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ROLTA INDIA LIMITED

Technical Specification Of Distribution Transformer Doc No. DMS-E-GEN-40001-00

Revision History
Revision Level Revision Date Revision Description Department Head (Approver)

This Document and all contained herein are proprietary of ROLTA INDIA LIMITED and is subjected to confidentiality restrictions between ROLTA INDIA LIMITED and the Recipient. Copyright Reserved.

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TABLE OF CONTENTS

Page No

1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0

SCOPE ....................................................................................................................3 GENERAL REQUIREMENTS ..................................................................................3 BASIC TECHNICAL REQUIREMENTS.......................................5 CONSTRUCTIONAL FEATURES AND ACCESSORIES..............................7 OIL................................................................................... 13 FITTINGS AND ACCESSORIES.............................................................................14 OPTIONAL FITTINGS17 TEST.18 LOSSES18 REJECTION.18 SPARE..19

1.

SCOPE

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This specification covers the minimum requirements related to the design, fabrication and supply of oil-filled distribution transformers. Transformer will be outdoor type, 3 phase, 50 Hz, with off circuit tap changer on HV winding which range from + 5 % to 5% including all equipment, manufacture, assembly, factory wiring, inspection, testing and delivery.

2. 2.1

GENERAL REQUIREMENTS Operating Conditions Considering Geographic, Climatic and Seismic Data.

2.2

Codes and Standards The design, manufacture and performance of equipment shall comply with all currently applicable statutes, regulations and safety codes in the locality where the equipment will be installed. Nothing in this specification shall be construed to relieve the VENDOR of his responsibility. The latest edition of the following specific standards shall apply to the extent specified herein: International Electro-technical Commission (IEC) and IS IEC 60044-1 IEC 60044-2 Instrument transformers Part 1: Current transformers Instrument transformers Part 2: Inductive voltage transformers Instrument transformers Part 6: Requirements for protective current transformers for transient performance Power transformers Insulated bushings for alternating voltages above 1000V Tap-changers - Part 1: Performance requirements and test methods Specification for unused mineral insulating oils for transformers and switchgear
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IEC 60044-6

IEC 60076 IEC 60137 IEC 60214

IEC 60296

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IEC 60446

Basic and safety principles for man-machine interface, marking and identification Identification of conductors by colours or numerals. Degrees of protection provided by enclosures (IP Code) Terminal and tapping markings for power transformers Low-voltage switchgear and control gear Part 5-1: Control circuit devices and switching elements Electromechanical control circuit devices Safety of power transformers, power supplies, reactors and similar products - Part 1: General requirements and tests

IEC 60529 IEC 60616 IEC 60947-5-1

IEC 61558

IEC 61000-3-6

Electromagnetic Compatibility. Part 3. Limits Assessment of emission limits for distorting loads in MV and HV power systems. Power Transformer Fittings and Accessories Distribution transformer Loading of oil immersed transformer Insulating Oil Bushing for > 1000 V, AC Degree of protection Buchholz relay, Electrical insulation classified by thermal stability Climate proofing

IS: 2026 IS: 3639 IS: 1180 IS: 6600 IS: 335 IS: 2099 IS: 13947 IS: 3637

IS: 3202

2.3

Language and Units

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All nameplates and other field identifications shall be made in English. All documents such as shop drawings, operation and maintenance manuals and similar documentation shall be in English. Unless otherwise stated, all units shall be in International System of Units (S.I. units), including drawings sizes, scales and measurements. 3. 3.1 BASIC TECHNICAL REQUIREMENTS Power System Characteristics

3.1.1 Primary System Voltage

Nominal voltage Voltage variation

6.6/11/33/66/132/220/400 KV rms

10% Frequency 50 Hz 3% Earthing Low resistance earthed Three-phase short circuit fault for 1 second HV LV

3.1.2 Power Supply for Accessories and Auxiliaries 415 V, 3-ph, 50 Hz. 230 V, 1-ph, 50 Hz.

3.2

Type and Ratings

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Transformers shall be step-down, outdoor type, oil-immersed two winding, three phase, ONAN type, 3 phase, 50 Hz, sealed tank design and suitable for pad mounting. Transformer capacity (KVA) ratings shall be as specified in the technical data sheet. 3.3 Voltages and Connections 6.6/11/33/66/132/220/400 kV delta/star-connected primary 433 V/6.6/11/33/66/132/220 KV delta/star -connected secondary 3.4 Temperature Rise Temperature rise limits shall be 65C average and 95C hot spot with maximum ambient temperature of 45C.

3.5

Impedance Values Impedances shall be as specified in the technical data sheets.

3.6

Short Circuit Requirements Transformers and all component parts shall be able to withstanding mechanical and thermal stresses produced by short circuits in accordance with IEC 60076.

3.7

Insulation Levels Minimum insulation levels for windings and bushings shall be as specified in the technical data sheets and in accordance with IS 6160

3.8

Sound Level Transformer shall meet the standard audible sound levels as listed in IEC 551.

3.9

Tolerances

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Tolerances shall be as per IEC 60076.

4. 4.1

CONSTRUCTIONAL FEATURES AND ACCESSORIES The design, manufacture and performance of equipment shall comply with all currently applicable statutes, regulations and safety codes in the locality where the equipment will be installed. Nothing in this specification shall be construed to relieve the VENDOR of his responsibility.

4.2

Tanks The interior of all transformer tanks and other oil filled chambers and internal structural steel work shall be cleaned of all scale and rust by shot blasting unless otherwise approved. These surfaces shall be painted with not less than two coats of heat resistant, oil insoluble and insulating varnish. Steel surfaces exposed to the weather shall be thoroughly cleaned and have two coats of epoxy based primer. The first finish coat shall be of an oil and weather resistant nature, preferably of distinct colour from the primer and final finish coats. The final finish coat shall be of glossy oil and weather resisting non-fading epoxy based paint of specified shade. Requisite quantity of paint for giving one additional coat of finishing paint at site and for touching up the external surface during subsequent maintenance shall be supplied in sealed non-returnable containers. Metal parts not accessible for painting shall be made of corrosion-resistant material. Nuts, bolts and pins used inside the transformers and tap changer compartments shall be provided with lock washers or locknuts.

4.3

Steel bolts and nuts exposed to the atmosphere shall be galvanized.

4.4

Unless otherwise stated, the tank together with radiators, conservator, bushings and other fittings shall be designed to withstand without permanent distortion the following conditions: a) Full vacuum of 760 mm of Hg, for filling with oil by vacuum. b) Internal gas pressure of 0.35 Kg/cm2 (5 lbs/sq.in) with oil at operating level.

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4.4

The tank cover shall be suitably sloped so that it does not retain rainwater.

4.5

The material used for gaskets shall be cork neoprene or approved equivalent.

4.6

Core The magnetic circuit shall be constructed from high-grade cold-rolled no ageing grain oriented silicon steel laminations and shall be of 'core' type. The laminations shall be free of all burrs and sharp projections. Each lamination shall have an insulating coating resistant to the action of hot oil. The construction may be of 'core' type. All steel sections used for supporting the core shall be thoroughly shot or sandblasted, after cutting, drilling and welding. The design of the magnetic circuit shall be such as to avoid static discharges, development of short circuit paths within itself or to the earthed clamping structure and production of flux component at right angles to the plane of laminations, which may cause local heating. The finally assembled core with all the clamping structures shall be free from deformation and shall not vibrate during operation. The core clamping structure shall be designed to minimize eddy current loss and bolt less design is preferable. However Main legs, auxiliary legs and top yokes shall be clamped by using Fiberglass or equivalent tapes of adequate strength without bolts. Bottom yokes may have bolted arrangement. The core shall be provided with lugs suitable for lifting the complete core and coil assembly. The insulation structure for the core to bolts and core to clamp plates shall be such as to withstand a voltage of 2000V for one minute.

4.7

Windings Windings shall be of high conductivity annealed copper conforming to IS-6160 : 1971. The conductors shall be transposed at intervals in order to minimize eddy currents and equalize the distribution of currents and temperatures along the windings. Winding shall be subjected to a shrinking and seasoning process, so that no further shrinkage occurs during service. Coils shall be supported at frequent intervals either by means of wedge type insulation spacers permanently secured

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in place or by means of synthetic resin bonded paper cylinders. These coil supports shall be so arranged to ensure proper oil circulation. To ensure permanent tightness of winding assembly, the insulation spacers shall be dried and compressed at high pressure before use. All low voltage windings for use in the circular coil concentric winding shall be wound on a preformed insulating cylinder for mechanical protection of the winding in handling and placing around the core. Varnish application on coil windings may be given only for mechanical protection and not for improvement in dielectric properties. In no case varnish or other adhesive be used which will seal the coil and prevent evacuation of air and moisture and impregnation by oil Coil clamping rings shall be of non-magnetic metal or of a suitable insulating material. Windings shall not contain sharp bends, which might damage the insulation or produce high dielectric stresses. No strip conductor wound on edge shall have width exceeding six times the thickness. Materials used in the insulation and assembly of the windings shall be Class A. The materials shall be insoluble, noncatalytic and chemically inactive in the hot transformer oil, and shall not soften or be otherwise affected under the operating conditions. All threaded connections shall be locked. Leads from the winding to the terminal board and bushings shall be rigidly supported to prevent injury from vibration. Guide tubes shall be provided where practicable. Permanent current carrying joints between sections of the windings and leads shall be welded or brazed. Clamping bolts for current carrying parts inside oil shall be made of oil resistant material, which shall not be affected by acidity in the oil. Steel bolts, if used, shall be suitably treated. All current carrying bolted connections shall be silver-plated to a minimum thickness of 5 microns. The terminals of all windings shall be brought out of the tank through bushings for external connections. Measures shall be taken to distribute the lightning and switching surges uniformly along the winding. VENDOR shall bring out in his tender the design features incorporated to achieve the same.

4.8

Internal Earthing All internal metal parts of the transformer, with the exception of individual laminations and their individual clamping plates, shall be earthed at one point only. The core shall be insulated from base of the tank. The magnetic circuit shall be connected to the clamping structure at one point only. The top clamping structure shall be connected to the tank by a copper strap through a disconnecting link. The disconnecting link shall be located inside the tank beneath an inspection opening in the tank cover. The connection to the link shall be on the same side of the core as the main earth connection to the tank. The

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bottom clamping structure shall be earthed by one or both of the following methods: By connection through vertical tie-rods to the top structure By a connection to the top structure on the same side of the core as the main earth connection to the tank. When the magnetic circuit is sub-divided by oil ducts or insulated barriers above 0.25 mm thick, tinned copper strip bridging pieces shall be inserted to maintain electrical continuity between segments of core. Core clamps and core bolts if used shall be insulated from the core by class B insulation such as flexi-glass etc. 4.9 Termination

4.9.1 Primary Bushings shall be outdoor type, side mounted throat enclosed. The throat flange shall be gasketted and coupled with a weatherproof air insulated cable box c/w gasketted and bolted removable front cover and cutout in bottom with removable non-magnetic cutout cover plate (to be drilled on site). Termination box shall be large enough for termination of primary incoming feeder cables and for stress cones installation as well as for the installation of the surge arresters and shall be designed in such a way to avoid induced current effect from single conductor cables. Termination box cable entry removable plate shall be made of aluminium or stainless steel.

4.9.2 Secondary Secondary bushings shall be outdoor type, side mounted, throat enclosed. The throat flange shall be gasketted, and coupled with a weatherproof air insulated termination box suitable for termination of secondary feeder cable bus. Termination box shall be design ready to accept cable bus system. Design coordination with cable bus system Vendor will be required. Transformer neutral bushing shall be mounted on tank cover. Neutral bushing CT shall be in accordance with IEC 60044-1. CT accuracy and ratio shall be as specified in the technical data sheets.

4.10

Bus Duct Termination

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When bus-duct termination is specified in Data Sheet a flanged bushing connection shall be provided to suit the PURCHASER'S bus-duct. The winding terminations shall be brought out on outdoor type of bushings. 4.11 Bushings Bushings shall be designed and tested to comply with the applicable standards specified in Data sheet. If type test certificates are not available, these tests shall also be carried out in addition to the routine tests. Bushing rated for 400A and above shall have non-ferrous flanges and Fittings made of steel or malleable iron shall be galvanized. Whenever specified in Data Sheet, bushings shall be supplied with terminal connector clamp suitable for connecting the terminal-bushing terminal to the Purchasers specified conductor. 4.12 Bushing Current Transformers Whenever specified in Data Sheet, bushing shall be supplied with current transformers. Secondary leads, including tapping, shall be brought to a weatherproof terminal box near the bushing. Bushing C.T. nameplate shall be mounted on the tank adjacent to the terminal box.

4.13

Cable Boxes and Disconnecting Chamber When specified in Data Sheet, cable boxes shall be supplied to suit the PURCHASER'S specified cables. The cable boxes shall be complete with cable joint fittings or sealing ends as required, tinned copper lugs to suit specified cable, compound and all other accessories including compression type glands, armour earth clamps and body earth terminal. When specified in Data Sheet, disconnecting chamber shall be provided to enable the transformer to be removed without unsealing the cables or draining oil from the main tank. The disconnecting chamber shall be air insulated and complete with seal-off bushings, removable flexible connectors/links and removable covers.

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Phase to phase and phase to ground clearances within the chamber shall be such as to enable either the transformer or cable to be subjected separately to H. V. tests. Clearances shall be subject to the Purchasers approval.

4.14

Marshalling Box/ Control Cabinet Necessary compression type, brass cable glands at the marshalling box for the above mentioned cables as well as for terminating the PURCHASER'S incoming cables from remote panels. The marshalling box shall be tank mounted, outdoor, weatherproof, sheet-steel (2.5 mm thick) enclosed, with hinged door having padlocking facility and painted as per clause. All doors, covers and plates shall be fitted with neoprene gaskets. Bottom shall be at least 600 mm from floor level and Whenever optional fittings as per clause (e.g. temperature indicators with auxiliary contacts, Buchholz relay) and bushing CT are specified in Data Sheet, the VENDOR shall provide a marshalling box and Marshall to it all the contacts/terminals of electrical devices mounted on the transformer. Each transformer shall be provided with independent marshalling box. It shall be in the VENDOR'S scope to provide. The interconnection cabling between the marshalling box and the accessory devices by either PVC insulated wires in GI conduits or PVC insulated armoured cable and provided with gland plate and cable glands as required. Top surface shall be sloped. All contacts for alarm, trip and indication circuits shall each be electrically free, wired for auxiliary D.C. supply as specified and brought out to separate terminals at the terminal blocks in the marshalling-box.

Terminals shall be 650 V/1.1KV grade, rated for 10A, one piece moulded complete with insulated barriers with identification strips, except for incoming control and space heater supply. The insulation between any terminal and framework or between adjacent terminals shall withstand a test of 2 KV for one minute. The mouldings shall be mechanically robust to withstand handling while termination. Wiring shall be with stranded, copper conductors of sizes not smaller than 1.5 sq.mm for control and 2.5 mm for C.T. circuits. C.T. terminals shall be provided with shorting facility. The wiring shall follow standard rule for colour code. Earth 24 V DC 110 V DC Green Brown Grey
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3 phase Power Neutral

Red, Yellow and Blue Black

At least 10 % spare terminals shall be provided in each type of terminal blocks. There shall be a minimum clearance of 250 mm between the first row of terminal blocks and the associated cable gland plate. Also the clearance between two rows of terminal blocks shall be a minimum of 150 mm. External cable connections to the control cabinet will be carried out using 1100/650V grade, stranded conductor (aluminium or copper), HRPVC insulated, FRLS/ PVC sheathed, armoured/unarmoured. All necessary cable supporting clamps and brackets etc. required shall be in the scope of VENDOR. Control cabinet shall subject to the following routine test. a. High voltage test for one minute (2000 V) b. Megger test c. Electrical control, interlock and sequential operation test . d. Verification of wiring as per approved schemes. 5.0 OIL Transformers shall be supplied complete with transformer oil complying with latest applicable standard. The oil shall be naphthenic based, EHV grade oil, make : CASTROL and No inhibitors shall be used in the oil. Radiators, coolers & valves shall be designed to withstand full vacuum and the pressure conditions specified for the tank. They shall be so designed as to avoid pockets in which moisture may collect, to completely drain oil into the tank and to prevent formation of gas pockets when the tank is being filled. The clearance between all pipe work and live parts shall be more than the clearance for live parts to earth. The cooling system for each transformer shall be independent and complete in itself. Unless otherwise approved, tank mounted Radiators shall be of detachable type with bolted and gasketed flanged connections. The following accessories shall be provided for each radiator a) Hut-off valves with locking facility and blanking plates on transformer tank at each point of connection. b) Lifting lugs. c) Top oil filling plug, Min. 20 mm size.
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d) Air release plug at top. e) Oil drain valve at bottom, 20 mm size. f) Thermometer pocket (with captive screw cap) on inlet & outlet side of separately mounted radiators Provision for installation of fans or air blowers in future needs shall be provide for mounted on suitable structural members using anti-vibration mounts .Air blowers shall not be overhung from radiator fins. 6.0 FITTINGS AND ACCESSORIES Lifting lugs or eyes for lifting of fully assembled transformer by crane. Following fittings shall be provided: 6.1 Earthing pads: Two earthling pads of copper or other non-corrodible material shall be welded at the bottom corners of the transformer tank. These pads shall have two M10 threaded holes at a center to center distance of 37mm suitable for the earthling lugs. Terminal marking and rating plates shall be as per the specified standard. 6.2 Conservators: The conservator shall be of sufficient volume to maintain the oil seal from the minimum ambient temperature of 0 deg C up to an oil temperature of 105 deg C, with oil level varying within the minimum and maximum visible levels. The conservator shall be provided with the following accessories: a) Filling plug, sump and drain valve for conservator of proper size. c) A bolted cover at one end for cleaning. d) Two numbers of weatherproof dehydrating breathers with silica gel and oil seal to eliminate constant contact with the atmosphere, mounted at proper level. 6.3 Gas and Oil Actuated Relay (Buchholz Relay) : Pitot or reed type gas and oil relay suitable for specified seismic zones shall be provided. All gas evolved in the transformer shall collect in this relay. The relay shall be provided with a test cock suitable for a flexible pipe connection for checking its operation. A 5 mm copper pipe shall be connected from the relay test cock to a valve located about 1.25 M above ground level to facilitate
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sampling with the transformer in service. The device shall be provided with two electrically independent ungrounded contacts, one for alarm on gas accumulation and the other for tripping on sudden rise of pressure. The contacts shall be rated minimum 1.0A making and 0.2A breaking at 110V DC. These contacts shall be wired up to the marshalling box. The relay shall be provided with shut-off valves (80mm size) on the conservator side as well as the tank side. 6.4 Temperature Indicators: a) Dial Type Oil Temperature Indicators: Transformers shall be provided with a 150 mm dial type thermometer for top oil temperature indication. The thermometer shall have adjustable, electrically independent ungrounded alarm and trip contacts, maximum reading pointer and resetting device. The contacts shall be rated minimum 1.0A making, 0.5A breaking at 110V DC and 5A breaking at 240V AC. b) Winding Temperature Indicator: Temperature sensing element i) 150 mm dia. local indicating instrument with four adjustable electrically independent ungrounded contacts, two for control of cooling equipment and two for winding temperature alarm and trip. The contacts used for control of cooling equipment shall have required rating. However, minimum rating of all contacts shall be 1.0A making and 0.2A breaking at 110V DC. ii) A pointer to register the highest temperature reached and capable of being reset without tools. Iii) Calibration device iv) Automatic ambient temperature compensation. v) Flush mounting type remote winding temperature indicators, one for each transformer for mounting on the PURCHASER'S panel, suitable for 4-20 mA signal. Suitable 110V DC rated transducer for generating 4-20 mA signal shall also be supplied and mounted in the marshalling box on the transformer tank. vi) The remote WTI shall be designed for operation with 24V DC power supply. vii) All trip and alarm contacts meant for use shall be wired and the contacts
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viii) All transducers shall have adequate load capability to feed SCADA. c) Pressure Relief Devices A pressure relief vent (explosion vent) mounted on the tank shall be provided for relieving pressure within the transformer. 6.5 Neutral bushing terminal complete with connector for earth conductor specified in Data Sheet. Drain cum sampling valve with plug or cover plate. Dehydrating breather (for transformers 25 KVA and above for rated voltage 11 KV and below and all ratings above 11 KV). Oil level Indicator with minimum marking. Thermometer pocket. Oil filling hole with cap (for transformers without conservator) Jacking Lugs (Transformers weighing above 3000 Kg) Filter Valve (for all transformers above 1000 KVA) Explosion vent with diaphragm/pressure relief valve (for transformers 50 KVA and above). The device shall be rain-proof after operation. For transformers 500 KVA and above an equaliser pipe connecting the pressure relief device to the conservator shall be supplied. The under base provided with channels for fixing on a platform or plinth.

6.6 6.7

6.8 6.9 6.10 6.11 6.12 6.13

6.14

7.0

OPTIONAL FITTINGS Following to be furnished if stated in Data Sheet

7.1

Dial type thermometer with two contacts for oil temperature 'high' and 'too high' alarms. Each contact shall be electrically independent and brought out to separate terminals, rated 110 V.D.C; minimum 0.5A. Magnetic oil level gauge with low oil level alarm contact for transformers
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7.2

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fitted with conservator. Contact rating suitable for 110 V D.C., minimum 0.5A. 7.3 Gas and oil actuated (i.e. Buchholz) relay, double float type with a valve between the relay and the conservator. Gas sampling device at an accessible height and an air release cock for Buchholz relay. Winding temperature indicator, consisting of: a) Temperature sensing element. b) Image coil c) Bushing or turret mounted CT. d) Local indicating instrument with electrically independent contact brought out to separate terminals for winding temperature 'high' and 'too high' alarms. Contacts shall be suitable for 110 V D.C., rated minimum 0.5A. 7.6 Off Circuit Tap Changing Mechanism It shall comprise: a) Operating handle or wheel, accessible from ground level. b) Tap position indicator. c) Pad locking arrangement. d) The tap-changer connections and contacts shall be accessible through an excess hole having a bolted gasketted cover. 7.7 Valves a) One (1) top filter valve with blanking plate. b) One (1) bottom filter valve with blanking plate 7.8 Four plain rollers in place of fixing channels.

7.4

7.5

8.0

TESTS The first three tests listed below shall be carried out and shall be deemed

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to be included in the scope. There shall be extra unit prices for carrying out the tests against Clause 8.4 to 8.6 as listed below:

8.1 8.2 8.3 8.4 8.5 8.6 9.0 9.1 9.2

Routine tests as per applicable standards. 2KV withstand test for all wiring. Zero phase sequence impedance test. Impulse test on any one phase of the HV winding of any one transformer. Temperature rise test. Short Circuit test. LOSSES Vendor shall guarantee the losses for each transformer: For the purpose of evaluation of bids, the quoted load losses and iron losses shall be increased to take into consideration tolerance as permitted by applicable standard.

9.3

Should the losses as measured on the transformer after manufacture be found in excess of the values of the guaranteed losses with plus tolerance indicated in the proposal, VENDOR shall pay penalty to the PURCHASER based on the charges indicated in Data Sheet.

10.0

REJECTION PURCHASER may reject any transformer if during tests or service any of the following conditions arise:

10.1 10.2 10.3 10.4

No load loss exceeds the guaranteed value by 20% or more. Load loss exceeds the guaranteed value by 20% or more. Impedance value differs the guaranteed value by + 10% or more. Oil or winding temperature rise exceeds the specified value by 5C
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10.5 10.6 10.7

Transformer fails on impulse test. Transformer fails on power frequency voltage withstand test. Transformer is proved to have been manufactured not in accordance with the agreed specification. The PURCHASER reserves the right to retain the rejected transformer and take it into service until the VENDOR replaces, at no extra cost to PURCHASER, the defective transformer by a new acceptable transformer. Alternatively the VENDOR shall repair or replace the transformer within a reasonable period to the Purchasers satisfaction at no extra cost to the PURCHASER. SPARES The VENDOR shall quote item wise prices for the spares recommended for trouble free operation as specified in Data Sheet.

10.8

10.9

11.0

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