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INSTITUTE FOR PLASMA RESEARCH
Technical Specifications
Design/engineering, manufacture,
inspection, testing at vendor’s
site, delivery at site of resin cast
dry type Cast Resin Transformer
2500kVA, 11kV/433V, 50 Hz with
required spares and accessories.
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I - PROJECT INFORMATION & AUXILIARY FACILITIES
1. Purchaser Institute for Plasma Research
Village Bhat, Gandhinagar Dt.
PIN-382 428
Gujarat, INDIA
Phone: +91-79-23962000
Fax: +91-79-23969017
Web: www.ipr.res.in
2. Site elevation (average) 55 meters above MSL
3. Ambient temperature Max. (annual): 47 C
Min. (annual): 4C
Average (annual): 35 C
4. Relative humidity Max.: 90 %
Min.: 17 %
5. Rainfall 823 mm average (annual) June-August
6. Wind data Max. wind speed: 130 kmph
Prevailing direction: SW to W
Design wind pressure: 100 kgm-2
7. Seismic data 0.04 g as per IS:1893-1973
8. Accessibility By Upto site (on Hansol-Gandhinagar H-
road: way)
By rail : Ahmedabad Rly. Stn. (12 km.)
By sea : Bombay Harbor (525 km.)
By air : Ahmedabad Airport (6 km.)
9. Auxiliary power supply a) AC 415 10 % V, 3 phase, 50 5 %
(each of the voltages can be Hz, 4 wire system
made available at one point of b) DC 220 20 % V, 2 wire, floating
connection to the sources)
10. Expected completion period Delivery: Within 3 months from the
date of approval of drawings
Installation & Commissioning: Within
2 months from the date of site clearance
from IPR.
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II - TECHNICAL PARTICULARS
SCOPE:
This specification covers the design/engineering, manufacture, inspection and
testing at vendor's works and delivery at site and supervision during erection,
pre-commissioning and commissioning tests of one no. of resin cast dry type
Cast Resin Transformer 2500 kVA, 11 kV/433V, 50 Hz with required spared and
accessories, as per the technical specification.
CODES - STANDARDS:
a) The design, manufacture and performance of equipment shall comply with all
currently applicable statutes, regulations and safety codes.
b) Except where modified by this specification, wherever applicable all material
and equipment shall conform to the requirements of latest Indian Electricity
Rule (IER) and below given standards including all amendments.
S.No. Description Standard
1. Dry type transformer IS 11171 and IS 2026
2. Current transformer (PS class) IS 2705
3. Degrees of Ingress Protection for control gear IS 12063
4. Bushing for Alternating voltage above 1000 V IS 2099
5. Thermal Evaluation and Classification of IS 1271
Electrical Insulation
6. Fittings and Accessories IS 3639
7. Measurement of transformer and reactor IEC 60076-10 or NEMA
sound levels TR -1
GENERAL CONSTRUCTIONAL FEATURES:
The dry type cast resin transformers shall be AN (Air Natural) cooled and shall
be provided for indoor applications.
The mechanical and electrical design of the transformers shall be based on the
following conditions and requirements:
a) The design shall be based on site and service conditions as specified.
b) The maximum permissible temperature rise of the transformer windings is to
be selected by the transformer manufacturer in accordance with the thermal
classes of the insulation.
c) The transformers shall be capable of operating continuously at full load at
any tap position within their temperature rise limit.
d) Neutral points shall be brought out and grounded.
e) Doors shall be suitable to be opened from outside.
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f) All the materials used shall be of the best quality and of the class most
suitable for working under the conditions specified and shall withstand the
variations of temperature and atmospheric conditions without distortion or
deterioration or the setting-up of undue stresses in any part and also
without affecting the strength and suitability of the various parts for the
work which they have to perform.
g) Similar parts, particularly removable ones, shall be interchangeable.
h) Nuts, Bolts and pins used inside the transformer and tap changer shall be
provided with lock washers or lock nuts.
i) Labels shall be provided for all identifiable accessories like relays, valves, CT,
thermometer pockets, switches etc.
j) All internal connections and fastenings shall be capable of operating under
overloads and over excitations allowed as per specified standards, without
injury.
k) The transformers must be of suitable size so as to be installed in a room of
dimensions 6 m x 6 m x 4 m. Care shall be taken to provide appropriate
clearances on all sides as per the latest standards and practices.
ELECTRICAL AND PERFORMANCE REQUIREMENTS:
a) The transformer shall operate without injurious heating at the rated kVA at
any voltage within 10% of the rated voltage of that particular tap.
b) The transformer shall be capable of overloading as per IS. The continuous
and short time over loading capacities shall be furnished in detail. Over loads
shall be allowed within the condition defined in the applicable standard.
Terminal, taps or any other auxiliary equipment shall not limit such over
loading.
c) The manufacturer should guarantee that no deterioration to insulation system
or life results on account of such an overloading pattern.
d) The neutral terminal of windings with star connection shall be designed for
the highest over-current that can flow through this winding.
e) The bidder shall ensure that the design and manufacturing of the transformer
shall be such as to reduce noise and vibration level. The sound level of the
transformer with its enclosure in position shall not exceed the value in
accordance with NEMA TR-1 standard.
f) The transformer HV winding shall be suitable for vacuum circuit breakers
switching.
g) All other performance requirement as per the relevant standards and codes
shall be met with condition specified above.
CORE:
a) Transformer design shall be core type. The core shall be constructed from
high grade cold rolled non ageing grain oriented (CRGO) silicon steel
laminations. The core shall be painted and insulated with suitable resin to
protect it against corrosion. The lamination shall be free from burrs and sharp
projections.
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b) The yoke laminations shall be interleaved and carefully assembled to avoid
air-gaps in the magnetic circuit. The core shall be earthed as per the relevant
standards.
c) The insulation structure in between core to bolts and core to clamp plates
shall withstand a minimum voltage of 2500 V, for one minute.
d) All steel sections used for supporting the core shall be free from burrs.
e) 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.
f) The finally assembled core with all the clamping structures should be free
from deformation and shall not vibrate during operation.
g) The core clamping structure shall be designed to minimize eddy current losses
and bolts passing through core laminations shall not be used for any purpose.
Epoxy coated fibre-glass tapes shall be used for clamping core laminations.
INTERNAL EARTHING:
a) Internal earthling of all metal parts of transformer with the exception of the
individual core laminations, core bolts associated individual clamping plates
shall be earthed.
b) Single point earthing shall be used for the magnetic circuit.
c) Flexible earthling braid shall be provided between all metal parts, joined
with gaskets.
d) 2 Nos. separate Earthing pad/terminal shall be provided on the cable box for
armour earthing from inside and other Earthing grid connection from
outside.
e) Earthing strip from Earthing Bushing up to earthing terminal shall be
provided.
f) Doors shall be earthed by suitable PVC insulated multi-stranded copper wire
of suitable size
WINDINGS:
a) The Cu-ETP-grade copper conductor shall be used for transformer HV and
LV windings and their insulation shall be such as to ensure uniform
distribution of the voltage surges among all the coils of the windings.
b) The windings shall be provided with Class-F epoxy resin cast insulation. The
insulation shall have high tensile and dielectric strength. Enough measures
shall be taken during casting to avoid the void formation, cracking and
crazing etc. of the cast coils.
c) Both HV and LV windings of each phase shall be separately cast on rigid
tubular coil co-axially arranged under vacuum in to molds. The epoxy resin
insulation system shall be fiber glass strengthened. LV winding should be
prepeg insulation materials and should be cured under require temperature.
d) The resin used for winding insulation shall be non-hygroscopic to prevent
the penetration of moisture into windings. It should be possible to energize
the transformer without pre-drying even after a long period of service
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interruption. The resin used shall be non-inflammable, self-extinguishing,
void free and suitable for tropical climate with 100% relative humidity. In the
case of windings provided with taps, the inter-turn insulation of tapped
windings shall be reinforced to obtain uniform stress distribution. No filler
materials are allowed to use in Resin Mixture.
e) The transformer shall be able to withstand short circuits as well as switching
and lightning/atmospheric impulse voltages as specified in the IS 11171
standard. The leads and connections shall be mechanically strong and
adequately brazed to withstand short circuit forces and transportation
shocks.
CORE AND COIL ASSEMBLY:
The cast coils are inserted on to the core limbs. The resin cast spacer blocks, end
blocks and separators shall be used as required. The coils should be placed on the
anti- vibration insulation materials.
TAPPING:
Off circuit tap changing link shall be provided with total tapping range of +5% to -
5% in steps of 2.5%. The tapings shall be on high voltage side. The transformer
shall be capable of delivering its rated output at any tap position without damage.
TERMINAL BOX ARRANGEMENT:
a) The HV side termination facility of the transformers shall be designed
for connecting 11 kV XLPE insulated armoured cable terminated in
crimping type lugs and heat shrinkable sleeves or pre-molded cast
resin push on type terminations. Suitable undrilled gland plate shall be
provided for terminating HV cables. HV terminals shall be extended up
to the cable terminals and the bus bars shall be located at a convenient
height. The cable entry shall be from the bottom. Preferably the bus-
bars shall be supported by the supporting insulators from the top fram
of the enclosure. The winding delta formation on HV side shall he in
supplier’s scope.
b) The LV side terminals and the LV termination box of transformers shall
be suitable for cable connection of approx. 3 runs of 1000 sqmm, single
core per phase and 2 runs for neutral (Total cables are 11 runs of 1000
sqmm, single core) . The earthing stud shall be provided on LV
termination box for clamping earthing conductor. The winding star
formation on LV side shall be in supplier’s scope.
c) The LV neutral terminal of the star connected winding shall be brought
out at two separate insulated terminals. One neutral terminal shall be
provided by side of the phase terminals for connecting neutral to
neutral bus-bar in the LV termination box. Second neutral terminal
shall be provided to facilitate the earth conductor down to the ground
level. The terminal shall be suitable for connecting two numbers of
earth conductors (75mm x 10mm GI) for neutral earth connection with
two separate earthing pads.
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SUPPORT INSULATORS:
a) Support insulators shall be designed and tested to comply with the
applicable standards.
b) HV terminals rated for minimum current 400 A shall have non-ferrous
and non-magnetic flanges and hardware.
c) Air clearance and creepage distances shall be maintained as per the
relevant standard.
d) Preferably the material for support insulators shall be Porcelain or epoxy
resin cast.
CURRENT TRANSFORMER (CT):
a) The REF (Restricted Earth Fault) CT shall be epoxy resin casted under
vacuum and having ratio of 3200/1A, class PS, 10 VA. The CT shall have
minimum Vknee 400V, maximum 30 mA Imag at Vknee/2 and Rct less than 7
Ohm. This CT shall be provided in the common portion of the LV neutral
(Before branching to LV neutral to earth connection). Class of insulation
system of the CT shall be class F.
b) CT secondary leads shall be brought to the marshalling box.
c) CT details shall be indicated on name plate of the transformer.
TEMPERATURE SENSOR AND WINDING TEMPERATURE INDICATORS (WTI):
a) Temperature sensors: Two (2) numbers, reputed make simplex type
(Platinum) PT 100 shall be provided in each phase at suitable place for
measuring hot spot temperature.
b) A multi-channel digital winding temperature indicator shall be provided
to display the temperature of the windings.
c) The indicating instrument shall be provided with four adjustable
electrically independent ungrounded contacts brought out to separate
terminals for winding temperature alarm and trip. One indicating
instrument shall be provided for each phase. Contacts shall be suitable
for 220V DC rated minimum 0.5A. Instrument shall be suitable for 220V
D.C auxiliary power supply if required.
MARSHALLING BOX:
a) The weather proof marshalling box shall be mounted on the transformer
housing. All doors, covers and plates shall be provided with neoprene
gaskets. Bottom of the marshalling box shall be at least 600 mm above
floor level and provided with removable bolted and undrilled gland plate
etc. The required number of knock-out punches shall be provided for
outgoing control cables.
b) All contacts for alarm, trip and indication circuits shall be electrically
potential free, wired for auxiliary supply as specified and brought out to
separate terminals at terminal blocks in the marshalling box. If required,
separate MCBs shall be provided for protection isolation and distribution
of AC and DC control supplies in the marshalling box. Wiring shall be
with PTFE insulating (Insulation for wire & cable shall be in consistence
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with the ambient temperature in the housing). The wiring conductor shall
be stranded copper and of sizes not less than 4 sq. mm for CT circuit and
2.5 sq. mm for other control circuits. CT terminals shall be provided with
standard shorting facility. The wires shall be drawn through neatly
clamped conduits. Engraved identification ferrules, marked as per the
approved wiring diagrams shall be provided on each wire. Ferrules shall
be of yellow colour with black lettering. Preferable the terminals shall be
stud type and provided with crimping type cable sockets.
ENCLOSURE FOR TRANSFORMER:
a) The core and coil assembly shall have CRCA sheet steel MS enclosure. The
purpose of having the enclosure is to provide safety from live parts, protect
and make the equipment suitable for outdoor conditions, prevent ingress of
foreign matters, vermin and rodents etc. the minimum number of louvers
shall be provided on the sides of enclosure and the louvers should be
covered with SS or galvanized sheet fine (openings not more than 2.5mm)
mesh. The enclosure should have structural steel framework with lockable
hinged door on HV and LV termination sides of the transformer. The
gasketted doors shall facilitate the inspection of the transformer.
b) The enclosure frame shall be fabricated using suitable CRCA pressed and
shaped sheet steel of thickness not less than 2.0 mm.
c) All panel edges and door edges shall be reinforced against
distortion/deformation by rolling, bending and addition of welded
reinforcement members.
d) The complete structure shall be rigid, self-supporting and shall be suitable
for connecting ventilation hood on the top. To remove heat from the
transformer, its metallic enclosure shall have sufficient heat dissipation
capability in outdoor conditions, throughout the year without any additional
cooling arrangement. GI or SS wire mesh shall be provided in the gap in
between enclosure and ventilation hood to prevent entry of birds etc.
Powder/enamel paint coated 3mm thick perforated MS mesh shall be
provided for enclosing the bottom side.
e) The enclosure shall not have degree of ingress protection less than IP 23.
f) Door switch with 2 NO + 2 NC auxiliary contacts of required rating shall be
provided. It will be used for providing interlock in the HV breaker circuit.
g) Painting: After thorough metal treatment enclosure surface shall be given
two coats of enamel/powder paint. Double coat of corrosion resistant primer
shall be applied before painting. The inside of the enclosure shall have semi-
glossy paint finish. All metal parts not accessible for painting shall be made
of corrosion resistant material. All paints shall be carefully selected to
withstand heat and tropical weather conditions. The color of painting shall
be Light Grey Shade 633 of IS-5.
FITTINGS AND ACCESSORIES:
Following fittings and accessories shall be provided:
a) HV/LV terminals suitable for the purchaser’s external conductors.
b) Rating, terminal marking and danger plates.
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c) Three earth terminals per transformer, each suitable for earth conductors of
size 2 nos. 75 x 10 mm GI strip for earthing of the body of the transformers
and its enclosure.
d) Lifting lugs for
- Complete transformer (with enclosure)
- Core-coil assembly
e) The under base shall be provided with channels etc.
f) Four bi-directional rollers in base frame for movement of complete
transformer assembly. The stopper arrangement to lock the transformer in
the required position shall also be provided.
g) Enclosure with provision for dismantling.
h) Marshalling box
i) Neutral earth terminal with lugs.
j) Six number PT 100 RTDs with WTI display
k) Off circuit tap links.
INSTALLATION SUPERVISION:
The bidder shall depute a qualified engineer for supervision of installation,
witnessing pre-commissioning and commissioning tests. The equipment shall be
commissioned in the presence of the bidder’s qualified engineer.
The bidder shall ensure that his personnel are present at site and supervise when
the following activities are being carried out:
a) Unloading of the distribution transformers at IPR, Gandhinagar site.
b) Erection and installation of transformer and its accessories. Wiring of
instruments up to marshaling panel.
c) Grounding of neutral, tank, Bus duct, etc. including supply of all
hardware and connectors.
d) IR testing of transformer for HV-LV, HV-E & LV-E.
e) Tap changer operation.
f) Checking of all the protection systems.
g) Pre-commissioning and commissioning tests on transformer.
h) Transformer load test with customer loads (if made available on
commissioning date).
ACCEPTANCE:
The acceptance of the transformer shall be given only after the transformer has
been successfully installed and commissioned.
LIST OF SPARES:
Sr.
No. Description Quantity
1 Winding temperature indicator (WTI) 1 No.
2 LV Bushing 1 set
3 HV Bushing 1 set
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III - TESTING/INSPECTION
Purchaser and their authorized representatives shall have access to the
manufacturer or sub-manufacturer works for the purpose of witnessing, tests and
ascertaining that the transformer being supplied conform to the requirements of
the specification. The stage-wise inspection shall be performed during fabrication
stage. The bidder shall provide the detailed activity schedule for stage inspection.
The bidder shall inform the purchaser at least 15 days advance the testing due
date and ask for their representative’s availability. The detailed test schedule shall
also be submitted after the placement of the order.
The transformers shall be demonstrated as capable of performing
satisfactorily the suppliers guarantee. All tests required by the specification
including repeated tests and inspection that may be necessary owing to the
failure to meet any tests specified, shall be carried out.
If the transformer fails to pass the tests specified, the Engineer shall have
the option to reject the unit. Additional tests shall be made to locate the
failure and after rectification, all tests shall be repeated to prove that the
rebuilt transformer meets the specification in all respects.
a) Routine Tests:
a) Measurement of voltage ratio at all tap positions and Check of voltage vector
relationship
b) Measurement of winding resistance.
c) Measurement of impedance voltage (principal tap), short circuit impedance
and load loss at rated current.
d) Measurement of no-load losses and current.
e) Induced over voltage withstand test.
f) Separate source voltage withstand test
The entire test as per standard IS-11171 shall be conducted, on completed
transformer assembly. The acceptable values shall be in accordance with the
relevant standard.
b) Type Tests
The test reports for the type tests (Lightning impulse and Temperature rise) as per
IS 11171 shall be submitted along with the offer. Test reports shall be from a
NABL/CPRI/ERDA/Govt. approved laboratory. These reports shall be of a
transformer of similar rating and same voltage class and shall be conducted in the
past 5 financial years. (2012-13, 2013-14,2014-15,2015-16,2016-17). If such
reports are not available with the bidder he shall get the transformer tested in an
NABL accredited laboratory at his own cost.
c) Tolerances:
Allowable tolerance for other parameters except losses shall be as per the IS 2026
Part-I. The losses in the guaranteed Technical particulars (GTP) submitted by the
supplier shall be the reference for percentage loss and bid evaluation.
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d) Acceptance Criteria after the testing:
Successful testing as per the clause mentioned above
IV- DOCUMENTATION
The bidder shall submit the documents at different stages as given below.
1. With Bid (Technical/Part-1)
a) Detailed catalogue/datasheet and literature indicating technical
specifications.
b) The documents mentioned in the eligibility criteria.
c) Duly Filled GTP as per the format given in this specification
2. After placement of purchase Order:
The following documents shall be submitted for IPR approval within 3 weeks of
placement of order, before taking up fabrication.
a) Detailed activity schedule for stage inspection of the manufacturer
b) Detailed transformer drawings along with LV and HV termination box
dimensions.
c) Earth terminals, marshalling panel details and bill of material etc.
d) Graph of core loss in watt/kg versus flux density (wb/sq.m) for the
transformer core material.
e) Continuous and short time over loading details.
3. On Completion:
Five (5) sets of bound manuals of final detailed drawings, control drawings
(marshaling panel), test reports, technical catalogues, installation instructions,
O&M instructions, guarantee certificate and compliance report etc. along with their
soft copy.
V- DELIVERY PERIOD:
The bidder shall quote for minimum deliver period. In this regard, a detailed
activity bar chart shall be submitted by bidder for manufacturing, testing at works,
transportation and delivery at IPR.
Fabrication/manufacturing shall be started only after final approval of the
submitted documents by IPR.
Expected supply of the transformer shall be 3 months from the date of approval of
drawings.
Installation and Commissioning shall be completed within 2 months from the date
of site clearance from IPR.
VI - GUARANTEE PERIOD:
The Transformers shall be guaranteed for a period of 2 (Two) years from the date
of acceptance at IPR.
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V - Technical Specifications for Transformers
Technical Particulars
1 Application For distribution to Assorted loads
2 Quantity 1
3 No. of windings Two winding
4 Rating (continuous) 2500 kVA
5 Frequency 50 Hz +/- 3%
6 No. of Phases 3 (three)
Rated Voltage
(i) HV 11000 V with +/- 10 % tolerances
7 (ii) LV 433 Volts
Winding connections
(i) HV Delta
8 (ii) LV Star
9 Vector Group Dyn11
10 Direction of Power Flow HV to LV
11 Primary Connection Delta
12 Secondary Connection Yn11 (Star)
13 Service Indoor
14 Other service conditions As per IS 11171/2026
15 Class of insutaltion minimum class - F
Allowable Max. temp. rise of
16 windings 90 ⁰C
17 Tapping +5% to - 5% in step of 2.5%
%Impedance voltage at
18 principal tap 6.25%
19 Type of cooling AN
Terminal arrangement
(i) HV HV Termination will be cable box
20 (ii) LV LV Termination will be cable box.
21 Sound level in transformer As per NEMA TR-1
System voltage
(i) HV side
(a) Nominal system voltage 11kV
(b) Highest system voltage 12kV
(ii) LV side
(a) Nominal system voltage 433V
22 (b) Highest system voltage 500V
23 System earthing Solidly grounded
24 System fault level 25 kA for 1s at 11 kV
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Technical Particulars
Insulation withstand voltages
a) Impulse 75 KV (peak)
b) Power frequency HV 28KV(rms)
25 c) Power frequency LV 3 KV (rms)
Tappings
a) Tapping on winding HV
b) Tap changer type Off-circuit
c) Tapping range - 5 % to + 5 %
26 d) Tapping Step 2.5% each
27 Short time rating: as per IS
Transformer Losses (at 75 deg As per ECBC 2009 standards
28. C) Maximum : 4.1kW (NL) 20.6kW (LL)
Various electrical clearances like phase to
earth and phase to phase clearances on
the transformer, inside cable terminating
Clearances
boxes, disconnecting chambers, etc. shall
be in accordance with applicable
standards and Indian Electricity Rules.
29.
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ANNEX-1
GUARANTEED TECHNICAL SPECIFICATION SHEET
The bidder shall submit the filled GTP along with the technical bid
Sr. No. Description Detail/parameter
1 Name of manufacturer
2 Model & Type
3 Service (Indoor/Outdoor)
4 Rated KVA
5 Cooling
6 Standard followed by the manufacturer
7 Rated no load voltage
a) HV
b) LV
8 Frequency
9 Rated current
a) HV
b) LV
Tapping: +5% to -5% in steps of 2.5% on
10 HV side, through off circuit tap links. (yes/No)
11 Vector Group reference
12 Terminal arrangement,HV/LV
14 Performance
a) No load loss,Kw
b) Load loss,Kw
c) Impedance,% MIN
15 % Efficiency at 75degC/Unity P.F.
a) At 100% load
16 % Efficiency at 75degC/0.8 P.F.
a) At 100% load
17 % Regulation at full load
a) Unity P.F.
b) At 0.8 P.F.
18 Short Circuit Withstand Capacity
19 Approximate L*B*H,mm
20 Approximate weights, kg
a) Total weight,kg
b) Core Coil weight, Kg
21 Enclosure protection class
22 Insulation class
23 Insulation Level kVp/kV rms
HV
LV
Transformer acoustic level (measured as
per standards IEC 60076-10 or NEMA TR-
24 1)
25 Guarantee period (Two years)
26 Accessories