderers Design Review
Requirements Specifications Technically
Yes
Is Tenderer No Post Contract

Assess Capability Do Not Use
Capable of Clarification of
of Manufacturer Manufacturer
Manufacturing? Requirements
Any previous
Service
Experiences of
manufacturer?
On Going Factory On Site installation

Post Contract End of Procurement
Manufacturers Acceptance Shipping to Site and
Design Review Process
Inspections Testing Commissioning
Concerns over No
Continue to Use
suppliers
Manufacturer
capability?
Yes
Re-assess
Capability of Enhanced
Manufacturer inspection and
review
Is Manufacturer Yes
Capable of
Manufacturing? Yes
No Can issue be
resolved with No
Terminate Contract
additional
supervision?
Figure 1 Example of a transformer procurement process
3
1 SCOPE AND STANDARDS
1.1 Scope
As a minimum the scope of a specification for a large transformer is meant to include
design and development; procurement of components and materials; manufacturing;
and acceptance testing at the manufacturers works. Depending on the delivery terms,
the scope of a specification may be extended to include transport, in whole or in part;
installation; commissioning, usually understood to include acceptance testing after
installation and before first energisation; and warranty/service provision. In some
cases the scope of a specification may be further extended to include provision of
spares components or maintenance equipment.
1.2 Standards
As was noted in the Foreword to this guide, it is strongly recommended that
purchasers use Standards as the basis for specifications. These may include
international standards and national standards, such as IEC and ISO standards. In
any case, the purchaser needs to consider suitability of particular Standards or even
the applicable revision of a Standard for the specific application.
Power transformers should comply with the requirements of the specification and the
standards listed therein, for instance such as those listed below:
IEC 60044 Current transformers
IEC 60050 International Electrotechnical Vocabulary
IEC 60050(421) International Electrotechnical Vocabulary - Chapter 421: Power
transformers and reactors
IEC 60060 High Voltage test techniques
IEC 60060-1 General definitions and test requirements
IEC 60060-2 Measuring systems
IEC 60071-1 Insulation coordination - Part 1: Definitions, principles and rules
IEC 60071-2 Insulation coordination - Part 2: Application guide
IEC 60076-1 Power transformers - Part 1: General
IEC 60076-2 Power transformers - Part 2: Temperature Rise for liquid-immersed
transformers
IEC 60076-3 Power transformers - Part 3: Insulation levels, dielectric tests and
external clearances in air
IEC 60076-4 Power transformers - Part 4: Guide to the lightning impulse and
switching impulse testing - Power transformers and reactors
IEC 60076-5 Power transformers - Part 5: Ability to Withstand Short-circuits
IEC 60076-6 Power transformers - Part 6: Reactors
IEC 60076-7 Power transformers - Part 7: Loading guide for oil-immersed power
transformers
IEC 60076-8 Power transformers Part 8: Application Guide
IEC 60076-10 Power transformers Part 10: Determination of sound levels
IEC 60076-18 Power transformers Part 18: Measurement of frequency response
4
IEC 60137 Bushings for Alternating Voltages above 1000V

IEC 60214-1 Tap-changers - Part 1: Performance requirements and test methods
IEC 60214-2 Tap-changers - Part 2: Application Guide
IEC 60270 High-voltage test techniques - Partial discharge measurements
IEC 60296 Fluids for electrotechnical applications - Unused mineral insulating
oils for transformers and switchgear
IEC 60422 Mineral Insulating Oil in Electrical Equipment Supervision and
Maintenance Guide
IEC 60529 Degrees of Protection provided by Enclosures (IP Code)
IEC 60567 Oil-filled electrical equipment - Sampling of gases and analysis of
free and dissolved gases - Guidance
ISO 8501-1 Preparation of steel substrates before application of paints and

related products visual assessment of surface cleanliness
ISO 9001 Quality management systems requirements
ISO 12944-2 Paints and varnishes corrosion protection of steel structure by
protective paint systems classification of environments
ISO 14001 Environmental systems requirements, with guidance for use
ISO 19011 Guidelines for quality and/or environmental management systems
auditing
The standard should be the most up-to-date published version available when a tender
is submitted. The latest version of IEC standards can be obtained from the IEC
website (www.iec.ch). Purchasers should also consider looking at other websites, e.g.
national standards, ISO, etc.
In the event of conflict between the requirements in a specification and those of the
specified standards, the usual practice is that the specification should prevail.
The following order is recommended, but the purchaser needs to re-confirm their own
order:
Particular technical specification/technical data sheet

General technical specification
International standards (e.g. IEC)
National standards (e.g. NBN, BS EN, DIN EN etc.)
2 DEFINITIONS
For the purpose of this guide specification, the definitions listed in IEC 60050(IEV) and
other relevant IEC standards have been used.
Additional more specific transformer terms, or terms used by purchasers that may not
be generally understood, or are not already covered by existing standards, should be
defined in this section.
5
3 EXTENT OF SUPPLY
Preface
In this section, the Purchaser should give a brief but a clear statement about the
equipment, the components to be supplied and the limits of contractual responsibility
that are to exist between the manufacturer and purchaser, in order that no
misunderstanding about respective liabilities can occur.
3.1 General
The supply of a transformer comprises the design, manufacture, quality assurance and
testing at the manufacturers works and depending on the contract, transport, complete
erection, commissioning, and setting to work at a site.
The basic parts of the transformer will comprise the main tank, active part,
terminations, cooling facilities, fittings and the systems and equipment for oil
preservation, tap changing, protection, control and monitoring, and any other
component necessary for the proper operation of the power transformer.
3.2 Additional Requirements

The extent of supply may also include other additional requirements such as,
making route surveys and obtaining any permits, licences and statutory
authority approval
alterations to existing routes to permit passage of the transformer
any additional auxiliary equipment or facilities
transport to site
site commissioning tests and inspections
site civil works, in particular transformer foundations, oil containment, fire
and blast containment
noise reduction measures
the supply and commissioning of secondary equipment.
warranties and service agreements
tools, spare components and maintenance procedures
documents, operating instructions and maintenance procedures
safety training of personnel to work on site
working language of all documents provided under the contract
3.3 Exclusions
In an enquiry, the purchaser should state any aspects of transformer engineering,
installation or operation that will not be acceptable.
Equally, the manufacturer should state any aspects of the purchasers specification
that will not be complied with.
3.4 Alternative offers

The purchaser may request offers based upon alternative means of obtaining the
required extent of supply, or describe the extent of supply required in a manner that will
6
permit a manufacturer to interpret what is required and submit alternative solutions and
offers. Alternatively, the manufacturer may tender alternative offers, which may only
be accepted in writing by the purchaser.
3.5 Transfer of liability/ownership

The purchaser should consider special issues of transformer ownership, condition
verification, and liability during transformer transportation between the factory and the
site. Refer to Section 9 - Transport of this document.
4 PURPOSE OF THE EQUIPMENT
Preface
It is of utmost importance for the purchaser to state the purpose of the equipment and
how it is to be used (see 4.1)
A Purpose of the Equipment statement is particularly important if the transformer is to
be used for an unconventional or select application such as for example, for
rectification, arc furnace, railway supply, heavy duty motor applications, use with solid
state power electronics equipment, or installed within a sound mitigation house or not.
The purchaser or manufacturer should resolve any doubts about the purpose of the
transformer preferably before the enquiry is issued but certainly before a contract.
4.1 Some Examples

The autotransformers referred to in this specification will be installed at XXX
transmission substation, placed within a sound mitigation enclosure, and
rated for both step-up and step-down operations
The transformers referred to in this specification will be installed at XXX

wind farm for connection to 3.6MW wind turbine generators and used wind
turbine step-up transformers
The transformers referred to in this specification will be installed at XXX

railway trackside substation to supply directly the YYY railway track
overhead (or underground as appropriate) electrical power supply system.
The transformers referred to in this specification will be installed at the XXX

foundry and used to supply individually and directly open hearth electric arc
furnaces.
The transformers referred to in this specification will be installed in the

indoor substation at the offices of XXX Co Ltd, address details, and used for
mixed non-industrial loads including a 100% secure demand supply to a
3MVA mainframe computer installation.
5 SYSTEM OPERATING CONDITIONS
5.1 General Description of Network

It is often helpful for the purchaser to give some background information concerning
system operating conditions where the transformer will be installed. Purchasers
should try to strike the correct balance between omitting potentially important
7
information and providing large amounts of information of little interest or use to the
manufacturer, which cause confusion as to their actual requirements.
A single-line diagram of the installation is often particularly helpful in giving general
information. It can also be referred to in providing other useful system information.
5.2 Insulation Co-ordination

Procedures for insulation co-ordination are described in detail in IEC standards 60071-
1 and 60071-2. Use of these procedures to determine suitable insulation levels for the
transformer is usually considered to be the responsibility of the purchaser. In practice,
insulation levels are usually pre-determined by an Industry or National Standard.
Purchasers may wish to refer to the network operator(s) for guidance.
Determination of suitable insulation levels should also be made with reference to IEC
standard 60076-3, which describes which tests are applicable to transformers of which
voltage class. Purchasers have a number of choices with regard to the applicability of
testing, notably whether a chopped wave lightning impulse test is required and whether
a switching impulse test or a short-duration ac induced voltage is required. Any such
requirements should be clearly stated in the specification.
For certain tests, there are a number of different methods allowed by IEC standard
60076-3. Where users have a requirement for a test to be performed in a certain way,
e.g. long-duration ac induced voltage test with three-phase excitation and the neutral
earthed, this should be stated in the specification.
5.2.1 Method of System Earthing

Purchasers should provide information in the enquiry document as to the method of
system earthing on the power system to which the transformer will be connected, e.g.
star point earthed, earthing transformer for unearthed systems etc. In addition the
purchaser should state whether the earth point is solidly connected to earth, or via
some form of earthing resistance or inductance. Where impedance earthing is used
the purchaser should state the value of the impedance to be installed to restrict fault
current.
5.2.2 Unusual Operating Conditions

Energisation imposes both electrical and mechanical transients on large transformers.
Certain applications involve frequent energisation, e.g. arc furnace supply, generator
transformers in pumped-stored schemes, and shunt reactors. This may require special
design considerations, especially if the transformer is directly connected to gas-
insulated switchgear or if it is to be energised from the LV side. The specification
should give information on the expected frequency of energisations, and on the
method of energisation.
5.3 Short-Circuit Withstand

Clause 3.1 of IEC standard 60076-5 requires that:
Transformers together with all equipment and accessories shall be designed and
constructed to withstand without damage the thermal and dynamic effects of external
short circuits ...
External short circuits are not restricted to three-phase short circuits; they include line-
to-line, double-earth and line-to-earth faults.
8
To meet the requirements of this standard, purchasers must provide sufficient

information about the power system parameters to enable a transformer designer to
calculate the steady-state short-circuit currents using the method of symmetrical
components. In practice this means specifying, for each system to which the
transformer is to be connected, the positive-, negative-, and zero-sequence
impedances. The positive sequence impedance is usually given as the short-circuit
apparent power of the system (in MVA). It is equally possible to specify a maximum
short-circuit current (in kA), which is often the breaking capacity of the switchgear to
which the transformer will be connected. The positive and negative sequence
impedances of transmission networks are usually assumed to be equal. The positive
and zero sequence impedances of transmission networks are not equal, and the zero
sequence impedance is usually given as the ratio of zero sequence impedance to
positive sequence impedance. For overhead transmission lines the ratio of zero
sequence impedance to positive sequence impedance is typically 3-4, although is often
assumed to be rather less.
Some users consider it best to assume the effect of the system impedance in limiting
short-circuit currents is negligible, i.e. that the transformer is connected to an infinite
busbar.
To meet the requirements of the standard, purchasers must also include sufficient
information to calculate dynamic short-circuit currents. In practice, this means
specifying the ratio of reactance to resistance for each system to which the transformer
is to be connected. Note that the ratio of reactance to resistance for large transformers
is typically very high, and the effect of the system is usually to reduce the ratio of
reactance to resistance.
Certain purchasers consider it best to make the pessimistic assumptions that the effect
of the system on the ratio of reactance to resistance is negligible. Other purchasers
consider it best to make the more pessimistic assumption that the ratio of reactance to
resistance is infinite. From this it follows that the ratio of dynamic to static short-circuit
current is 22.
Further guidance may be found in power systems text books, e.g. Short-Circuit Duty
of Power Transformers, by Giorgio Bertagnolli and published by ABB.
Unusual Operating Conditions

Certain specialised applications involve unusually frequent or unusually severe short-
circuits, e.g. arc furnace supply (directly or indirectly). Transformers operating on
certain networks may also be exposed to unusually frequent or unusually severe short-
circuits. These applications may require special design considerations. The
specification should give information on the expected frequency of short-circuits and if
necessary their expected duration and severity.
5.4 Over-Excitation
Over-excitation under steady-state or transient conditions can cause damage to
transformer cores and the associated insulation and supporting structures.
Transformers specified in accordance with IEC standard 60076-1 have only a limited
tolerance of over-excitation (10% at no load, 5% at full load). Large transformers are
frequently subject to more severe over-excitation.
Over-excitation can arise owing to operation at:
Below rated frequency
9
Above rated secondary voltage, either as a result of a high network voltage or

a low load power factor
Note that certain applications impose severe over-excitation requirements, e.g.
generator transformers which are also used for synchronous compensation and SVC
transformers.
A typical requirement for large transformers is as follows (taken from IEEE standard
C57.12.00-2010).
Transformers shall be capable of:
a) Operating continuously above rated voltage or below rated frequency, at maximum
rated kVA for any tap, without exceeding the limits of observable temperature rise [...]
when all of the following conditions prevail:
1) Secondary voltage and volts per hertz do not exceed 105% of rated values.
2) Load power factor is 80% or higher.
3) Frequency is at least 95% of rated value.
b) Operating continuously above rated voltage or below rated frequency, on any tap at
no load, without exceeding limits of observable temperature rise [...] when neither the
voltage nor volts per hertz exceed 110% of rated values.
5.5 DC Magnetisation
Under certain operating conditions, dc currents may flow through transformer windings
causing asymmetrical magnetisation of the core and possible saturation. Rectifier
transformers of all kinds, including HVDC transformers, may be exposed to dc
currents. Trackside transformers may also be exposed, especially during severe
winter weather conditions. Quasi-dc currents may flow in power systems owing to
solar activity (geo-magnetically induced currents), exposing generator and network
transformers to the risk of dc magnetisation.
According to IEC standard 60076-1, any requirement for tolerance of dc currents is
unusual and the requirement should be stated in the specification. The specification
should state the maximum expected dc current and duration, and any requirements
concerning noise or reactive power absorption whilst exposed to the maximum
expected dc current. In practice, it may be difficult to assess conformity with any such
requirements through design review or test.
5.6 Harmonics
Transformers specified in accordance with IEC standard 60076-1 have only a limited
tolerance of harmonics in the load current (5% total harmonic content, including 1%
even harmonic content). Where these requirements are exceeded, transformers
should instead be specified in accordance with IEC standards 61378-1 and -3
(industrial applications) or IEC standards 61378-2 and -3 (HVDC applications).
5.7 Loading
Transformers specified in accordance with IEC standard 60076-1 are usually also
specified as being capable of loading in accordance with IEC standard 60076-7. This
may not be appropriate in all cases, e.g. transformers directly connected to semi-
conductor convertors which have a lower over-load capacity than a transformer
specified in accordance with IEC standard 60076-7. Note that IEC standard 60076-7
10
does not apply to arc furnace transformers.

In the case of generator transformers, the active power the prime mover is capable of
supplying may vary ambient temperature. Certain users consider it best to include the
capability curve of the prime mover in the specification.
5.8 Neutral Point Loading

Unbalanced loading or neutral point loading is unusual for large transformers. If there
is any requirement for unbalanced loading or neutral point loading, then this should be
included in the specification. Note that certain winding arrangements are incompatible
with neutral point loading owing to high zero-sequence impedance. For further
guidance, see IEC standard 60076-8.
6 SITE INFORMATION
IEC 60076-1 contains details of the general site conditions under which transformers
are expected to operate.
For the purposes of a contract, purchasers are advised to provide additional
information detailing the conditions at the site where a transformer is to be installed or
at other sites where it may be subsequently installed, including for example, details of
transport routes, site access, the layout of the site and any site limitations or
restrictions.
In addition, the purchaser shall specify any unusual site conditions, such as high
altitude, environmental contamination, high or low ambient temperatures.
7 CONTRACT WORKS
Preface
The purchaser should state all the general or specific details that the manufacturer is
contractually required to comply with, in this part of the specification.
7.1 Installation Details

This should include details of:
arrangement of the contract works at site or method of supply
the environmental conditions and requirements for the installation and its
equipment
7.2 Documentation Requirements

The documentation requirements differ among purchasers. The purchaser should be
well aware of any internal needs for documents. In case of confidential documents, the
manufacturer will probably refuse to make these available to the purchaser. In such a
case, it can be agreed to have these documents readily available for (re)viewing at the
premises of the manufacturer.
Below is a list of documents a purchaser can request, which may at times be
considered confidential:
drawings detailing overall and individual major component dimensions and
11
weights
drawings, photographs and other records detailing the transformer internal
arrangements and parts
permits and licences verifying approval and details of a transport route to
site, including identification and description of the most difficult parts of the
route
calculations (refer to design review guide)
7.3 Details of Additional Requirements

power supply available for auxiliary equipment
transport gauge profiles
method of line, neutral and earthing connections
7.4 Details of Requirements for Interfacing with Other Equipment, or to

Achieve Interchangeability or Permit Parallel Operation
bushing electrical connection points
bushing securing flange diameter
bushing flange details: number and size of securing bolt holes, bolt hole
diameter and pitch circle diameter
insulation levels (BIL)
connection design, cable bushing
size of winding connections to accommodate the different lengths of
standardised bushing fittings and maintain a minimum gap to earth
details of any current transformers mounted within or external to the
bushings or bushing turrets, including tolerances and definition of tolerances
to facilitate work by other manufacturers
other fittings, e.g., gas and oil actuated relays, cooling pumps, valves, etc.
for parallel operation, details of the existing transformers including no-load
voltage per tap step, number of tapping steps and percentage step, the
tapping step numbers, impedance voltages per tap position, vector group
details; please refer IEC 60076-1 for additional details.
8 ENVIRONMENTAL CONSIDERATIONS
Preface
The requirements specified in this section relate to the care for the environment and
include any special conditions and precautions that have to be incorporated in the
design, manufacture and operation of the transformer to comply with such
environmental considerations. Some of these considerations may be of legal nature.
8.1 General
The principal considerations are:
audible sound
losses
oil pollution
12
fire hazard and risk of producing contaminants or other unacceptable by-

products
blast hazards
visual impact
seismic risk
Control or avoidance of oil pollution, fire and blast hazards are largely a civil
engineering matter but the effects can be mitigated by attention to transformer design.
These considerations apply to both new and existing installations and are largely site
specific, but other purchaser or statutory requirements may also apply. Consequently,
there are responsibilities on both purchaser and manufacturer to ensure that the site
conditions are properly assessed and the requirements and responsibilities clearly
defined and fulfilled.
8.2 Audible Sound

Low sound power levels in the vicinity of substations are an increasing environmental
requirement. The purchaser should state in the specification the maximum permissible
sound power and/or pressure level allowed for the transformer and the method of
measurement (e.g. IEC 60076-10). The specification should also state any contractual
liabilities that will ensue in the event of exceeding the specified sound power and/or
pressure/intensity level during the factory acceptance tests.
Sound panels and sound houses have been useful in helping to reduce sound
pressure levels. It is important that the transformer design considers these sound
mitigating options to ensure that they will not adversely affect the thermal and dielectric
performance of the transformer.
8.3 Losses
The provision of the financial value per kW (unit cost / kW) of no-load and load losses
forms an essential part of a transformer specification. Without this information and
without any guidance from a purchaser of the transformer loading regime or the system
operating costs, a tenderer will very likely offer a tender which has the lowest purchase
price, but may not necessarily provide for the lowest total lifetime cost of ownership.
The better alternative is for the purchaser to provide information that will permit a
tenderer to optimise his designs. This is done by the purchaser calculating the cost of
the no-load and load losses that will arise under the intended transformer operating
regimes, together with projections of service life, load growth, interest rates etc., and
stating them in the specification. In most cases, by providing the cost of losses in this
manner, a purchaser can avoid the risk of disclosure of confidential information and the
submission of a multiplicity of offers. It also allows each tenderer to focus on
submitting the most efficient design possible within the limits of those economic loss
values and on reducing his tendering costs.
There is more specific information relating to loss evaluation, penalties, bonuses, and
rejection provided within Appendix A in this specification.
Loss guarantees
Typically, the purchaser requests the manufacturer to provide the following loss
guarantees in the tender:
no-load losses measured on the principal tapping at 100% rated voltage, or
13
as specified by the purchaser

load losses at reference temperature at principal tap position and rated
power between windings, or as specified by the purchaser
cooling equipment losses (kW)
8.4 Oil pollution

Joints between oil containing parts of the equipment should be leak tight under all
circumstances. Gasket joints should be designed to avoid deterioration of the gasket
due to oil or excess strain.
The probability of an oil spill occurring within a substation is typically very low.
However some substations, for example due their proximity to waterways, have a
higher risk for discharging harmful quantities of oil into the environment. The
purchaser may consider the application of natural or synthetic ester fluids, since they
are less harmful to the environment.
8.5 Explosion or blast hazards

The probability of a transformer exploding is even smaller than a transformer catching
fire. In the unlikely case, however, the explosion or blast hazard can at best be
mitigated to some extent by fitting adequate pressure relief devices to the principal oil
containing components at greatest risk, such as the main tank and tap changer
diverter, together with means to control the diffusion of oil when they operate.
However, in some cases, the rate-of-rise of pressure can be so rapid that relief devices
cannot prevent tank rupture.
Oil impregnated paper (OIP) bushings fitted with porcelain insulation may fail
explosively creating a potential for damage to persons or property. Modern equivalent
bushings of the epoxy resin impregnated paper type are now widely used, particularly
with silicon rubber or other composite type insulators. The application of these
alternative bushing designs greatly reduce the risk of explosion due to bushing failure.
If the risk of explosion is a major issue on the specific site, the application of solutions
such as ester fluids does not relieve the problem. Possible solutions that need to be
considered include installation of the transformer in underground bunkers or in blast
proof above ground housings. If neither of these solutions is possible then the
purchaser may need to consider the use of SF6 gas insulated transformers.
Other additional means may need to be provided to mitigate the consequences.
8.6 Fire hazards

Routine monitoring, maintenance, testing, and good asset health assessment
programs can greatly help to prevent internal transformer faults, which in turn helps to
prevent fires from occurring. The consequences of a transformer fire can be reduced
by using fire protective walls and/or water deluge or gas blanketing protection systems,
but these facilities are not always readily available or feasible at all sites. Fire risk
might be reduced by considering natural or synthetic ester fluids, since they have
higher flash points as compared to typical petroleum based fluids, as long as the
transformer designs can accept their use. Ester fluids also self extinguish when the
ignition source is removed whereas petroleum based fluids do not.
Considerable quantities of water may be required as well as oil-water separators and
storage facilities for the effluent.
14
Consideration should be given during the transformer and site design stages to provide
the best means to cope with a transformer fire or explosion. In the case of fire, it is
very important that the fire is contained and quenched as quickly as possible. In the
absence of deluge techniques, this is often best achieved by electrical isolation of the
transformer and, if conditions allow, applying water directly through a remote entry
point in the oil system, or by gas blanketing.
Reference is also given for further information in a new CIGR technical brochure
Transformer Fire Safety Practices, which is under preparation by CIGR WG A2-33
with planned publication during 2013.
8.7 Visual impact

The visual impact of a transformer installation may be reduced by screening, height
reduction, choice of finishing colour and in general, by attaining tidy surfaces and clean
aesthetic lines. The purchaser should state any requirements in the enquiry. One
should pay attention that any screening does not interfere with the cooling of the
transformer.
8.8 Seismic impact

Where the transformer is intended for operation in an area of known seismic volatility,
the specification should state this and indicate the degree of severity of any seismic
shock which needs to be contained.
9 TRANSPORT
Preface
The available means of transport between a manufacturers works and site should be
pre-planned and stated by the party who will be responsible for the transport (either
purchaser or transformer manufacturer) and agreed upon between the parties involved
before the contract is signed. In any case the local requirements near to and at the
site of assembly should be specified and stated by the purchaser.
Additional provisions may also have to be included to permit subsequent transportation
to other sites. Any statutory requirements governing transformer movement, and that
of any associated loose equipment including oil, should also be clearly stated in the
enquiry.
In some cases, transport may be more effectively achieved by adopting a particular
transformer design and construction, e.g. in the case of three phase transformers, for
instance by adopting a 3 x single-phase type of construction. Alternatively, built-on-site
design and construction techniques may be used.
It is advisable to define the costs, risks, and responsibilities for transport of
transformers between purchaser and manufacturer by using international regulations
like the Incoterms. The current version of this is Incoterms 2010. The codes used are
listed below.
Incoterms 2010 rules for any mode or modes of transport:
EXW Ex Works
FCA Free Carrier
CPT Carriage Paid To
CIP Carriage and Insurance Paid to
15
DAT Delivered At Terminal

DAP Delivered At Place
DDP Delivered Duty Paid
If both parties want the manufacturer to deliver the transformer at the purchaser site of
assembly, loaded or unloaded, without or with customs activities performed and duties
paid, DAP or DDP should be used respectively. (Note that unloading on site and
placing in the cell of assembly is not included in either DAP or DDP and must be
specified or agreed upon in the contract)
Incoterms 2010 rules for marine and waterway transport:
FAS Free Alongside Ship

FOB Free On Board
CFR Cost and Freight
CIF Cost Insurance and Freight
For full details see Incoterms 2010 published by International Chamber of Commerce
(ICC).
Reference is also given for further information in a new CIGR Technical Brochure
Guide on Transformer Transportation, which is under preparation by CIGR WG A2-
42, autumn 2012, and with planned publication during 2013.
9.1 General
In the enquiry, the purchaser should state the maximum transport dimensions and
weights permissible by road, rail or water, in addition to the requirements at the site of
assembly.
Responsibility for the load profile for each transport mode, transport route to site, the
means of transport, any necessary route alteration, modification or refurbishment,
statutory approval or licences, shipping reservations and documentation or any other
requirement concerning the delivery of the contract works to site should be agreed
between purchaser and manufacturer before a contract, if not specified in the enquiry
by the purchaser.
9.2 Design for transport

The Transformer with its active part (windings, core, framework, clamping
arrangements and general structure) and tap changer must be of robust design and
safeguarded for transportation, capable of withstanding any shock (and duration of
shock) to which it may be subjected to during transport, taking all planned transport
modes into consideration. Necessary mechanical withstand capability has to be built
into the design without any in-tank temporary bracings / supports / reinforcements.
It is required to give information about the peak impacts which will be used in the
design of the transformer to withstand transport impacts. These values are requested
to be filled in the table below.
16
Outside tank Inside tank Duration

Axis Max g-forces used for the (cont. or Comments:
design msec)
Longitudinal
Vertical
Lateral
9.3 Impact recorders

During transport, at least one 3D - accelerometer impact recorder with measurements
in X, Y and Z axis (both plus and minus directions) should be used. The impact
recorder(s) should have the possibility to measure acceleration events with 3D curve in
the range of 1024ms or more. The number of such stored events must be sufficient for
the transport. Acceleration range should be adjustable up to 10g with a frequency
range of 1-100Hz. In addition the impact recorder should also be able to register both
dynamic inclination curves and time-synchronous inclination events.
In case of transportation without oil one impact recorder should also be fixed to the
active part during the transportation and one outside the tank. A master-slave
connected system could be of value as events inside and outside the tank will be time
synchronised.
Mounting:
the impact recorders should be bolted rigidly to the transformer tank (or
active part).
impact recorders on the transformer tank should be mounted at or near the
location where the transformer is supported by the transport vehicle.
a) in most cases: the bottom plate of the transformer.
b) girder trailers: near or at the supporting brackets of the transformer.
the mounting location inside the tank is dictated by accessibility, i.e. near a
manhole or cover of bushing turret. Fixing to the core and coil clamping
system is a good option.
the mounting orientation is irrelevant as long as the axis of the impact
recorder align with the axis of the transformer.
the mounting location should be rigid, preferably near the corner of three
intersecting surfaces, i.e. bottom plate near a stiffener and the tank wall.
9.4 Transportation with or without oil

If the transformer is transported without oil, provision should be made to prevent the
ingress of moisture and to maintain the internal insulation in first-class condition. In
addition the transformer should be filled with breathable dry air and maintained at a
continuous positive pressure. The use of nitrogen is possible but is not preferred on
the grounds of safety. The air pressure and dew-point should be monitored
continuously throughout the period immediately after the oil is removed until the
transformer is refilled with oil at site. At all times alternative standby means should be
provided to restore any loss of air pressure immediately.
The dew point of the dry air should be measured and recorded to ensure it is below -40
17
C. The dew point should be checked again within 24 hours of the oil having been
removed and the transformer dry air filled, the measurements being recorded in the
test report and on the shipping tag. If the dew point readings indicate an average
moisture level at the surface of the transformer insulation is higher than 0.5%, the
manufacturer must dry the transformer.
The maximum acceptable dew point shall also be indicated on the shipping tag. The
dew point of the shipping gas shall be recorded along with the pressure and
temperature of the shipping gas at the time of the dew point measurement. This
information shall be recorded on the test report, the shipping documents and on a tag
at the location of the dew point measurement.
All tubing, valves, cable connections, and fittings attached to the payload should be
adequately protected to minimise risk of damage during loading, transport and
unloading.
9.5 Loose equipment

Other transformer equipment such as bushings, cooling equipment, tap changers,
power, and control and regulation cabinets may be shipped disassembled, and
transported and secured in accordance with the manufacturers shipment and storage
guidelines and precautions. Where necessary, airtight seals or covers should be used.
Parts such as instruments, cabinets, terminal boxes that are mounted on the main tank
should be attached by means of anti-vibration mountings, and be protected with
covering/enclosure to prevent physical damage during transport.
9.6 Inventory
Each individual component or part should be properly prepared for despatch, itemised
and labelled. Each item should be named, coded and identified by make or
manufacture, size, type, drawing number or part number and recorded in a transport
inventory that should form part of the contract documentation.
9.7 Handling and markings

To facilitate handling, the longitudinal and transverse axes and centre of gravity for
transport of the main indivisible unit and any other parts as may be required to conform
to regulations, should be clearly marked. The axes of the transformer main unit should
also be permanently marked on the four sides.
The transformer must also be equipped with necessary and well functional bracing
locations and brackets for securing the transformer to the transporter (rail-car, truck
flat-bed, girder-trailer, ship, barge and airplane). In addition to lifting brackets, jacking
pads and haulage points for use at load breaks during the shipment and final assembly
should be provided. All these appliances must be dimensioned and labelled for the
intended purpose. In addition, these should be shown on the transport layout drawing
for the transformer with allowable load and minimum sling angle for lifting purposes.
All other items arranged for transport must also have their lifting and haulage points
and a safe working load (SWL) clearly marked at all stages of delivery and erection.
9.8 Documentation
The manufacturer should provide for approval and in advance of delivery,
documentation which fully describes the transport arrangements and specifies all the
18
instructions and requirements necessary to ensure that the transformer and all its
equipment will be delivered to site properly and with any necessary and statutory
approval.
A transport outline drawing must include:
dimensions, weight and centre of gravity for transport of the transformer.

the shipping centre of gravity should be shown on all four sides.
details of transformer base showing acceptable jacking, blocking and
skidding/sliding locations, as well as locations that are not acceptable for
these purposes. These acceptable locations must be marked on the
transformer with symbols or notification as to their purpose.
the location of lifting and pulling eyes, jacking steps and bearing surfaces for
moving the transformer by sliding or use of rollers.
acceptable means of securing the transformer to the carrier for all modes of
expected shipment.
size, position and height above foundation of the jacking steps.
maximum sling angle from vertical when lifting main tank.
any special lifting requirements including the use of spreaders or special
slinging equipment shall be shown on the drawings.
special precautions when moving the transformer.
if transported with oil, the oil level suitable for shipping the transformer.
the transport outline drawing must accompany the transformer during
shipment and be readily available to those handling the transformer during
shipment.
9.9 Storage
Transformers may require to be stored for short and long periods of time, but as a rule
of thumb they should not be stored for more than 6 months without oil. It is not
necessary for the radiators and bushings to be installed on the transformer during the
storage period, but they need to be properly stored as recommended by the
manufacturers and transformer manufacturer. Special bushings installed within the
blank-out plates of the bushings are recommended which will accommodate low
voltage testing during the storage period to confirm the condition of the transformer.
The transformer bushings (if installed) or special test bushings should be properly
grounded.
It is important that all blanking plates and covers are designed for long-term outdoor
storage and have a surface treatment that prevents corrosion during the storage
period.
Heaters within all control cubicles should remain energised during the storage period to
help prevent condensation from corroding electrical components.
9.10 Storage without oil

Storage without oil should, as a general rule, only be used for shorter term storage (up
to 6 months), i.e. during breaks in transport operations or shorter storage pending a
site of assembly is finished. Longer storage (more than 6 months) should be avoided
because of the danger of cavities in the solid insulation developing, which might be
difficult and even impossible to remove with vacuum treatment before oil filling.
19
When stored without oil, provisions should be made to prevent the ingress of moisture
and to maintain the internal insulation systems within the transformer in first-class
condition. In addition the transformer should be filled with breathable dry air and
maintained at a continuous positive pressure of 14 kPa for instance and with a dew point
below -40 C. The air pressure and dew-point must be monitored continuously
throughout the period of storage. In addition the unit should be subject to regular
inspection during the storage period. At all times an alternative standby means of
restoring any loss of air pressure immediately should be provided.
Following an extended storage period with air, it is recommended that an extended
vacuum process be performed prior to the final oil fill.
9.11 Storage with oil

Storage with oil is suitable for long term storage of transformers. The storage site must
be equipped with an oil retention system to handle a volume large enough to pick-up the
full content of oil in the stored transformer. The pressure equalisation system for the
main tank and tap changer(s) (i.e. for instance a conservator) should be installed and
filled with a sufficient amount of oil to allow for normal oil level variation caused by the
changes in ambient temperature. In addition, any dehydrating breather(s) must be
installed.
The oil level within the main tank and tap changer should be routinely inspected to
ensure proper filling. The best practice is to remotely monitor the oil levels by activating
gauges.
10 SAFE WORKING SYSTEMS

Purchaser specifications may include details of health and safety requirements at the
installation. Possible requirements might include:
languages to be used on site

limitations on working hours
compulsory safety training for workers and supervisors
details of local safety regulations likely to affect the installation and
commissioning of the transformer. These may be consolidated into an
appendix to the specification, or a separate document where they would apply
equally to the installation and commissioning of other types of equipment.
Typically the specification will include the requirement for the manufacturer to provide a
draft work plan (method statement and risk assessment) for the installation of the
transformer. This then allows the user to check which activities may be subject to local
safety regulations. This also allows the user to check which activities may affect normal
operation or other work at site.
Less typically, purchaser specifications may include details of health and safety
requirements at the manufacturers works. One possible approach would be to ask for
certification to OHSAS 18000. Another would be to ask for documents on health and
safety, e.g. health and safety policy, independent health and safety advisers report,
details of accidents reported to the lawful authorities.
A more conventional approach would be to make an assessment of the manufacturers
works, in accordance with the guidelines in CIGR TB 530, Guide for Conducting Factory
Capability Assessments for Power Transformers.
11 TECHNICAL REQUIREMENTS
Preface
The IEC standards include detailed requirements that affect the design and
manufacture of transformers depending upon their rating, voltage and application.
Often, however, there are other additional local or regional technical requirements that
need to be included in a specification, as well as requirements which arise from the
purchaser's previous experience.
Therefore, in this section, the purchaser should state any technical requirements
different from or not contained in the IEC standards or other listed standards. Any
additional technical information that will assist a manufacturer to optimise the design
and manufacture of the transformer should also be provided by the purchaser.
It is important to remember that the purpose of a specification is not solely to describe
what is wanted but also, to state what is not wanted. The latter often result from the
purchasers previous experience. Equally, the manufacturers' experience can also
complement the purchasers specification. Therefore the opportunity exists during the
tender stage for exchanges of further information between the purchaser and the
manufacturer by means of formalised design reviews and consultations.
11.1 General
Transformers should conform to the standards listed in the specification. Please see
1.2 above for recommended list of standards.
Where the purchaser has a distinct preference for either a core type or shell form
transformer this must be clearly stated in the specification.
11.2 Normal and Abnormal Operating Conditions

The following should be specified:
11.2.1 Gas and Oil Actuated relays

Gas and oil actuated relays, used to indicate presence of accumulated gas or sudden
oil movements, should not operate inadvertently when any combination of pumps start
up and run, or in the event of loss or restoration of the auxiliary supply.
11.2.2 Overloads
It is only necessary to specify overload requirements in detail where they are in excess
of what is listed in IEC standard 60076-7. It would be as well to state this directly.
Where more onerous requirements are specified, the following information should be
included as a minimum:
Preload (and duration)

Overload (and duration)
Ambient temperature
Maximum allowable temperatures during overload
Method of test or verification
In case of partial loss of cooling equipment, similar considerations will apply.
21
Note that restrictions may apply to the use of tap changers during overloads.
11.2.3 Geomagnetic Induced Current (GIC) Effects

Solar activity can cause Geomagnetic Induced Currents to flow in the earth and these
currents can find their way onto the power system usually via the earthed neutral
points of transformers. The occurrence of GICs in electrical grids is linked to position
on the earths surface and to the orientation and length of overhead line circuits
connected. Higher latitudes are generally more affected, being closer to the magnetic
poles. Purchasers should determine whether the transformer being specified will be
located at a site which may be subjected to GIC events from time to time.
GICs are quasi-dc currents (they are not true dc but have a frequency of around 1 Hz)
that will flow through the transformer neutral into the windings, creating an effective dc
component on the transformer magnetising flux. When a GIC flows in the transformer,
the core may half cycle saturate and this can cause a significant increase in stray
flux, increase in VAR consumption and generate harmonics. The stray flux can heat
up windings, clamping, structural parts, flux shields and the transformer tank.
The temperature rise experienced in any object is depending on:
details of the design

constructional details
intensity of the GIC in duration and magnitude
loading condition of the transformer
heat transfer capacity of the affected structures
Purchasers should note that certain transformer types are more susceptible to GIC
type events, including the use of five limb cores, single phase units and shell type
transformers. Where GICs are a potential risk the purchaser may state this and any
preference in transformer design for avoiding GIC effects. Additionally the purchaser
may specify the maximum magnitude of the GIC to be considered in the design and
the time period that this current must be carried by the transformer.
11.3 Design Requirements

11.3.1 Flux density
The flux density in any part of the magnetic circuit including shunts should not attain a
value that causes saturation. This should apply under the specified voltage, frequency
and tap positions, including transitory effects of combined system voltage and
frequency fluctuations. An adequate safety margin should be included.
The purchaser should state the over-excitation capability of continuous operation
above rated voltage and at frequencies above and below rated frequency. A minimum
acceptable V/Hz ratio could be specified for unloaded and fully loaded conditions.
For GSUs (and unit auxiliary transformers) the purchaser should specify the short time
over-excitation vs. time due to load-rejection.
11.3.2 Voltage regulation

The purchaser shall state any requirements for de-energised tap changer (DETC) or
on-load tap changer (OLTC), and specify the voltage and impedance variations for all
tap positions.
22
11.3.3 Cooling
The purchaser should specify the internal and external cooling mediums and the
circulating mechanisms that are required, by referring to the cooling method
identification symbols in an appropriate standard, such as IEC 60076. Any different
cooling method should be clearly stated in the specification.
The purchaser should state the percentage of any spare cooling capacity if required.
In the absence of such a requirement being specified, the manufacturer should state
the minimum percentage cooling capacity that can be removed for maintenance or
replacement.
If any forced internal or external cooling medium is specified, the specification should
also state the minimum amount of inherent natural cooling required. If no amount of
natural cooling is specified, the manufacturer should state the maximum natural
cooling capability of the cooling equipment offered in the tender.
11.3.4 Control detail

The cooling equipment and its control scheme shall be designed to ensure that the
desired transformer ratings can be obtained.
Pumps and fans are usually initiated by thermostatic control derived from winding
temperature hottest-spot indicators or other temperature monitors.
The appropriate sequence in which forced internal and external cooling mediums are
required to operate should be specified, for instance ONAN / OFAN / OFAF or ONAN /
ONAF / OFAF. It may be preferable to start or stop pumps sequentially, and/or with
soft start capability to avoid sudden excessive oil velocity changes.
To accommodate sudden load increase, the cooler control system should incorporate
means to initiate pumps and fans immediately upon sudden load increases above a
threshold value agreed between purchaser and manufacturer.
Outdoor mounted cooling pump and fan control equipment should be housed in a
weatherproof cabinet designed, for instance, for protection grade IP53.
11.3.5 System Earthing

The purchaser should state the method of earthing any transformer neutral terminals in
the specification. In the absence of such information a manufacturer may design the
transformers for use with solidly earthed neutral connections, and shall state on the
name plate that the neutral shall be directly earthed.
The purchaser must state the type and ohmic impedance of the alternative earth
connection if solidly earthed neutrals are not to be used.
11.4 Core
The temperature of any part of the core or its support structure in contact with oil is not
to exceed what is specified in IEC standard 60076-2. Refer to CIGR Technical
Brochure of WG A2.38 regarding thermal modelling and direct temperature
measurements of the core and its structural parts.
The purchaser or manufacturer may prefer to test these parts of the transformer to
higher levels of voltage than specified in some standards.
23
11.5 Tank
Transformer tanks are usually constructed from welded steel plate and reinforced to
withstand transport, handling or excess pressures during fault conditions without
distortion. The purchaser can specify whether or not a cover-type or a bell-type tank is
required.
The design and positioning of lifting points, stiffeners and underbases on the tank
should prevent distortion of the core during lifting and transport.
For personnel safety it is recommended to specify the maximum tank surface
temperatures, according to local laws and regulations.
11.5.1 Handling facilities

Handling facilities may be required to permit movement, assembly and dismantling of
the complete oil-filled transformer at site or elsewhere and should be agreed before a
contract, unless otherwise specified. Possible facilities include the following:
four jack pads near the corners of the tank, designed to take the weight of
the complete transformer
lugs for lifting the transformer during transport. The lifting lugs and
attachments shall be designed to allow for possible unequal lifting forces,
together with an adequate factor of safety allowance
lifting eyes for main transformer tank cover, conservator tanks and on-load
tap changer
if applicable, a suitable reinforced base frame to form a skid assembly for
skidding the transformer in any direction using rollers
if applicable, permanently mounted or removable wheels, arranged to permit
bidirectional movement
hauling eyes on all sides of the tank
if applicable, riding lugs for transport on a side-beam road trailer or railway
car. The riding lugs (removable if necessary) should be capable of taking
the weight of the main unit, complete with oil filling if requested
11.5.2 Cover
The tank cover may be bolted or welded to the tank. If the purchaser has a
preference, this should be stated in the enquiry. In case of a welded cover, it is
preferred to weld before final testing.
The tank cover should be designed with a sufficient slope to shed water. Fixings
should be provided for attachments to ensure a safe working environment when
personnel have to work on top of the transformer. All tubes, equipments, etc. on top of
the transformer should be located in such a way as to minimise hindering movement of
personnel.
11.5.3 Oil-tight Joints

Oil leaks from the main tank-cover joint or other joints are unacceptable under any
static oil-head or forced oil conditions at any ambient or maximum operating
temperatures. Only joints of proven design, capable of preventing deterioration of any
seal or gasket materials should be specified or supplied.
24
All bolted flange joints should be provided with suitable gaskets and made from oil
resistant, non-perishable material installed within smoothly machined grooves
designed to stabilise the gasket position and to provide suitable compression stop.
The thermal performance of the material must exceed the maximum temperature
attained by the metal parts in contact with the gaskets under all conditions.
For bolted pipe joints or similar, the "O-ring" type of flange seal may be preferred. If
cork type gasket materials are used, the metal mating surface shall be thoroughly
cleaned to prevent the gasket from sticking.
11.5.4 Vacuum and pressure requirements

The assembled transformer, including the tank, coolers or radiators, conservator (if not
equipped with a rubber diaphragm), oil pumps, all oil connections, valves, pressure
relief devices and other fittings, should be capable of withstanding, with minimum
permanent distortion:
when oil filled, an internal overpressure of 35 kPa

without oil, full internal vacuum
The transformer conservator tank, if equipped with a rubber diaphragm, need not be
designed for a full vacuum but a vacuum-tight valve should be provided in the
connection between tank and conservator. The pressure relief diaphragm should be
replaced by a steel plate.
Note: It is necessary to ensure that the transformer tank is not accidentally
sealed, as it might be the case by a valve between the tank and the
conservator, unless a suitable bypass arrangement is specified.
It is usual for power transformers to be designed and equipped for vacuum filling and
oil treatment in the field, whether or not the transformer is shipped with oil.
11.5.5 Valves
The transformer tank should typically be equipped with the following valves and fittings,
the positioning of which shall be subject to approval of the purchaser.
at least an oil valve at the top and bottom of the tank for taking oil samples
shall be provided, unless an alternative arrangement is proposed
a drain connection valve at each end of the tank at the bottom wall of the
tank, complete with a blanking plate. The connection should vent the tank
as close as possible to the junction of the tank wall and the base, so that no
more than a few mm of oil will remain in the tank when empty
two elbow valves, complete with a blanking plate for filling connections,
should be provided on the tank cover and located at diagonally opposite
corners
a valve fitted with a blanking plate and located on the tank cover in line with
the bottom sampling valve should be provided for attaching a vacuum
gauge, a pressure gauge or an oil level indicator when vacuum filling
one or more valves for immediate or future connection of on-line monitors for
dissolved gas
a siphon valve with no return valve for draining the OLTC tank (if applicable)
residual oil discharge valves for the expansion tank(s)
25
11.5.6 Circulating and eddy-currents

The tank should be designed or incorporate measures to minimise the losses caused
by circulating and eddy-currents and avoid onerous temperatures at any part of the
tank surface and at flanges between parts of the tank and its components especially at
gasket sealed joints.
11.5.7 Access Openings

Access openings should be provided as appropriate in the tank cover and walls to
permit unhindered access to inspect, repair or remove current transformers,
tap-changer components, winding connections and other devices that may require
routine or emergency maintenance.
An opening that allows personnel access should not be less than 500mm diameter or
500mm x 500mm. Hand holes should be approximately 400mm diameter or 300mm x
600mm. All openings on the cover should have a raised flange to prevent water from
entering the openings when individual covers are removed.
At least two openings should be provided on the tank cover for access to the interior
without lowering the oil below the top of the core.
11.5.8 Conservator Tanks

A conservator tank shall be provided of sufficient size to accommodate the change in
oil volume that will occur between the specified ambient temperature limits in service
with the transformer operating at full load or overload and the cold oil temperature with
the transformer out of service. The typical conservator oil volume is approximately
10% of the sum of the oil volumes of the main transformer tank and the coolers.
The main tank and on-load tap changer diverter compartment shall have separate
conservator tanks. Oil proof rubber diaphragms (bladders) are typically used within the
conservator tanks for the transformer main tank to minimise atmosphere contact with
the insulating fluid.
Each conservator tank should have a suitable oil level gauge mounted on the
conservator tank so as to be easily read from ground level. The gauge shall be
graduated to indicate the oil level at temperatures of -10C, +5C, +15C and +20C or
other values specified by the purchaser. A float switch shall be provided having a set
of low and high oil-level alarm contacts.
A dehydrating breather shall be connected to each conservator tank. The inner
diameter of the pipe connecting the breather and the conservator tank shall be sized
large enough to not inhibit pressure equalisation.
11.5.9 Tank Earthing

The following grounding and bonding facilities for earthing purposes should be
provided on the tank and other separate free standing parts such as radiator banks:
at least two suitable earthing terminals on the main tank

one earthing terminal should be located, for instance, towards the extreme
right hand end of the low voltage side and the other diagonally opposite on
the high voltage side
one suitable earthing terminal on each cooler bank support structure
26
earthing straps, to bond the tank cover to the main tank

one earthing terminal on the main tank near each set of surge arresters to
allow a high frequency earthing connection from the arresters
Other internal and external metal parts of the transformer shall be earthed to the tank
or separately and directly earthed. Whichever method is adopted, a uniform earth
potential is required throughout the installation.
Closed circulating current loops within the earthing systems must be avoided.
Flanged joints should be electrically bridged.
Internal earthing connections from the core and core clamping structure shall be
brought out to bushings mounted in a secure, weatherproof terminal box, mounted on
the tank surface and earthed externally in order to facilitate testing of the core earthing
system.
11.5.10 Pressure relief

At least one suitable spring operated pressure relief vent should be located on the
main tank (preferably on the cover) and on-load tap changer diverter compartment (s)
complete with an approved oil deflection collar. In addition, piping can be connected to
the oil deflection collar of each pressure relief device in order to direct the oil down
near the base of the transformer.
The number of pressure relief devices required on a transformer is normally dependent
on the total oil volume of the transformer.
Suitably rated auxiliary contacts should be provided for these devices.
11.6 Insulating Fluid

The purchaser should state which type of insulating fluid that should be supplied and
the specification with which it must comply. The insulating fluid should be free of pcb,
copper sulphide, or other chemical having a corrosive sulphur tendency. The
purchaser should state whether the fluid should be inhibited or non-inhibited, and if any
special additives are required or conversely not permitted.
The fluid should comply with the recognised IEC standard and any additional regional
or purchaser requirements.
Under no circumstances shall any degree of forced-oil circulation create a static
electrification hazard in any part of a transformer under any operating condition.
11.7 Bushings
Bushings should comply with a recognised standard such as IEC 60137.
The specification of oil/SF6 bushings should be agreed between purchaser and
manufacturer before a contract.
The interface between the transformer and gas insulated external connections requires
special attention to dimensions, limits and tolerances. These design aspects should be
agreed between purchaser and manufacturer before a contract and should take into
account any purchaser standardisation policies.
27
11.8 Secondary Wiring and Control Cabinets

All conductors, connectors, terminal blocks, wire-ways, terminal markings, etc. shall
meet recognised standard and purchaser requirements.
Control cabinets should be mounted in a manner to reduce vibration and should be
designed to prevent moisture ingress and condensation. Control cabinets should be
mounted at a height that enables operational access from ground level.
11.9 Fittings
Preface
The number and type of fittings required or provided on a transformer will depend upon
several factors including its purpose, construction, rating and voltage. Some other
considerations are, the amount of surveillance required or provided by the purchaser,
the requirements for automatic control and protection, purchaser policies concerning
on-line diagnostic and monitoring requirements.
Certain fittings may incorporate protection, control and remote indication facilities.
Details of such facilities should be stated explicitly at the time of enquiry or tender,
including any requirements for conformity with existing practices.
All labels, plates and markings should be manufactured from durable, non fading
material.
Any instruments or indicators should be capable of being read from ground level.
Where any equipment is to operate in parallel or perform in a similar manner with
existing equipment, the purchaser should provide complete details of the key
parameters of the existing equipment in the enquiry document.
Where alarm and trip contacts are required, the purchaser should state the range of
operating settings required in the enquiry.
Fittings List
The following list is representative of the fittings that may be required on each power
transformer. In practice purchasers and manufacturers select fittings from such a list
as this but may also adopt or recommend additional or alternative fittings for reasons of
policy, improved safety, efficiency, security, and maintenance or lifetime costs.
thermometer pockets in each top and bottom oil pipe adjacent to the
transformer
gas and oil actuated relays for main conservator/tank oil pipes and externally
mounted tap changer selector compartments, as appropriate. Sampling and
test stopcocks may be required and mounted for operation at ground
working height
conservators for the main tank and tap changer diverter compartments
where required. Conservators should be provided with an oil gauge, drain
valve, oil filling facility, lifting lugs, oil sumps and removable end covers
dehydrating breathers
air release and drain plugs or valves for pipe work, oil expansion bellows,
pumps etc
separate drain and filter valves at the top and bottom of the main tank,
externally mounted tap changer selector compartments and cooler headers
28
isolating valves complete with an open/shut indicator and locking facility

valve location plate. The position of each valve in normal service should be
shown, i.e. Normally Open (N.O.) or Normally Closed (N.C.)
fans
pumps
oil-surge relays and pressure relief devices for tap changer diverter
compartments
oil sampling devices easily accessed by personnel
anti-vibration pads
provision for blanking plate storage
earthing lugs on the main tank and each separate cooler structure
main tank jacking lugs
main tank transport lugs
name plate
diagram and rating plate
owners serial number plate
vacuum capabilities plate
main haulage points
main tank haulage rope guides
transport anchoring lugs
co-ordinating rod stands with co-ordinating gaps or fixings for mounting
surge arresters and supporting brackets
current transformer test loop(s) for HV and/or LV bushing turrets
terminal box for LV current transformer test loop
terminal box for HV current transformer test loop
terminal box for core and core structure earthing
current transformer terminal boxes
lifting lugs for tap-changer, cooler structures, main tank cover and other
components as necessary
winding temperature indicator pockets with protective covers
on-line combustible gas and moisture monitors
protective covers to protect projections, such as valves, from damage during
transport
pressure relief devices and associated ducting
tank attached fixings for mounting external neutral current transformers
cover mounted safety lugs to permit fixing of toe boards / safety fences for
safe working purposes
winding and oil temperature indicating instruments
11.10 Tap Changers

If the transformer application requires that variation of the voltage ratio is required in
order to make corrections for changes either in the supply-side or demand-side
voltages, de-energized tap changers (DETCs) and/or on-load tap changers (OLTCs)
should be specified.
29
The choice of which type of tap changer to be used will be dictated primarily by its
function and economics, e.g.:
the size of the tapping range needed to match the expected system voltage
variation
the step voltages required and number of steps
whether or not the transformer can be electrically disconnected from the
network in order to change taps
De-energised tap changers (DETCs) are only used when the need for voltage
correction is infrequent because all tap changing by this means has to be undertaken
when the transformer is off-line, which requires an outage. In practice, DETCs are
mainly fitted to high voltage windings and when a low number of tap steps are
required, e.g., 4, 6 or 8 steps. Usually, each tap step will vary the high voltage winding
turns between 1% and 2.5%. The number of tap steps and percentage voltage
variation per step should be specified by the purchaser and determined by the purpose
of the tappings, i.e., to maintain the low voltage on load at rated value when the high
voltage changes or alternatively to maintain the low voltage network voltage at some
value as the load varies. In most other respects the electrical, mechanical and thermal
design requirements of DETCs, e.g., current rating of contacts and voltage withstand
considerations, are similar to those of on-load tap changers.
On-load tap changers (OLTCs) are designed for connection to line-end or neutral-end
of high voltage or low voltage windings. The size of the tapping range is usually
specified by the purchaser and is a compromise between the network high and low
voltage ranges. Similarly, the number of tap steps will be determined by the range of
voltage variation expected in service and the size of voltage change per step required.
In practice the number of steps can vary between 10 and 40, depending on voltage,
application and current rating of the tap changer. The range of voltage that can be
accommodated is determined by the ac power frequency and impulse voltage
withstand strength between adjacent taps.
OLTCs are specialised precision electro-mechanical devices. They are invariably
purchased by the transformer manufacturer under a sub-supplier contract from an
original equipment manufacturer (OEM) and selected from a type tested and proven
product range. The choice of OLTC suppliers is often specified by the transformer
purchaser.
Several types of OLTCs are commonly available and may be categorised as:
line-end
neutral-end
in-tank
externally mounted
Line-end and neutral-end describe the electrical position of the tap changer within
the configuration of windings and connections. Line-end OLTCs are usually
positioned at the line end of lower voltage windings. This position is chosen for auto-
transformers, for instance, when the voltage ratio is low, e.g., of the order of 2:1.
Designs employing neutral-end tap changers are usually more economic when the
voltage ratio is greater than 2:1. Where delta connected high voltage windings are
required, line end tap changers may be specified on the high voltage winding.
In-tank and externally mounted OLTCs refer to the physical position of the tap
changer in or on the transformer.
30
It should be noted that tap changers, particularly OLTC types, are still a frequent
source of incipient or major transformer faults and a cause of unplanned transformer
outages. It is important therefore that proven equipment is used wherever possible
and that a transformer design is adopted which best meets the needs of the
purchasers operating regime, supply responsibilities and long-term maintenance
requirements.
11.11 Monitoring
Purchasers of power transformers are routinely selecting equipment for on-line
monitoring of the transformer operating status to minimise forced outages; planning
maintenance activities; increased personnel safety; and as well for maximising the
performance of their transformers. IEC standard 60076-1 and CIGR Technical
Brochure 343 provide monitoring recommendations.
On-line monitoring equipment is available for DGA, moisture in oil, oil temperatures, oil
pressure, load current and voltage measurements, pump/fan operation, conservator
membrane condition, tank vibration, winding hot spot calculations and/or direct hot spot
measurements, bushing condition, partial discharges and OLTC condition.
Purchasing monitoring equipment in the original specification is an efficient means to
the option of adding monitors at a later date.
11.12 Interchangeability
Interchangeability refers principally to transformers of similar rating, voltage and other
operating characteristics that are or have been purchased under different contracts and
sometimes from different suppliers, but are all designed to have common dimensions
and layout, in order to allow them to be physically interchangeable with each other with
a minimum of adaptation, if any. It is possible for transformers purchased earlier to be
replaced later by more modern designs, having larger ratings but designed to be
installed and occupy the same space. Utilities purchase transformers to meet
requirements of this kind in order to increase the availability of electricity supply and
reduce costs by minimising the outage time in the event of a transformer having to be
removed from service and replaced by a spare, stored strategically for that purpose.
Interchangeability is of special importance where transformers are required for
installation and connection to gas insulated busbars. In these instances the concept of
interchangeability extends beyond the transformers to include also the busbars,
especially at the interface between the two systems.
When interchangeability is required, the purchaser should undertake to specify and
detail the key features, dimensions and interfaces that are to be repeated on each
transformer and provide all necessary reference drawings. The arrangement and
physical dimensions of the high, low and possibly other voltage bushing connection
points, (sometimes referred to as cover layout), is a vital part of this information.
When specified, the transformer including fittings and other major interfacing
components shall be interchangeable with other transformers and related equipment
defined by the purchaser.
11.13 Standardisation
The concept of standardisation is not to be confused with that of interchangeability.
There is some similarity between the two requirements, especially when transformer
components such as tap changers, valves and other interfacing fittings are required to
31
be replaceable.
Standardisation refers to a policy to limit the variation of transformer types, ratings,
voltage ratios, impedances, tapping ranges and other principal electrical, mechanical
and thermal characteristics of a purchasers transformers. The policy reduces the
complexity of the purchasers stock of transformers, bushings, fittings, tap changer
components and other items and tends to minimise maintenance practices and costs.
The aims of standardisation are:
minimise system design, operating and capital costs

simplify maintenance procedures and requirements, and system planning
reduce stock held items
optimise spares
reduce purchasing and other front-end costs
Standardisation need not be confined to utilities and other organisations that have large
and varied stocks of transformers. Smaller purchasers can purchase transformers by
reference to national and international standards that include recommended
transformer ratings and other features, including in some cases, losses and
dimensions, for which manufacturers have proven up-to-date designs offering
economic savings that are not obtainable from custom made nonstandard alternatives.
This will also give the possibility to replace the transformer with one from another
company in case of an emergency.
11.14 Exclusions
In most cases, every opportunity is taken by a manufacturer to comply with the
requirements of the specification or to propose alternatives that permit improvements
that best fulfil the purchasers needs or meet the manufacturers capabilities.
Deviations of this kind from a purchasers specification may be raised in pre-tender
discussions between a purchaser and potential manufacturer but ultimately, any tender
submission must either comply with the specification or, if this not possible, a
manufacturer should categorically state the non-compliance and exclusions. All
exceptions should be discussed between the purchaser and tenderer and a resolution
made prior to an award of order. The purpose is to avoid misunderstandings. If no
exclusions are stated, the contract works have to be treated as fully compliant with the
specification.
The tenderer should state any non-compliance with the specification in the tender
submission and any alternative offers should be submitted in full and separately from
the main offer.
12 MANAGING QUALITY
Preface
Quality assurance certification indicates the manufacturers general ability to design
and consistently manufacture transformers to a purchasers specification, IEC
standards and other requirements. It also establishes evidence to some degree of the
capability with respect to transformer engineering, design and manufacture attainable
by the manufacturer. The purpose is to ensure that the final product will fulfil its service
function and be comparable to other similar products previously proven by type and
routine tests and service experience. However, the possession of the requisite quality
assurance certification does not by itself guarantee that the transformer manufactured
32
will be of a suitably high quality. It is important for the customer to ascertain

competence and capability in addition to the acceptance of the manufacturers quality
assurance documentation. It is likely that in some situations a potential manufacturer
who has ISO 9001 certification may be deemed unsuitable as being not capable of
producing the transformer required as a consequence of the assessment of capability
procedure.
Further information relating to the proper management of quality is provided in CIGR
Technical Brochure 530; Guide for Conducting Factory Capability Assessment for
Power Transformers.
A Quality Inspection and Test Plan is a major component of the quality assurance
concept. It is prepared by the manufacturer and submitted with each tender for
approval by the purchaser. As with other quality assurance requirements, it forms a
vital and essential part of a transformer contract.
12.1 Quality Inspection and Test Plan (QITP)

A Quality Inspection and Test Plan should be submitted with each tender and agreed
with the purchaser before contract.
Any subsequent alteration to and deviation from the agreed QITP should be submitted
to the purchaser in advance for approval in writing. No changes to the QITP ought to
be permitted without the prior written approval of the purchaser.
The manufacturer should establish a QITP for each transformer, containing a summary
of all the inspections and tests needed during manufacture, factory acceptance tests,
site erection and commissioning tests.
It should be clear from the QITP where inspection activities will be performed, the
parties to be present, inspection plans in force and the distribution of testing and
inspection documents.
The main QITP should be approved by the purchaser before manufacture commences.
The purchaser or his representative should also have the right at any time, without
advance notice, to witness any inspection, manufacturing procedure or test at the
manufacturers or the sub-suppliers plant and to be informed of the result.
Inspections and tests performed in the presence of the purchaser or his representative
will not imply any limitation of the manufacturers responsibility.
12.2 Quality Inspection and Test Plan (Outline)

The following description of the elements contained in a quality plan, is for a
transformer manufactured to this type of specification and may form the basis of a
document to be agreed between purchaser and manufacturer before a contract.
A quality plan describes:
lists of activities, identifying all the activities involved in the design,

manufacture and supply of the transformer by the manufacturers internal
procedure document reference number.
references to all the mechanical, electrical and test requirements needed to
ensure that the design and manufacture of the transformer will be at least to
the minimum standard, necessary to ensure that it will be in accordance with
the specification and be fit for service.
all the activities and responsibilities of the manufacturer, sub-supplier and
33
purchaser, that are required to execute the design, manufacture and testing
of the transformer at the factory, preparation for despatch, delivery,
installation, commissioning and setting to work.
the identification reference of all documentation, standards, procedures,
works instructions, drawings, test methods, acceptance criteria etc.
the controls which each activity must succeed in passing, for example:
a) identifiers - serial number, model number, type number (usually used
to substantiate purchased items)
b) performance (usually statements accrediting the electrical,
mechanical, thermal and chemical performances, against which
manufacturing activities and specification requirements can be
checked)
c) status (usually confirmed by visual examination)
d) dimensions (usually approved by reference to drawings and other
similar reference documentation)
details of the means of recording the progress of the design and manufacture
of the transformer, in particular, inspection and approval points by labelling,
inspection cards, certification etc.
the identity and authority of persons with assigned responsibility for
approving the satisfactory completion of each activity.
the location of each activity, inspection and approval
each deviation, failure to comply, modification to the plan or to any
supporting documentation, e.g., drawings, works instructions, scheduled
information, design changes.
Each sheet of the quality plan is usually referenced by:
contract reference
sheet number
issue number
date of issue
authorisation reference
A quality plan is usually divided into sections, each section covering a distinct part of
the design, manufacture and supply chain. Each activity in this chain is identified by a
unique reference number, usually the section and a subsection number.
The principal sections in a quality plan include:
electrical and thermal design, e.g., core, windings, tests

mechanical design and thermal design, e.g., core, tank, fittings, coolers, tap
changers, controls, oil preservation, protection, monitoring, etc.
purchased items
manufacturing work, e.g., core, windings, connections, fabrications,
processing
testing, e.g., instructions, methods, acceptance criteria, responsible persons,
acceptance formalities
dismantling, preparation for despatch, surveillance during despatch, tests on
arrival at a site
erection at site, commissioning, setting to work
For example, a quality plan sheet relating to transformer tank manufacture could
comprise the elemental activities and requirements illustrated on the following page.
34
Similar sheets are required for all the other activities involved in transformer design,
manufacture, supply and tests, including purchasing and sub-supplier activities. A
typical quality plan for transformers complying with this specification may comprise fifty
sheets or more and cover twenty or more principal activities containing as many as
twenty sub-items per activity.
12.3 Quality Assurance Plan

When submitting a tender, a manufacturer should include a description of the quality
assurance plan (QAP) that will be used to ensure that the transformer design,
materials, workmanship, tests, service capability, maintenance and documentation, will
fulfil the requirements stated in the contract documents, standards, specifications and
regulations.
The quality assurance plan should be based on and include relevant parts to fulfil the
requirements of ISO 9001.
The manufacturer is responsible for any sub-suppliers setting up and executing their
own quality assurance systems.
12.4 Quality Assurance Manuals

A complete quality assurance manual, describing the execution of all the elements of
the quality assurance system, should be available from the manufacturer as a
reference for the purchaser or his representative.
12.5 Final Quality File

This should comprise:
completed Inspection Points Schedule

certificates for:
c) bushings or other line and neutral terminations
d) oil
e) current transformers (where installed)
f) on-load tap-changers or de-energised tap changers
g) other transformer accessories
h) paint and anti-corrosion protections
i) materials
reports on deviations and remedial actions

final test protocol
statement of compliance with specifications, drawings, and purchase
requisitions
contract drawings
35
QUALITY PLAN (For illustration only) Issue No:
Date:
Customer: Customer Ref: Site: Sheet No.
Manufacturer: Manufacturer Ref: Issued by:
Activity ACTIVITY Activity Doc. Acceptance Inspection Inspector - Inspector - REMARKS

No. Ref. Criteria Manufacturer Purchaser
17 Tank and cover
(1) (2) (3) (4) (5) (6)
17.1 Steel plate AAA S, D,Q C, TC, BBB CCC DDDD
17.2 Machining
17.3 Welding
17.31 Weld tests
17.4 Location - openings, fixings etc.
17.3 Internal surface - condition
17.4 - preparation
17.5 - treatment
17.6 External surface - condition
17.7 - preparation
17.8 - treatment
17.9 Paint treatment
(3) (5)
C = inspection card Purchasers inspectors reference.
(1)
eg. Works instruction, IEC standard TC = test certificate
(2) (4) (6)
eg. S = Status Manufacturers inspectors reference includes any additional requirements, references
D = dimensions or other documentation, instructions or advice
Q = quality or performance
36
13 FACTORY ACCEPTANCE TESTS AND FINAL INSPECTIONS
Preface
The importance of the final factory inspections and acceptance tests cannot be over
emphasised in terms of ensuring the transformer manufactured is fit for the intended
purpose. The key purpose in carrying out the final tests is to ensure that the design is as
intended with regard to type testing and that the quality of manufacture is consistent with
the design in terms of type testing. One overriding principle must be considered and that
is that any test made on the transformer must add value, either to the Manufacturer or to
the Purchaser.
The purchase specification should detail all tests that are required to be carried out on
the specific transformer. The requirements for testing transformers are described in the
international standards. IEC 60076-1 breaks factory acceptance tests into three
categories, namely; a) type tests - tests carried out on the first unit of a design and
intended to prove the design, b) routine tests tests carried out on every transformer
and c) special tests additional tests specified by the Purchaser. Purchasers should
note that tests defined as type or special tests at some voltages may well be routine
tests at another.
One important requirement of any purchase specification with regard to testing is to
ensure that any non-mandatory tests which may be required are clearly detailed in the
purchase specification. Some purchasers may wish a test that is described as a type
test or a special test carried out as a routine test and this should be clearly detailed.
Where the purchaser wishes to test the transformer not in accordance with the
international standards for whatever reason, the required test methodology should be
clearly described together with the acceptance criteria. Purchasers who deviate from
the published international standards should also be clear as to why this deviation is
required and be able to justify this in technical terms.
Sometimes the predicted performance of a transformer on test may need to be verified
in advance by non-destructive investigatory tests and measurements. For example,
recurrent surge oscillographic (RSO) tests may be advisable to confirm the transformer
predicted transient voltage behaviour or to determine the most appropriate test
connections.
If a transformer has been specified for use in a non-conventional or otherwise special
application or it is to be subject to unusual operating conditions, then the programme
and sequence of tests shall be specified by the purchaser.
The operating characteristics of transformers fitted with tappings, dual or multiple voltage
ratio connections or alternative vector group connections will alter when these
connections are changed. In the absence of supporting evidence from other identical
previously tested transformers, additional tests may be necessary to determine the
method of test connection that best demonstrates the transformer is fit for purpose.
In certain cases, the test environment at the time of test may not conform to the IEC
standards. Similarly, at the time of test, the transformer may not be fully prepared as for
service and as required by the specification. Unless otherwise agreed, in these
37
circumstances the purchaser may postpone the tests until the circumstances for test are
as specified.
It is important that the specification document highlights the following issues in such a
way as to ensure that agreement with regard to the test procedures is part of the post
contract design review process.
13.1 General
The manufacturer should produce a test programme describing all routine and type tests
and final inspections. The test programme should be submitted to the purchaser for
approval before manufacture commences.
The factory acceptance tests may be witnessed by the purchaser or his representative.
The purchaser should be notified in writing in a reasonable time period before the start of
any test.
For the purpose of acceptance tests the transformer should be assembled as for service,
i.e. complete with conservator, coolers, auxiliary transformer, supervisory equipment etc.
This means that oil-SF6 bushings must not be replaced by corresponding oil-air
bushings. Deviations from this requirement should be by agreement between the
purchaser and manufacturer.
Type test evidence obtained on an identical transformer may be offered to the purchaser
for consideration instead of further type tests, providing the evidence is not more than
five years old and is submitted at the time of tender. Otherwise, type tests should be
made.
Routine test and type test evidence for transformer components, for example bushings
and tap changers, should be provided by the manufacturer prior to the transformer tests
and final inspections.
13.2 Standards and testing specifications

Factory acceptance tests should be performed in accordance with recognised standards.
Bushings for instance should be tested in accordance with IEC 60137 and on-load tap
changers in accordance with IEC 60076-1, IEC 60214-1, and IEC 60214-2, in the
absence of any other standards being specified.
13.3 Testing environment

During the tests at the manufacturers works, the test room ambient temperature should
conform to the specified standard unless otherwise agreed.
The ambient temperature during site tests should not be less than 0C.
13.4 Measurement accuracy

All measuring equipment should conform to the relevant specified standards or better.
The equipment must have a valid calibration certificate, which should be available for
inspection at the test location before starting any tests. Indication of calibration status
38
and the calibration certificate reference number should be clearly displayed on the test
equipment.
Some equipment, such as microphones or partial discharge measurement systems, may
require calibration before and after every measurement. In this case the device used to
calibrate the test equipment requires a valid certificate of calibration.
The latest calibration curves should be available at the test location. Each piece of
measurement equipment should have attached a visible record identifying the equipment
and showing the last calibration date and calibration reference.
13.5 Tolerances
Purchasers need to consider whether the tolerances detailed in the published standards
are consistent with their needs. Where tighter tolerances are required this needs to be
specified otherwise tolerances on measured losses shall be in accordance with the
specified standards. For example: Purchasers may wish to specify a no positive
tolerance clause. Special qualifications on tolerances agreed at the pre-contract award
stage may apply, for example for the purposes of calculating penalty and bonus
payments.
Individual tolerances on impedances may be specified but shall be agreed with the
manufacturer before contract placement.
13.6 Summary of tests

Unless otherwise agreed, the Test Programme should detail all the tests to be performed
on the transformer, in accordance with the specified standards and generally in the order
specified by the purchaser or agreed otherwise at the design review.
If the test methods are not prescribed in IEC 60076-X or other standards, they should be
subject to agreement before contract placement.
The following descriptions of the different tests are based on the categorisation in IEC
60076-1. Purchasers may wish to allocate type or special tests to a different category
for various reasons and this should be clearly specified.
13.6.1 Routine tests

measurement of winding resistance
measurement of voltage ratio and verification of vector group phase
displacements
measurement of short circuit impedance and load loss
measurement of no-load loss and current
switching impulse tests (Um>170 kV)
lightning impulse tests (Um>72.5 kV)
applied voltage test at power frequency
induced over voltage AC tests
partial discharge measurements in combination with the induced overvoltage
test (Um>72.5 kV)
39
functional tests on on-load tap changers at rated voltage and rated current
measurement of insulation resistances to earth and between windings
measurement of dissolved gasses in dielectric liquid from each separate oil
compartment except diverter switch compartment (Um>72.5 kV)
SF6 bushing flange isolation
check of core and frame insulation for liquid immersed transformers with core
or frame insulation.
determination of capacitances windings-to-earth and between windings (Um
>72.5 kV)
measurement of dissipation factor (tan ) of the insulation system
capacitances (Um >72.5 kV)
leak testing with pressure for liquid-immersed transformers (tightness test)
check of the ratio and polarity of any built-in current transformers
13.6.2 Type tests

load loss and impedance measurements on every tap position.
temperature rise (*)
lightning and/or switching impulse (if not a routine test)
sound power levels for each cooling mode specified
tank vacuum test
measurement of fan and oil pump power consumption
(*) Transformers that are to be equipped with sound panels or an enclosure may be
temperature rise tested both with and without the sound panels or enclosure, when
possible. In either case the transformer guaranteed temperature rises shall not be
exceeded.
13.6.3 Special tests

recurrent surge oscillograph (RSO) measurements
dielectric special tests not carried out as routine or type, e.g. partial discharge
measurement at Um<72.5 kV see IEC 60076-3
winding hot spot temperature rise measurements (direct with fibre optics)
measurement of zero sequence impedance on three phase transformers
measurement of capacitances: from windings to earth and between windings
(Um<72.5 kV)
measurement of dissipation factor (tan ) of the insulation system
capacitances (Um <72.5 kV)
determination of transient voltage transfer characteristics
short circuit withstand test (It should be noted that this test is very expensive
and can only be performed at a very limited amount of specially equipped HV
laboratories and it is possibly a destructive test. The need for this test should
be carefully considered by the purchaser.)
measurement of no-load current harmonics
40
low voltage impedance measurement

vacuum deflection and tightness test on liquid immersed transformers
pressure deflection test on liquid immersed transformer
frequency response analysis (FRA)
13.6.4 Additional tests

checks on correspondence relating to the approval of drawings
verification of accessory performance and operation
corrosion protection
no-load current at low voltage (mains voltage)
determination of core temperature rise
verification of oil quality
inrush current test (site test)
thermographic survey (tank temperature survey)
13.7 Test sequence

The test sequence should be agreed wherever possible before the contract stage or at
latest prior to the commencement of manufacture. The sequence illustrated below is
typical and shows changes in categories of test from that specified in IEC 60076-1 as an
example.
RT = Routine Tests - to be performed on each transformer
TT = Type Tests - to be performed on new or modified designs and as required
by the purchaser
ST = Special Tests - to be performed as agreed at the time of tender
TS = Tests on Site - to be performed on each transformer
TT recurrent surge oscillograph (RSO) measurements
RT winding resistance
RT voltage ratio
RT vector group
ST short-circuit withstand
RT & TT losses and impedance
TT zero-sequence impedance
RT determination of sound power level for transformer
RT oil samples before temperature rise test
TT temperature rise
TT determination of sound power level of cooling equipment
TT oil samples after temperature rise test and before dielectric test
RT switching impulse withstand test
RT lightning impulse withstand test
RT applied voltage withstand test (previously referred to as separate
source)
RT induced overvoltage withstand test
RT partial discharge measurement coupled with induced overvoltage
RT oil samples after dielectric tests
41
RT insulation resistance
RT applied voltage withstand test of current transformer test loops
RT SF6 bushing flange isolation
RT magnetic circuit and associated insulations
ST frequency response analysis (FRA)
RT tanks, conservators and oil filled compartments: - oil leakage test
TT tanks, conservators and oil filled compartments: - pressure and
vacuum tests.
TT barrier board pressure test (if applicable)
TS site commissioning tests
Note:- The oil samples taken at key places throughout the test programme as described
above, are for the purpose of identifying the stage at which detectable gas may
have been produced. In practice, the first and last samples are tested and
compared and only when a positive disparity has been observed are the
remaining samples tested.
13.8 Test results and test reports

Copies of the data recorded during a test should be given to the purchasers inspector
as soon as any part of a test is completed. A preliminary or draft copy of the
manufacturers test report should be given to the purchasers inspector as soon as
possible after completion of each test but before the end of the test programme.
Routine test reports for bushings, on-load tap-changers, auxiliary transformer and
current transformers should be made available to the inspector without request. Type
test reports for the other equipment should be available for inspection at the test
location.
The results from all routine, type, special and additional tests shall be compiled in a
document together with the test programme and any non-conformance reports.
Note:- Reports on acceptable type tests performed on a different transformer or on any
accessories should be included.
A specified number of copies of the final test report should be provided to the purchaser
soon after completion of the factory acceptance tests, e.g., within three weeks and
included in the operation and maintenance manual for the transformer.
13.9 Site acceptance tests - erection tests
13.9.1 General
Prior to removal from the transporter at site, purchasers should specify certain tests to
be carried out to ascertain if any damage has occurred in transportation. Typical tests
would be insulation resistance measurement of core and frame insulation, winding
insulation to earth and between windings, frequency response analysis and interrogation
of any shock recorders fitted for transport.
After the assembly of the transformer at site tests should be performed as a minimum to
verify that the unit has not been damaged during transport and that it has been erected
correctly. Purchasers should include any additional testing required in the specification
42
and these will depend on the degree of disassembly required for transportation. The site
test program should be agreed between purchaser and manufacturer preferably prior to
contract award and should detail the tests to be carried out on site and the acceptance
criteria.
13.9.2 Required tests

Voltage ratio
Vector group
Insulation resistance measurement
a) all windings to earth
b) between windings
c) current transformer windings to earth
d) between current transformer windings
e) control cabling
f) auxiliary power cabling
g) between core and tank
h) between core and core clamping
Check of protective earthing connections
a) bushing turrets
b) on load tap changer and motor drive
c) cubicles
d) control cabling
e) auxiliary power cabling
f) coolers, pipes and bridging of flanges
Current transformer polarity check
Control equipment circuit check
Oil tests
a) oil level check
b) dielectric withstand test
c) oil samples for gas-in-oil analysis
Operation test of supervisory equipment
Operation test of cooling equipment
Operation test of on load tap changer
Operation test of off-circuit tapping switch
13.9.3 Commissioning tests

It is advisable that some or all of the following tests and inspections should be performed
before commissioning a transformer.
visual inspection
verify and adjust if required:
a) conservator oil level
b) dehydrating breather
c) valves
43
d) cubicles
e) touch up painting
f) cubicle heaters
g) de-aeration of the gas and oil actuated relay
h) oil leaks
i) tank protective earthing
j) neutral earthing
k) line and bus connections
l) air clearances
fingerprint tests (Um>72 kV)
a) Determination of capacitances windings-to-earth and between
windings(Um >72.5 kV)
b) Measurement of dissipation factor (tan ) of the insulation system
capacitances (Um >72.5 kV)
c) frequency response analysis (FRA)
d) insulation dielectric response (PDC, RVM or FDS etc.)
e) low voltage no-load magnetisation current measurement
f) low voltage impedance measurement
13.10 Energisation
Energisation shall only take place after correct oil treatment and stabilisation time,
including any other requests agreed upon between purchaser and manufacturer that
may have an impact on the warranty.
If possible, the applied voltage should be raised slowly to rated value during the initial
energisation. If this is not possible, the transformer is allowed to be directly switched on
to the network.
During the period after energisation, the transformer should be carefully supervised,
especially gas and oil actuated relays, temperature indicators and monitoring equipment.
Oil samples for dissolved gas analysis should be taken at frequent intervals to check for
diagnostic gases which may indicate a potential problem with the unit. Thermographic
measurements should be made of the tank, bushings and connections. Oil leaks should
be reported to the manufacturer.
13.11 Trial operation

The purpose of a trial operation is to prove the functional capability of the transformer
and to show that it will meet its performance target. Where purchasers require a trial
operation period this should be clearly detailed in the specification.
13.12 Special tests

These are tests such as normal and emergency overload tests, which require special
agreement between the manufacturer and the purchaser. Where purchasers require
any special tests of this nature these should be clearly detailed in the specification.
44
13.13 Site test reports

The result of the site tests and inspections should be recorded and be compiled in a
document, together with the test programme and any non-conformance reports for
inclusion in the transformer operation and maintenance manual.
14 LIST OF GUARANTEES AND WARRANTIES
Preface
The values of the principal transformer parameters such as voltage ratios, losses and
impedances, are critical and must be subject to guarantee. The parameters can be
specified by the purchaser. Most guarantees need to be subject to tolerances, but
because differences are likely to occur between design targets and what will be
achieved in manufacture, realistic tolerances, suitable for transformers for use in normal
service conditions, are provided in the IEC standards.
Other parameters such as sound power level, overload and overvoltage capability,
weights and dimensions and others, may also be the subject of guarantee and
tolerances.
For whatever purpose, additional guarantees, tolerances and warranties or alternatives,
differing from those contained in the IEC standards, may be specified by the purchaser
in the enquiry or agreed between purchaser and manufacturer before contract.
14.1 Guaranteed performances

Submitted tenders should guarantee that the equipment offered is capable of the
performances required in the purchasers specifications. For this purpose the purchaser
may establish a list of the characteristics for which the manufacturer must give
guaranteed values. It may be impossible to accurately determine all quantities at the
time of the tender or they may only be determined during or after manufacture, in which
case they may be subject to manufacturing and measuring uncertainty. Therefore,
tolerances are necessary on certain values like losses, voltage ratio, short circuit
impedances, no-load current. These tolerances are given in the relevant equipment
standard but may also be agreed between the purchaser and manufacturer.
Temperature rise and sound power level limits are typically maximum permitted values
and tolerances are not allowed.
When the maximum losses are not specified by the purchaser, a capitalisation formula
may be used to compare the tenders and penalties may be applied if the no-load and
load losses are higher than the values declared by the manufacturer. Information on
capitalisation of the losses is given in Appendix A of this document. Other critical design
and performance parameters, such as impedances, may also require special tolerances
in certain circumstances.
14.2 Other types of guarantee

The purchaser will require some other guarantees such as:
financial guarantee from the manufacturer
45
a guaranteed delivery time

a warranty period after commissioning
15 CONTRACT DOCUMENTATION
Preface
This refers to the final documentation usually provided by the manufacturer on
completion of the contract works. In most cases the documents are a standard package
and consequently, may not contain all that is necessary for a particular purchasers
application. In these circumstances, the purchaser should specify any additional
requirements in the enquiry or before a contract.
It is also in the purchasers interest to provide all the information in order to speed up the
submission of tenders and the completion of the contract works.
15.1 An Enquiry document should include the following details, where

applicable:
outline and foundation drawings of existing transformers if interchangeability is
required
proposed drawing of substation showing general position of transformer
specified
details of primary connections, such as LV phase isolated connections and
gas insulated connections
list of applicable purchasers, statutory or regulatory requirements
if parallel operation with existing transformers is required, information in
accordance with IEC 60076-1 should be provided
15.2 A Tender should include:

a description of the transformer offered, including tap changers, bushings, oil
preservation system, fittings and protective devices.
technical data sheets
references to other similar transformers previously supplied, including
quantities supplied and delivery dates
type test reports of similar transformers and components
outline, foundation and transport drawings
list and details of all non-compliance and departures from the specification
details of the Quality Assurance system and a copy of the present Quality
Assurance certificate
a Quality Plan
a Quality Inspection and Test Plan
15.3 A manufacturer should provide the following documents as part of a

Contract:
46
The documentation required to fulfil a contract will depend on the rating, voltage and
type of transformer involved and whether documents relating to identical transformers
have been supplied previously. In most cases, most documents will be selected from
the typical list below, either as drawings, text or some other agreed form.
Final technical particulars

General arrangement drawing
Diagram and rating plate
Foundation details
Terminations
Valve plate
Protection scheme plate
Cooler control scheme
Tap changer control scheme
Outline arrangement of control cabinets, including any foundation details
Internal arrangement of control cabinets
Photographs illustrating important features of the transformer assembly
Test reports, including commissioning reports
Instructions for operation and maintenance, transport, short and long-term
storage
16 EXAMPLES OF TECHNICAL AND OTHER INFORMATION SCHEDULES

RELATING TO A TRANSFORMER SPECIFICATION
The following examples of schedules are typical, with goal to summarise the transformer
features, performances, guarantees and other details, forming the basis of a
specification or tender and ultimately of a contract.
The schedules included in this section are for illustration purposes. While they are
typical, they neither represent all the schedules that may be included in a specification
nor their content. Purchasers and manufacturers must therefore prepare their schedules
in such a way that they contain all the information they require or have to offer, for a
contract. Also, it must be recognised that, in some cases, it may be necessary that the
information exceeds or supersedes that recommended in a standard.
The technical schedules relating to the transformer performance and guarantees are
probably the most important since, in practice, they are intended to be clear and precise
statements about what the purchaser requires, together with similar firm statements of
what the manufacturer is offering. The layout and content of these schedules will vary
not only with the transformer rating, voltage and application but also with the originality
and complexity or otherwise of a purchasers requirements. Neither schedules nor the
information they contain is intended to be complete, but together with Technical
Specification represent purchaser technical requirements and manufacturer offer.
Only characteristics marked as guaranteed are subject of penalties or rejection.
The Product Source schedule is an example of a summary that records where materials
and finished goods are obtained, their identity and other details, like in this case their
47
place of test. These records assure both purchaser and manufacturer that the items
listed are acceptable.
The List of Trips, Alarms and Analogue outputs is only example. The items or facilities
listed will vary, depending on needs of a particular transformer specification, but again,
the advantage of such a schedule is to provide complete information both to purchaser
and manufacturer of what is required and what is to be supplied.
48
SCHEDULE 1A
Performance and Guarantees Schedule
(To be completed by Purchaser and Manufacturer, as appropriate)
Item Description Units Required Offered
1 Type of transformer
2 Applicable standard
3 Rated power at all taps MVA
4 Number of phases 1 or 3
5 Rated frequency Hz
6 No-load rated voltage at principal tap (IEC rated voltage)

(a) HV winding kV
(b) LV winding kV
(c) Tertiary winding kV
(a) Delta connected Tertiary stabilising winding required? Yes / No

(b) Tertiary winding required for loading, complete with Yes / No
terminals?
Winding connection, e.g. star/delta/auto

(a) HV winding
(b) LV winding
(c) Tertiary winding
(d) IEC vector group symbol
Type ( graded/non-graded ) of windings

(a) HV winding
(b) MV winding
(c) LV winding
Highest voltage for equipment

(a) HV winding kV
(b) MV winding kV
(c) LV winding kV
Rated lightning impulse withstand voltage at:

(a) HV terminal kV
(b) MV terminal kV
(c) Neutral terminal kV
(d) LV terminal kV
Rated switching impulse withstand voltage at:

(a) HV terminal kV
Rated power frequency withstand voltage at:

(a) HV terminal * kV
(b) MV terminal * kV
(c) Neutral terminal kV
(d) LV terminal kV
*Note: Only 3-phase ACSD testing, if applicable
Maximum partial discharge intensity measured during AC

induced voltage withstand test
49
SCHEDULE 1A (Continued)

(a) at 1.1 x system highest voltage Um
(b) at 1.3 Um pC
(c) at 1.5 Um pC
pC
Cooling method
Power for different cooling methods %
Maximum temperature rise at rated power at:

(a) Average windings K
(b) Hot spot of windings K
(c) Top oil K
(d) Core K
(e) Tank K
Overload capabilities according to IEC 60076-7? Yes / No
Type of tap changing No tap / On-load

/ De-energised
On-load tap changer is mounted inside or outside of

transformer main tank? Inside / Outside
Which winding is tapped? HV / MV / LV
Category of voltage variation C.F.V.V. /

V.F.V.V.
Tapping range
(a) Plus ( maximum tapping ) %
(b) Minus ( minimum tapping ) %
Tapping step
Number of tap steps
Arrangement of tapping ( Taps, Linear, Coarse/Fine,

Reversing )
HV/MV impedance voltage at rated 100% power and 75C

and tolerances ( guaranteed value ) :
(a) on principal tapping
(i) HV/MV %
(ii) HV/LV %
(iii) MV/LV %
(iv) Fault current available at LV kA x
terminals
(b) on minimum tapping
(i) HV/MV %
(ii) HV/LV %
(iii) MV/LV %
(iv) Fault current available at LV
50

terminals kA x
(c) on maximum tapping
(i) HV/MV
(ii) HV/LV %
(iii) MV/LV %
(iv) Fault current available at LV %
terminals kA
Zero sequence impedance voltage ( approx. value ) at

rated 100% power and 75C, on principal tapping,
assuming rated voltage (single phase ) applied between
line terminals and neutral, LV delta winding ( if exist ) is
open circuit :
(a) Supply on HV with MV open circuit %
(b) Supply on HV with MV short circuit %
(c) Supply on MV with HV open circuit %
(d) Supply on MV with HV short circuit %
Evaluation of losses to be used in assessing tender

(a) No-load loss currency/kW
(b) Load loss at Rated Powerbmission currency/kW
(c) Cooling plant losses currency/kW
No load losses at rated voltage and rated frequency on kW

principal tap ( guaranteed value )
Load losses at rated power and 75C:

(a) On principal tapping:
(i) HV/MV ( guaranteed value ) kW
(ii) HV/LV at LV rated power kW
(iii) MV/LV at LV rated power kW
(b) On tapping for maximum loss:
(i) HV/MV kW
(ii) HV/LV at LV rated power kW
(iii) MV/LV at LV rated power kW
Tap position number
Cooling plant losses kW
Guaranteed sound power level at 100% rated voltage and Guaranteed

frequency: sound
(a) at no-load dB(A)
(b) at (a) plus cooling equipment dB(A)
(c) at (b) plus rated current dB(A)
(d) cooler bank only dB(A)
Terminal connection ( oil/air bushings, oil/SF6 bushings,

cable boxes-oil or air insulated, plug-in )
51

(a) HV terminals
(b) MV terminals
(c) Neutral terminal
(d) LV terminals
Bushings
(a) Rated current
(i) HV bushing A
(ii) MV bushing A
(iii) Neutral bushing A
(iv) LV bushing A
(b) Insulation level
(i) HV bushing kVp
(ii) MV bushing kVp
(iii) Neutral bushing kVp
(iv) LV bushing kVp
(c) Power frequency test level
(i) HV bushing kV
(ii) MV bushing kV
(iii) Neutral bushing kV
(iv) LV bushing kV
(d) Creepage distance
(i) HV bushing mm
(ii) MV bushing mm
(iii) Neutral bushing mm
(iv) LV bushing mm
Bushing current transformers ( BCTs)

Test winding is required ? Yes / No
Compensation winding is required ? Yes / No
(a) HV BCTs
(i) Number of cores
(ii) Ratio A
(iii) Class
(iv) Rated output VA
(b) MV BCTs
(i) Number of cores
(ii) Ratio A
(iii) Class
(c) Neutral BCTs
(i) Number of cores
(ii) Ratio A
52

(iii) Class
(d) LV BCTs
(i) Number of cores
(ii) Ratio A
(iii) Class
Transformer oil Inhibited/

Uninhibited
Number of stand-by:
a) radiators / coolers
b) fans
c) pumps
Anti-corrosion protection of radiators or coolers Painted / Hot dip

galvanised /
HDG+painted
Transformer tank fittings:

- Draining and filtering valves Yes / No
- Valves for tank oil sampling Yes / No
- Radiator isolation valves Yes / No
- Pulling eyes for complete transformer Yes / No
- Supports for hydraulic jacks Yes / No
- Lifting lugs Yes / No
- Tank earth terminals Yes / No
- Core earth terminal box Yes / No
- Inspection manholes Yes / No
- Ladder Yes / No
- Skids or wheels adjustable in two directions Yes / No
Transformer accessories:
- Oil preservation system with or without rubber bag With / Without
- Dehydrating breather standard or maintenance Standard /
free Maintenance
free
- Oil level indicator of magnetic type Yes / No
- Contact thermometer for the oil temperature Yes / No

on HV/MV/LV
side
- Winding temperature indicator
Yes / No
- Direct winding temperature measurement using h
fibre optic sensors
Yes / No
- Pressure relief device
Yes / No
- Rapid pressure relay
Yes / No
- Buchholz relay
53

- Buchholz relay gas sampling Yes / No
- Non-return valve Yes / No
- On-line gas monitor Yes/ No/

Preparation
- On-line monitoring system Yes/ No/

Preparation
Yes/ No/
- Fire protection system Preparation
Supply voltage for transformer auxiliaries V 400 / 230 AC
Control / Protection voltage V x DC or y AC
Routine tests according IEC 60076-1 Yes / No
Type tests:
- Temperature-rise type test (IEC 60076-2) Yes / No
- Dielectric type tests (IEC 60076-3) Yes / No
- Determination of sound level (IEC60076-10) for Yes / No
each specified sound level h
- Measurement of the power taken by the fan and Yes / No
liquid pump motors h
Special tests( depending on voltage level, some of them

could be routine tests acc. to IEC 60076-1 ): H
- Dielectric special tests (IEC 60076-3) Yes / No
- Determination of capacitances windings-to-earth, Yes / No
and between windings h
- Measurement of dissipation factor (tan ) of the Yes / No
insulation system capacitances h
- Determination of transient voltage transfer Yes / No
characteristics (IEC 60076-3 Annex B) h
- Measurement of zero-sequence impedance(s) on Yes / No
three-phase transformers h
- Short-circuit withstand test (IEC 60076-5) Yes / No
- Measurement of d.c. insulation resistance Yes / No
windings-to-earth, and between windings h
- Vacuum deflection test on liquid immersed Yes / No
transformers h
- Pressure deflection test on liquid immersed Yes / No
transformers h
- Vacuum tightness test on site on liquid immersed Yes / No
transformers h
- Measurement of Frequency Response (Frequency Yes / No
Response Analysis) h
- Check of external coating (ISO 2178 and ISO 2409 Yes / No
or as specified) h
- Measurement of dissolved gasses in dielectric Yes / No
liquid
54
Quality Assurance:
- Manufacturer quality assurance acc. to ISO 9001 Yes / No
- Manufacturer Quality Manual is submitted with Yes / No
offer
Yes / No
- Manufacturer a sample of Quality Inspection and h
Test Plan is submitted with offer
A informative transformer general arrangement drawing Yes / No

showing overall dimensions and transport dimensions is
submitted with offer
55
SCHEDULE 1B
Performance Schedule
(To be completed by Manufacturer)
Item Description Unit Offered
1 Core construction
(a) Limbs: Banded / Bolted
(b) Yokes: Banded / Bolted
(c) Banding / Bolting material
(d) Core bolt insulation ( if applicable )
(e) Number of limbs
(f) Number of limbs wound
2 No-load current on principal tap

(a) at 100% excitation % of rated
current
(b) at 110% excitation % of rated
current
3 Insulation of:
(a) Yoke clamps
(b) Leg plates
(c) Core laminations
Whether tank or other flux shields are incorporated
Flux density in magnetic circuit

(a) Maximum value at rated voltage, rated frequency
and principal tap
(i) Limb
(ii) Yoke
(iii) Shields
(b) Maximum value under any condition of voltage and
frequency specified
(i) Limb
(ii) Yoke
(iii) Shields
Winding type, e.g. interleaved disc, disc, helical etc.

(a) HV windings
(b) MV windings
(c) Tapping windings ( as applicable )
(d) LV windings
(e) Windings arrangement, i.e. core/////
Presence of non-linear resistors? Yes/ No
56
SCHEDULE 1B ( Continued )
Conductor insulation
(a) HV windings
(b) MV windings
(c) Tapping windings
(d) LV windings
Oil circulation ( i.e. natural/partially directed/directed ):

(a) to windings
(i) HV windings
(ii) MV windings
(iii) Tapping windings
(iv) LV windings
(b) through windings
(i) HV windings
(ii) MV windings
(iii) Tapping windings
(iv) LV windings
(c) maximum oil velocity in windings, all pumps operating m/s
Maximum current density in any winding at principal tap and

rated power
(a) Winding
(b) Current density
A/mm2
(c) Current density in HV or MV winding under most
A/mm2
onerous earth fault condition
(d) Current density in LV winding under most onerous
earth fault condition A/mm2
Oil:
- Manufacturer
- Type designation
- Applicable standard
OLTC or DETC:
- Manufacturer
- Type designation
- Applicable standard
- Rated current A
Type of tank:
- cover or bell type
- cover connection: bolted or welded
57
SCHEDULE 1B ( Continued )
Minimum thickness of transformer tank:

- Sides mm
- Bottom mm
- Cover mm
Thickness of radiator plates mm
Colour of finishing paint RAL
Overall Dimensions
(a) Maximum height from floor level mm
(b) Maximum length of transformer mm
(c) Maximum width of transformer mm
(d) Minimum height to crane hook for lifting active part mm m
out of tank, including allowance for slings
(e) Minimum height above transformer cover for lifting mm
of OLTC diverter switch insert
mm
(f) Maximum dimensions for transport
mm
(i) height
(ii) length
(iii) width
Masses
(a) Mass of transformer and coolers, complete with kg k
necessary equipment and filled with oil kg
(b) Mass of transformer dry active part kg
(c) Total mass of copper in windings kg
(d) Total mass of cellulose insulation kg
(e) Mass of active iron in core kg
(f) Mass of tank empty kg
(g) Mass of coolers complete with oil kg
(h) Maximum mass for transport kg
(i) Mass of main tank, erected and filled with oil
kg
(j) Mass of complete oil
kg
(k) Maximum mass of one bushing
58
SCHEDULE 2
Product Source information Manufacturers, Type, Places of Manufacture
(To be completed by either the Manufacturer)
Item Manufacturer Manufacturers type Place of

designation Manufacture
Transformer
OLTC equipment
DETC tapping switches
HV bushings
MV bushings
LV bushings
Neutral bushing
Insulating cylinders N/A
Core plate material
Winding conductor N/A
Transformer tank N/A
Radiators N/A
Air cooled oil coolers
Water cooled oil coolers
Oil
Oil valves N/A
Oil pumps
Oil flow indicators
Fans
Gaskets for oil tight joints N/A
Pressure relief device
Oil level indicators
Dehydrating breather
Gas and oil actuated relay(s)
Control cabinet N/A
Temperature indicating devices
Material for anti-vibration mountings N/A
Current transformers N/A
Monitoring devices ( to specify )
59
SCHEDULE 3
Trips, Alarms and Analogue outputs
(To be completed by the Purchaser)
Item / Function If required Type Comments
Main gas and oil actuated relay Yes Trip/Alarm
Tap changer gas and oil actuated relay Yes Trip/Alarm
Tap changer diverter overpressure relay Yes/No Trip/Alarm
Pressure relief device operated Yes/No Trip/Alarm
Oil temperature Yes/No Trip/Alarm/Analogue
Main windings temperature Yes Trip/Alarm/Analogue
LV winding temperature Yes/No Trip/Alarm/Analogue
Conservator low oil level Yes/No Alarm/Analogue
Rubber bag failure Yes/No Alarm
Transformer auxiliary voltage fault Yes/No Alarm
Power supply fan/pump fault Yes/No Alarm
Transformer control cubicle fault Yes/No Alarm
Oil flow fault Yes/No Alarm
Dissolved gas in oil monitor fail Yes/No Alarm
High dissolved gas in oil Yes/No Alarm
Dehydrating breather fail Yes/No Alarm
Tap change incomplete Yes/No Alarm
Tap changer automatic control fault Yes/No Alarm
Tap changer lockout relay Yes/No Alarm
60
SCHEDULE 4
Clarification / Exclusions Technical Schedule
(To be completed by the Manufacturer)
Note: Contents of this schedule should be included in commercial part of Purchaser Order
Specification reference Brief details of clarification / exclusion
61
SCHEDULE 5
Recommendation for spare parts to be included in the contract
(To be completed by the Manufacturer)
Item Spare Part Description Quantity Required Offered

No. (Yes/No) (Yes/No)
62
APPENDIX A - Loss evaluation, penalties, bonuses and rejection

The total evaluated cost of a transformer is usually taken to be its capital cost plus the
lifetime operating costs, particularly the losses. The relative magnitude of transformer
no-load and load loss as well as other factors such as the rated power, operating voltage,
impedance and thermal performance, has a fundamental effect on the transformer design
by affecting the volume, weight, shape and cost.
The major determinant of total evaluated cost is the cost of the no-load and load losses,
but purchasers are increasingly considering other additional costs to determine the true
lifetime ownership costs. For instance, the overall transformer lifetime ownership costs
involve:
transformer capital cost

lifetime cost of losses
erection and commissioning costs
lifetime maintenance, replacement and disposal costs
environmental costs
The capitalised cost of losses therefore depends on the accuracy of future estimates of
the cost of electricity, interest rates and yearly transformer utilisation rates involving load
prediction. These factors tend to become less accurate as the expected future
transformer service life is extended.
The optimum combination of capital cost and lifetime cost of losses may also be affected
by other constraints such as purchasing and system operating policies. For instance:
adoption of standard ranges of transformer types, ratings and voltage classes

where applicable, the ratio of naturally cooled ONAN rating to forced cooled
ratings, e.g., OFAF
ratio of normal operation rated power to planned or emergency outage
throughput power
estimated loss ratio to maximise transformer operating efficiency to meet
predicted medium or longer term loads
In the absence of the requisite data, resources or methodology for evaluating the cost of
losses a purchaser is advised to consult a number of potential manufacturers or other
specialists for guidance on how to prepare a suitable statement on loss evaluation for
inclusion in an enquiry document.
It should be apparent that an estimate of lifetime cost of losses is dependent on the use
of accurate forecast information, including the guaranteed losses. To prevent any
additional costs arising due to measured losses exceeding guaranteed values,
purchasers can impose penalties on manufacturers in order to recover these costs and
also seek lower tolerances on losses. A purchaser may also recompense the
manufacturer with a bonus payment if the difference between measured and guaranteed
losses will result in lower purchaser operating costs.
A.1 Loss evaluation formula

There appears to be no limit to the simplicity or complexity of the methods used to
63
determine the cost of the losses but the following general method may be used in the
absence of any other. However, no general method can fulfil the function of a
customised technique specially devised to meet the needs of a purchasers particular
application.
The factors usually involved are:
factor a = intended life of the transformer, years
factor b = availability (the number of hours a transformer is energised
expressed in per unit terms, based on 8760 hours in a year).
factor c = financial discount rate, (%).
factor d = cost of power, unit cost (1) / kW at maximum demand, per annum
factor e = cost of energy, unit cost / kWh
factor f = load factor (expressed in per unit terms based on rated power)
and n = number of a given year of transformer life (n = 1 through a)
(1)
Note: unit cost means a unit of currency
For generator transformers that are normally intended to operate at rated power
throughout the period of their annual availability (i.e., b = 1.0), the formula for determining
the evaluated cost of losses is:
n=a
Generator transformer losses = { ( e . 8760 . f ) + d } . c unit cost/ kW
n=1
This formula is also applicable to shunt reactor losses but with a correction to take
account of the lower total time they are connected to the system, i.e., their lower
availability:
n=a
Shunt reactor losses = { ( e . 8760 . f . b ) + d } . c unit cost / kW
n=1
Transmission transformers and series reactors normally operate at less than their rated
power for a significant part of service life. In addition, two or more transmission
transformers are normally connected in parallel to share a common load and to ensure a
secure supply. Also, their load usually increases throughout their service years due to
load growth up to a prescribed maximum value. The load can also fluctuate from no-load
to emergency load conditions.
Transmission transformer no-load loss

n=a
= { ( e . 8760 . b ) + d } . c unit cost / kW
n=1
and the associated load losses

n=a
= { ( e . 8760 . f 2 . b ) + d } . c unit cost / kW
n=1
64
where in this case, the factor f is the load factor value that is likely to occur in a given
year when load demand on the transformer is at a maximum.
A.2 Penalties, bonuses and rejections to be applied to losses outside a

guarantee.
The following clauses are typical of those used sometimes to qualify the contractual value
of losses measured on test and are provided here for illustration purposes only.
If the individual no-load and load losses or the total losses exceed the guaranteed values
by more than 10% the transformer shall be rejected.
Where a measured loss exceeds 105% of the guaranteed value, a penalty shall be paid
to the purchaser by the manufacturer.
Where a measured loss is less than 95% of the guaranteed value, a repayment shall be
made to the manufacturer by the purchaser.
The difference between the above limits and the measured losses shall be used together
with the capitalised value of losses to determine the value of any penalty or bonus to be
applied under the contract. The capitalised values of the losses used in these
calculations shall be those declared in the enquiry document and contract.
65

CIGRE Brochure 528 Transformer Specifications

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CIGRE Brochure 528 Transformer Specifications

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528

WORKING GROUP A2.36

Convenor: T. Breckenridge (UK)

N. Buthelezi (SA), A. Cancino (MX), L. Cornelissen (BE), E. de Groot (NL),

Ownership of a CIGRE publication, whether in paper form or on electronic support only

1 SCOPE AND STANDARDS .................................................................................................. 4

3 EXTENT OF SUPPLY ........................................................................................................... 6

4 PURPOSE OF THE EQUIPMENT ........................................................................................ 7

5 SYSTEM OPERATING CONDITIONS .................................................................................. 7

6 SITE INFORMATION .......................................................................................................... 11

7 CONTRACT WORKS .......................................................................................................... 11

8 ENVIRONMENTAL CONSIDERATIONS ............................................................................ 12

9.9 Storage ........................................................................................................................ 19

10 SAFE WORKING SYSTEMS ......................................................................................... 20

11 TECHNICAL REQUIREMENTS ..................................................................................... 21

12 MANAGING QUALITY ................................................................................................... 32

13 FACTORY ACCEPTANCE TESTS AND FINAL INSPECTIONS .................................. 37

13.9.1 General ............................................................................................................... 42

14 LIST OF GUARANTEES AND WARRANTIES .............................................................. 45

15 CONTRACT DOCUMENTATION ................................................................................... 46

16 EXAMPLES OF TECHNICAL AND OTHER INFORMATION SCHEDULES RELATING

APPENDIX A - Loss evaluation, penalties, bonuses and rejection ................................... 63

Identify Prepare and Assess Tender

Is Tenderer No Post Contract

On Going Factory On Site installation

Figure 1 Example of a transformer procurement process

1 SCOPE AND STANDARDS

IEC 60137 Bushings for Alternating Voltages above 1000V

ISO 8501-1 Preparation of steel substrates before application of paints and

Particular technical specification/technical data sheet

3.2 Additional Requirements

3.4 Alternative offers

3.5 Transfer of liability/ownership

4 PURPOSE OF THE EQUIPMENT

4.1 Some Examples

The transformers referred to in this specification will be installed at XXX

The transformers referred to in this specification will be installed at XXX

The transformers referred to in this specification will be installed at the XXX

The transformers referred to in this specification will be installed in the

5 SYSTEM OPERATING CONDITIONS

5.1 General Description of Network

5.2 Insulation Co-ordination

5.2.1 Method of System Earthing

5.2.2 Unusual Operating Conditions

5.3 Short-Circuit Withstand

To meet the requirements of this standard, purchasers must provide sufficient

Unusual Operating Conditions

Below rated frequency

Above rated secondary voltage, either as a result of a high network voltage or

does not apply to arc furnace transformers.

5.8 Neutral Point Loading

7.1 Installation Details

7.2 Documentation Requirements

drawings detailing overall and individual major component dimensions and

7.3 Details of Additional Requirements

7.4 Details of Requirements for Interfacing with Other Equipment, or to

fire hazard and risk of producing contaminants or other unacceptable by-

8.2 Audible Sound

no-load losses measured on the principal tapping at 100% rated voltage, or

as specified by the purchaser

8.4 Oil pollution

8.5 Explosion or blast hazards

8.6 Fire hazards

8.7 Visual impact