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ELECTRICAL ENGINERING TECHNICAL SPECIFICATION POWER TRANSFORMERS

UTTAR PRADESH JAL NIGAM

Name Date

Name Date Chckd By

Name Date Appd By Type of Revision

REV

Prepd / Revsd By

PCS International

GANGA POLLUTION CONTROL UNIT , UPJN 42 MLD SPS & 42 MLD STP , KARANKHERA, KANPUR

Specn. No.

KNP-102/PCS/E-01

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Specification No. KNP-102/PCS/E-01

GENERAL SPECIFICATIONS FOR POWER TRANSFORMERS


1.1 SCOPE The scope comprises of design , engineering , supply in well packed condition of 1) 33 /0.433 kV , Oil Cooled ( ONAN ) , two winding , Power Distribution Transformers of kVA ratings and quantities as indicated below , duly filled with new and tested oil before dispatch and complete with all fittings and accessories as specified : Item 1 : 500 kVA , Qty - 1 No. Item 2 : 1500 kVA , Qty - 1 No. Item 3 : 3000 kVA , Qty 1 No. 2) 10 % of total quantity of oil in non-returnable container which can be stored in open 3) Spare parts for two years trouble free operation with item wise unit prices required for Uttar Pradesh Jal Nigams Sewage Pumping Stations and Sewage Treatment Plants of Ganga Pollution Control Unit in Karankhera , Kanpur , UP.

1.2 GENERAL

All equipment shall be in accordance with its specifications unless otherwise stated specifically. In case of any discrepancy arising, the most stringent condition will be followed. The following site conditions shall be taken into consideration in the design of the equipment:Maximum air temperature Minimum air temperature Maximum daily average temperature Minimum daily average air temperature Maximum relative air humidity Average relative air humidity 48 degree centigrade 4 degree centigrade 32.4 degree centigrade 19.8 degree centigrade 95% 64%

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Maximum wind speed (Approx.)

Specification No. KNP-102/PCS/E-01 150 Km./hr.

1.3

STANDARDS: The equipment to be furnished under this specification shall, unless otherwise stated, be designed, constructed and tested in accordance with the latest revision of relevant standard specification IS:2026 , British Standard (BS) , International Electro-Technical Commission (IEC) publications, ASA & NEMA Standards and India Electricity Rules. The equipment conforming to any other National Standards which ensure equivalent quality will be acceptable. In such cases, the bidder shall clearly indicate the standard adopted and furnish a copy of the English translation of the standard along with the Bid. Should there be any dispute on design standard, the most stringent one shall be applicable.

1.4

COMPLETENESS OF SUPPLY: A) All the enclosures and the drawings, issued along with this specification become a part of the specification. The bidders shall consider them in details for instructions pertaining to the work and shall be responsible for and governed by all the requirement indicated therein. B) The equipment governed by this specification shall be complete in all respects. Any material or accessories which may not have been specifically mentioned but which is usual and/or necessary for satisfactory and trouble free operation and maintenance of the equipment shall be provided free of cost. C) The successful bidder shall supply all equipment and accessories listed in this specification. Any modification or alteration if required, shall be as agreed upon in writing after mutual consultation between the owner / purchaser and the successful bidder.

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1.5

Specification No. KNP-102/PCS/E-01 REQUIREMENT AND SERVICES TO BE FURNISHED UNDER THE SCOPE OF WORK OF THIS SPECIFICATION:

1.5.1 The transformers shall be complete with all accessories and auxiliary equipment in accordance with this specification and listed in the following Annexure: i) ii) Annexure-A Desired technical particulars of equipment to be furnished. Annexure-B Accessories to be furnished with Transformer

1.5.2 First filling of the oil and an excess quantity of 10% the total oil in non-returnable container. 1.5.3 Special tools & tackles for erection and maintenance of the transformer & other requirement. 1.5.4 All relevant final drawings, data and Instruction Manual for operation & maintenance of the transformers and other equipment in sextuplicate. 1.6 DESIGN CRITERIA:

1.6.1 The estimated fault level of different system with which the transformers will be connected are given in the enclosed Annexure A. 1.6.2 The transformer shall be suitable for outdoor service in hot humid and tropical climate and will be installed outdoor. All equipment, accessories and wiring shall therefore be provided with tropical finish to prevent fungus growth. The design shall be made to suit the site condition stated in clause 1.2 of this technical specification. 1.6.3 Type of Cooling: The transformer shall be oil immersed and designed for cooling as specified in the Annexure-A annexed with this specification. 1.6.4 Temperature Rise: The transformers shall be capable of continuous operation at its rated output without exceeding the limit of temperature rise as follows:a) b) Top off by Thermometer: Winding by resistance: 90OC minus Ambient Temp. 0C 105O minus Ambient Temp. 0C

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Specification No. KNP-102/PCS/E-01 The de-rating of the transformer shall be done by taking 45 degree centigrade as an ambient temperature or the actual maximum ambient temperature of the site stated in clause 1.2 of the Technical specification whichever is higher if it is designed at a lower ambient temperature.

1.6.5 Voltage & Fluctuation withstanding capacity: The transformers shall be appreciably free from noise and vibration and shall be capable of continuous operation at the rated output under the following conditions:a. The voltage varying by + 10% of rated voltage. b. Frequency varying by + 3% of the nominal value of 50 Hz. c. The transformer shall be able to withstand for 5 seconds without damage a short circuit between phases and between phases to ground at one side maintaining rated voltage on the other side. The under frequency condition will not occur simultaneously with the over voltage condition. 1.6.6 The transformer shall be designed and constructed so as not to cause any undesirable interference in radio and communication circuits. 1.7 SPECIFIC DESIGN REQUIREMENT:

1.7.1 Tanks: a)

Tanks shall be of welded construction and fabricated from good commercial grade low carbon steel of adequate thickness. All beams shall be properly welded to withstand requisite impact without distortion. All welding joints shall preferably be stress relieved.

b)

The tank wall shall be reinforced by stiffener for rigidity so that it can withstand without any deformation. i) ii) Mechanical shock during transportation and In full vacuum during filling of oil.

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c)

Specification No. KNP-102/PCS/E-01 The tank cover shall be bolted on to the tank with weather proof, hot oil resistant, resilient gasket in between for complete oil tightness. If gasket is compressible, metallic stops shall be provided to prevent over compression, Bushings, currents, cover of access holes and other devices shall be designed to prevent any leakage of water into or oil from the tank.

d)

Each transformer tank shall be provided with one set of bidirectional roller for rolling the transformer parallel to either centre line of the transformer.

e)

Jacking pads, lifting eyes and pulling lugs shall be provided to facilitate movement of the transformer. All heavy removable parts shall be provided with eye bolt for ease of handling.

f)

Manholes/handholds of sufficient size shall be provided for access of leads, windings, bottom terminals of bushing and taps if provided.

g)

Oil sampling trap with valves shall be provided to collect samples of oil for testing from different levels of the tank.

h)

To facilitate the oil filtration by stream line filter, suitable inlet and outlet taps with valves at the bottom and at the top of the tank on diagonally opposite corners shall be provided. The valve at the bottom may be used as drain valve.

i)

Thermometer- Pocket for noting top oil temperature by liquid thermometer shall be provided.

j)

The transformer tank shall be fitted with a diaphragm type of explosion relief vent at the top.

1.7.2 Core & Coils a) The transformer may be of core type. The core shall be built up with high grade, non-ageing, low loss, high permeability silicon steel laminations especially suitable for core material.

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b)

Specification No. KNP-102/PCS/E-01 The coils shall be manufactured from electrolytic grade copper conductor and shall be fully insulated.

c)

All insulating material shall be of proven design. Coils shall be so insulated that impulse and power frequency voltage stress are minimum. Insulation level of graded insulation shall conform to the relevant standard.

d)

Coil assembly shall be suitably supported between adjacent sections by insulating spacers and barriers. Bracing and other insulation used in assembly of the winding shall be arranged to ensure a free circulation of the oil and to reduce the hot spot of the winding.

e)

All leads from the windings to the terminal boards and bushing shall be rigidly supported to prevent injury from vibration or short circuit stresses. Guide tube shall be used where practicable.

f)

The core coil assembly shall be securely fixed in position so that no shifting or deformation occurs during movement of transformer or under short circuit stresses.

1.7.3 Tappings: a) Off-load taps as specified shall be provided on the high voltage, winding. If tappings ae provided on the low voltage winding, the tenderer shall clearly indicate the same stating reasons thereof. b) The transformer shall be capable of operation at the rated KVA at any tap position provided the voltage does not vary more than +/10% of the voltage corresponding to the tap. c) The winding including the tapping arrangement shall be designed to preserve the electro magnetic balance between HV and LV windings at all voltage ratios.

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Specification No. KNP-102/PCS/E-01 1.7.4 Off-Load Tap Chargers: a) The off-load tap changing shall be effected by a 3 phases hand operated tap changing switch. The operating shaft shall be brought out of the tank and provided with a hand wheel so that it can be operated at standing height from ground level. b) A visual tap position indicator for the tapping in use shall be provided at the external operating handle and provision shall be made to padlock the handle in each tap position. The arrangement shall be such that padlock cannot be inserted unless the contacts are correctly engaged. c) All contacts of the tappings shall be silver plated and held on a position under strong contact pressure so as to avoid contact pitting of any type whatsoever. 1.7.5 Insulating Liquid: a) The insulating liquid shall conform to the latest revision of IS:335 or BS:148. b) The transformers shall be dispatched with leak proof, first filling of oil, 10% excess oil shall be supplied for each transformer in nonreturnable containers suitable for outdoor storing. c) The bidder shall indicate clearly the following aspects of the designi) ii) 1.7.6 Conservator Tank a) Oil preservation shall be by means of conservator tank. The tank shall be suitably mounted on a rigid foundation. The conservator tank shall be connected with the main tank by the pipes with stop valves at both side. b) The conservator tank shall be provided with level indicator visible from the ground level oil filling plug & cap and oil drain valve. Composition and properties of the insulating liquids. Liquid preservation system adopted and method of sealing.

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c)

Specification No. KNP-102/PCS/E-01 The conservator tank shall be provided with dehydrating breather.

1.7.7 Temperature Indicator: Oil and winding temperature indicators where called for, shall be provided. The local temperature indicator where provided, shall be so mounted that the same becomes readable at a standing height from the ground level. Alarm and trip contact where called for, shall be provided for suitable termination. 1.7.8 Buchholz Relay (Gas Operated Relay) a) The Buchholz relay placed in a pipe line between conservator tank and the main tank shall be provided with drain cock , air vent and facility for testing with air injection by hand pump. b) There shall be two disconnecting valves located in the pipe line on both sides of the Buchholz relay. c) The Buchholz relay shall be provided with two floats and contacts , one for alarm and other for tripping. 1.7.9 Terminal Marking: The physical position of the terminals and their markings shall be as per latest version of IS-2026.

1.7.10 Terminal Arrangement: i) Cable Connection a) High and low voltage terminals of transformers, which have been specified to be suitable for cable termination shall be brought out through tank side wall pushing to a weather proof cable end box with self supporting disconnecting chambers. b) The cable end box shall be of plate steel construction, self supporting weather proof type having suitable bus extension, if required, rigidly mounted on porcelain insulators.

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c)

Specification No. KNP-102/PCS/E-01 The cable termination arrangement/cable end box shall be complete with pot head. Brass wiping/compression glands with beveled washer for armour clamping, cable lugs, necessary hardwares and provisions for termination and connection of insulated aluminum conductor cable specified in the drawings/specifications.

ii)

Bus Duct Connection: Terminals of transformer, which have been specified to be suitable for bus duct termination shall be brought out through side wall/top cover mounted bushings with suitable terminals and matching flange for connection to metal enclosed phase segregated (for HV) and non segregated (for 415 volts) aluminum bus duct.

iii)

A separate neutral bushing on 415 volts side shall be provided for neutral earthing to the station ground grid.

1.7.11 Transformer Cable box : All cable box shall conform to the requirements as per relevant ISS. 1.7.12 Cooling Units: The radiators of the transformer shall be designed for same pressure and vacuum conditions as these are for the main tank. 1.7.13 Wiring: All controls, alarm indications and relaying devices provided with the transformer shall be wired up to the terminal blocks housed in a suitable marshalling box and the terminal blocks shall be suitable for termination of 7/0.737 mm copper conductor cable (1100 volt grade PVC insulated, PVC sheathed armoured and overall PVC served cable conforming to IS:1554) No two wires shall be connected to one terminal. 10% spare terminals shall be provided.

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Specification No. KNP-102/PCS/E-01 1.6.14 Painting: a) All steel surfaces shall be thoroughly cleaned by sand blasting or chemical agents, as required, to produce a smooth surface free of scales, dust and grease. b) All paints shall be carefully selected to withstand tropical heat , rain , etc. The paint shall not scale off or crinkle or be removed by abrasion due to normal handling. c) All steel surface in contact with insulating oil shall be painted with head resistant insulated varnish which shall not react with and be soluble in the insulating liquid used. d) After cleaning, the external surfaces shall be given a coat of high quality red oxide or yellow chromate primer followed by filter coats. e) The transformer shall be finished with two coats of battle ship grey (colour shade no. 632 of IS:5) synthetic enamel paint. f) If it is considered necessary, the transformer may be given further coating at site by the Owner. The tenderer shall, therefore, indicate the type and quality of the paint with full specification for this purpose. All external surfaces including that of radiators shall be so arranged that no point becomes inaccessible in painting during maintenance work. 1.6.15 Auxiliary Power Supply: All indications, alarms and trip contacts provided shall be suitable for operation on nominal 24 V D.C. system. 1.6.16 Explosion Vent: These shall be suitable for rotation in any direction and shall be provided with sight gauge and equalization connection. 1.7 TESTS:

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Specification No. KNP-102/PCS/E-01 1.7.1 Routine Tests: During manufacture and on completion, all transformer shall be subjected to the routine tests as laid down in IS-2026. In addition, the following tests shall be performed on each transformer.

a) After fabrication, each tank fitted with all valves, covers etc. shall be tested for leaks at the normal head of oil 0.352 Kg/cm2 for a period of 12 hours . If any leakage occurs the test shall be conducted again after all tanks have been repaired. b) The tank shall be subjected to full vacuum for 12 hours. c) After assembly each core shall be pressure tested for one

minute at 2 KV AC between all bolts, side plates, structural steel works and the core. d) Excitation loss and current measurements shall be made at 90%, 100% and 110% of rated voltage. 1.7.2 Type tests: Following type tests shall be performed on the transformers in accordance with relevant standards. a) b) Impulse withstand test Temperature rise test.

Copies of such tests, shall be given separately by the bidder at the time of presenting the bill. 1.7.3. Test on Miscellaneous Equipment: All component parts such as oil, bushings, etc. and auxiliary equipment shall be tested in accordance with the relevant Indian Standards. 1.7.4 Witnessing of Test: The owners / purchasers representative shall witness the tests to be conducted on the transformers . The manufacturer shall note that

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a)

Specification No. KNP-102/PCS/E-01 Equipment (Panel & Transformers) shall be finally tested at site after commissioning as per ISS or BS.

b)

Transformers shall be tested on load by the owner before supply. This testing will be done at manufacturers works or at U.P. state Electricity Board approved Laboratory or authorised service centre of the concerned manufacturer.

The manufacturer / contractor shall intimate the department (when this material will be ready) at least 30 days before the expected date of this test. 1.7.5 Test Certificate: a) Test certificate of manufacturing shall be submitted in six copies as per clause 1.7.2 and 1.7.4 (a) & (b) . b) Four (4) copies of each of routine and type test certificates of the transformer shall be furnished to the Owner for prior approval before dispatch of any equipment. c) The reports shall furnish complete identification of data including serial number of the transformer. 1.8 Drawings, Data and Manuals: 1.8.1. The following drawings and details shall be furnished in triplicate along with the tender:a) The General arrangement drawing showing constitutional features and also description of cooling units and various fittings. b) c) d) Drawing of major components such as bushing etc. Foundation plant and loading. Transport/shipping dimension with net weight and weights of various parts. e) Technical leaflets oni) ii) iii) Relays meters furnished Tap change control Cooling system

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iv)

Specification No. KNP-102/PCS/E-01 General constructional details.

1.8.2 Within fifteen (15) days from the date of award of contract in the form of letter of intent, the successful bidder shall submit six (6) copies of the following drawings for approval of the Engineer. a) Dimensional outline diagram of the transformer showing general arrangement and disposition of cooler banks and various fittings. b) c) Foundation plan and loading for foundation design. Transport/shipping dimension and the dimension of space required for handling the parts for maintenance including net weight and weights of various parts. d) e) Wiring and control diagram. Detailed drawing for major components like cable boxes and their arrangement. f) Any other relevant drawings and date necessary for satisfactory operation and maintenance. g) Instruction manual of Transformer, its various fittings, gauge and other auxiliary equipment. The manual shall clearly indicate the method of installation, checkups and tests to be carried out before commissioning of the equipment. h) The complete layout of the substation along with the requirement of building shall be submitted by the tenderer within 15 days or receipt of order. This drawing shall be duly got approved by Directorate of Electrical Safety Department , U. P. It will be the sole responsibility of contractor to get the drawing approved by the Electrical Safety Department at their own cost. Before starting manufacturer of the equipment, the manufacturer shall have to take approval of these design drawing from the Engineer in writing. Any manufacturing done prior to approval of drawings shall be rectified in accordance with the approved drawings by the manufacturer

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Specification No. KNP-102/PCS/E-01 at his own cost and the equipment shall be supplied within the stipulated period. TECHNICAL REQUIREMENTS OF DISTRIBUTION TRANSFORMERS Sl. No. 1.
1. 2. 3. 4. 5.

Description 2
Service Type Rating in KVA Rated frequency (in Hz) No. of phase (i) HV side (ii) LV side (iii) Neutral site (separate outside) Rated voltage (i) HV winding ( kV ) (ii) LV winding ( volt ) Vector group Type of cooling (ONAN/ONAF) Tappings (i) Range (ii) No. of steps (iii) In steps (iv) Tapping provided on HV side Tap changer type Impedance voltage at 750 C (i) at principal tapping percentage Temperature rise above 500 C ambient (Deg.C) (i) Top of oil by thermometer (ii) Winding by resistance Terminals (i) HV side (ii) LV Side

FOR 500/1500/3000 KVA 3


Outdoor type Oil filled 500/1500/3000 50 3 3 ph. 4 wire Yes 33 433 Dynll. ONAN - 7.5% to + 7.5% 6 2.5% Yes Of circuit 4.5 40 50 ( i ) Cable box suitable for XLPE cable ( ii ) Terminal box suitable for Bus duct/LT Cable

6.

7. 8. 9.

10. 11. 12.

13.

14.

15.

Insulation level (i) Impulse (a) HV KV peak (b) LV KV peak (ii) Power frequency (a) HV .KV rms. (b) LV ..KV rms. (c) LV Neutral KV rms. Winding conductor material (i) HV (ii) LV

170

28 3 3 Copper Copper

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Specification No. KNP-102/PCS/E-01

16.

17.

18.

19.

20.

Losses (at 750 C) and principal tappings (i) No load loss at rated voltage and frequency KW. (ii) Load loss at rated current (ONAN) KW (iii) Total loss at maximum rated power Efficiency at 750 C and UPF (i) At full load (ONAN ) %age (ii) At 75% load (ONAN) %age (iii) At 50% load (ONAN) %age Approximate weights (i) Core and windings KG. (ii) Tank and fittings KG. (iii) Oil weight . KG. (iv) Total weight . KG. (v) Oil volume . Liters Dimensions (i) Height (ii) Width (iii) Length Painting (i) colour (reference of standards)

To be furnished by bidder

To be furnished by bidder

To be furnished by bidders.

To be furnished by bidders. Synthetic enamel 631 of IS:5, IS:2026 part I to part IV

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Specification No. KNP-102/PCS/E-01 ANNEXURE B TRANSFORMER ACCESSORIES The transformers furnished under this specification shall be equipped with fittings and accessories as listed below:(i) (ii) (iii) (iv) Oil conservator with filter tap, drain plug and oil level gauge. Silica gel breather with connecting pipe and oil seal Shut off valve between the conservator and main tank Explosion relief vent mounted on the tank with double diaphragm and equalizer pipe and connection to conservator air space. (v) (vi) Air release plug 150 mm. dial magnetic oil level gauge with low level alarm contacts (only for 1000 KVA transformer and above) (vii) 150 mm. dial wdg. Temperature indicator with maximum reading pointer and electrically separate set of contracts for alarm and trip ( for 1000 KVA transformer and above) (viii) (ix) (x) (xi) (xii) (xiii) (xiv) (xv) (xvi) (xvii) Thermometer pocket for oil temperature Drain valve with threaded adopter Sample valve Filter valves with threaded adopter (top and bottom() Hand hole of sufficient size for acid to the interior of tank. Two grounding terminals with tapped holes M 10 bolts and washers Cover lifting eyes Jacking pads, hauling and lifting lugs. Bidirectional roller Skids

(xviii) Clamping device with nuts and volts for clamping the transformer on foundation channel. (xix) (xx) (xxi) (xxii) Rating plate and terminal marking plates. HV, LV and neutral with terminal connectors Weatherproof marshalling box for terminal connections. A separate neutral bushing brought out side on LT side.

(xxiii) Other item as described earlier in tender documents.

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Specification No. KNP-102/PCS/E-01