~ JANUARY 2014 IEEMA-25-2014 ink to electricityPOWER TRANSFORMER STANDARDISATION MANUAL JANUARY 2014 IEEMA-25-2014 iGeMc your link to electricityPreface Power Transformerisvey vital equipment in our Transmission System, High Voltage AC andDC transmission to supply bulk power from generation source to load points is successful oni through effectively andefficienty designed Power Transformers, Converter Transformer and Reactors Its heartening to note that India has put up enough manufacturing capacity ta the order af 300000 MVA to meet ‘market demand of power transformers. Indian companies are capable of designing and supplying transformers up to 1200kV. Transformer Industry has undergone many changes and transformations in terms of design philosophy, selection of ‘materials and field applications. \While suppliers have focused on cost competitive product by optimizing designs, Utities and customers choice and demand has been reliable and defect free product. The wide fluctuating raw material cost dominates the design process. However, IT has supplemented designers to implement thelr innovative design ideas. Customer feed back and field data on transformer performance played vital role in design improvement, Concept of Asset Management has not picked up well among Utities In India, but realization has come to assess the health of power transformer through condition monitoring. ‘There is always concern and keen interest from all stakeholders to have Power Transformers, which does not fail before its expected life. It is not simple to get answer to this wish, because many aspects from pracurement to ‘commissioning are required to be carefully and rightly addressed, Role of Utlity / Customer is very important to address The need and actual application of poner transformer with proper data. Mary a times, a bulky document with multiple and superlative requirements is given. It ultimately leads to contractual dispute and delay in deliver. Inmany occasions, power transformers remain at site without erection & commissioning for long time. The storage and preservation are important. Erection and commissioning has to be done with utmost care duly following erection ‘manual of suppliers. ‘There are several interface paints with switchyard layout, which need to be accounted from day ane. In commercial front, Utlitles assign importance to transformer losses and therefore loss capitalisation exercise is done at tender evaluation stage. Whereas designers are constrained to satisfy the lass figures once bid is awarded, Utility is equally compelled to accept unit with penalty, Itis nota desirable practice. Undler the above background, Technical Committee of TRAFOTECH-2010 decided to review, discuss & finalize the standardisation process through committee. Accordingly, during closing meeting on 18th February, 2010, it was decided to commence the process of standardization as early as possible. The task was assigned to Mr S.K. Negi, MD, GETCO, as Chaitman of standardisation committee under the aegis of IEEMA. Itwas an open invitation to participate and contribute, however technical experts and designers from leading companies, Institutions and utilities would be permanent members, It was decided in first meeting that emphasis will be to standardize design & engineering specification, drawings, ‘uality plans, erection, testing and commissioning in the form of data and figures as far possible to understand quickly ‘and facilitate the process af procurement and commissioning, igemaFurther, Steering Committee on “Power Transformer Standardisation manual" was constituted as below: fc Cas Chairman: Mr. S. K. Negi, MD, Gujarat Energy Transmission Corporation td: T 1 Technical Specification & Parameters | Mr. P. Ramachandran ABB Ltd, Me. ML Jain EMCO Ltd. 2 Design and Engineering features Mr. Mi, Wayakumaran ALSTOM Ltd) Architectural features and General Mr ML Jain EMCO Lid. Arrangement Drawings MrV.K. Lakhani TaR Lid On Load Tap Changer Mr. M. M. Goswami POWERGRID Bushings Fittings and accessories 3 Contract drawings and documents Mr. ¥. M. Varkey SIEMENS Ltd. Mr P. Ramachandran ABB Lid 4 Standard Manufacturing Quality lan | Mr. M..M. Goswami POWERGRID imap) Mr. ¥.V. Joshi GETCO 5 Transportation, Erection, Testingand | Mr. S. K. Negi GEICO Commissioning Mr. ¥. V. Joshi GETCO ansformer Oil Mr. S. K.Negi GETCO 7 Design Review Mr. Mf. Vijayakumeran ALSTOM Ltd, Mr. K. Negi GETCO 8 Frequently Asked Questions FAQs) (Mr P, Ramachandran ABB Ltd, MV. K. Lakhani TRR Ltd Convener : Mr. Anil Nagrani, IEMA Nodal Officer : Mr. . V. Joshi, GETCO The basic abjectives of standardisation are: 1) Toachieve countrywide standard design for each class wise rating wise transformers 2) To reduce lead time, human efforts & errors, materials inventories resulting in to conservation of essential materials 3) To define/enhance quality, productivity & overall efficiency. It improves process capability in many areas & to address for on-going defect 4) To liminate waste & hence impraving productivity 5) To promote berter understanding & application of the principles and techniques 6) Toachieve schedule of delivery, The task was divided into variqus chapters and allocated to team of domain experts. The chapter was thoroughly debated to standardize design requirements in the simplest form of data which can be implemented universally ‘according to rating and voltage class of power transformer and leave no scope of subjectivity between supplier and ‘customer for commercial and technical parameters. In the above standardization process, idea of adding chapters on Design Review and Frequently Asked Questions (FAQs) emerged for inclusion in the manual. (twill greatly help practicing engineers to take key decisions and sharpen ‘their skills in the entire value chain of transformer business. Transmission system in India is becoming large and complex with a highest system voltage of 765 KV. We cannot afford break downs and outages of any kind. Its essential that continuous customer feed back system isin place to ‘gauge the design and manufacturing quality of each and every unit installed, in Utilities. This Standardisation Marual vill definitely help Utilities in procurement to commissioning process of power transformer, for defect free service beyond its design Ife. yesrtnk to elactekyINDEX iP _ Technical Speciation & Parameters Guaranteed Technical Particulars i Standardised Losses for Power Transformers Transformer Ratings considered in Standardisation Manual Applicable Stadards for Transtormers At begnandtnecne rns Part -Arctectl eates, ar Aaneent Dawgs ccs Par 2- Powe arto ftns ad cess fe i Genera irene or selec of 47. Star atgs of UTC staat onan changer Par 3 Sanda sng Pover Toso Gene easements for econ usings Star using er Apts . Star Regs sigs Tasos Part overated cess Lstorhngs ana aceessres Temperate nds rare opi sensos aso cst es Bx ey) Presi Rte ake Meprete Ol Gaige 0} 0 WaterRow ncars acer Consent eect Rly factors Aonat og eps AVR) Pe octon Sten Tame! onecers LZ 3) Contract drawings for Power Transiormers ListoF Contract Drawings Minimum Details required in Drawings Typical Cable Schedule Typical Circuit Diagrams a 8 4 23 28 31 50 5a 57 58 e 6 eo 68 80 85 87 a1 94 100 103 104 106 19 123 125 126 138 1a igemc euro ecreyJf Standard Manufacturing Quality Plan (MQP) ‘Raw Materials and Components Inrocess inspection Routine Tests “Transportation, Erection, Testing and Commissioning S Transportation and Unloading at Site Minimum Toots ana Plants Erection Flow Diagram Safety Measures and Precautions Precommissioning Tests Final Commissioning Checks Enorgisation of Unit and Site Closing Transfarmer il Precommissioning Checks {JEEMA Standard Specification fos Trasrformer Oh If Design Review Objectives of Design Review Elements of Design Review References for Design Review Typicat Rating Plate Diagrem 8) Frequently Asked Questions (FAQs) v TRANSFORMER Design and Engineering Manufacturing & Oval Eetion, Commissioning and Service ssues oure Design and Engineering rection and Commissioning ausHING Design anal Engineering Erection and Commissioning Yourtineto lacey NN 163 166 175 173 183 185 192 193 197 198 252 253 255 257 258 261 263 264 267 268 am 24 a8 278 204 285 286 286Chapter - 1 Technical Specification & Parameters Working Group Members Mr. P. Ramachandran - ABB Ltd. Mr. M. L. Jain ~ EMCO Ltd.sor linkto ectetyCHAPTER - 1 TECHNICAL SPECIFICATION & PARAMETERS INTRODUCTION: 1. Ratings, Voltage Ratio, Tapping range, Impedance and other technical parameters may be selected as per C8lP Publication No, 295, Manual on Transformers, 2012. 2. This Manual gives the recommended losses for the standardised ratings of power transformers (Annexure - 1.1) Two ranges of losses are given - High Losses (for maximum specific loadings of current density 3A/mrm? and flux density 1.7 Tat rated tap) and Law Lassas (for maximum specific loadings of 2.3 A/mm and flux density of 1.6T atrated tap). Current Density refers to all taps and flux density refers to atrated tap and voltage. Low losses may be adopted where the capitalization rates are high (say & 2 laklis per no-load lass kW and ® 1 lakh per load loss kv) and high losses where low capitalization rates are applicable (say® 1 lakh per no-load loss kW and 0.5 lakh peer load loss kW). When fixed maximum losses are specified, transformer buyers need not capitalize the losses for bid comparison. With fixed losses and using standardised GTP, buyers can compare various bids effectively and expeditiously. They can compare quoted weights of active materials with standardised losses, indicated stray losses and type of conductors (rectangular conductor Vs continuausly transposed cable ~ CTC) can be ‘compared. Hardness of conductor and epaxy coated CTC gives an indication of short circuit withstand strength cof winding. 3. Where the buyer wants losses different from the above standardised losses, he may get losses from reliable \vendors after indicating the loss capitalization rates or maximum specific loadings, After evaluating the market losses, fixed losses for the special duty transformers may be decided and bids may be invited for the fixed 4, The GTPs are prepared in two parts. One is to be specified by buyer and other by vendor. The tick mark" ¥'* is ‘shown in the column indicate by whom the data isto be filled in 5. Ratings are also standardised covering 132 kV and atiove and up to 765 kY class transformers and accordingly considered in this manual (Annexure - 1.2) 6. _List of applicable standards for transformer is enclosed for ready reference (Annexure 1.3) Guaranteed Technical Particulars for Power Transformers, A. GENERAL 1 | Genera information 1 Supplier 1 Manufacturer v in)Place of Manufacture | iw Type of Transformer (Core/Shell 2 | Applications 1) Indoor/Outdoor I) 2Weg/3Wep/Auto : ii) G1/Step down/ICT/Station Start up/Auxllary/Rall Trackside Supply 2 | Corrosion Level at Ste Light WMedium il)Heawy iy Vary Heavy igemaee een 4 | Applicable Standards 1) ec: 60076 : ip 182026 7 ipANSICS7412.00 5 | type 1 Liguid immersed v Moy 6 _| Full Load Rating tewiviww) MA v 7__| 3 Phase/Bank of Three Phase/Single Phase | A.0.C) v } 6 | Rated No Load voltages (Hv/I/} w , | Currents (V/V) Amp i © _| Rated Frequency He v 10 _| Connections ane phase displacement symbols (Vector Group) v 11 | Welght Schedules (Maximum) / (Minimum with no negative toleranc a Aetve part e i ol [ee ¥ iil) Tank and nas Z ke f v iv) Total Weight HH Z kg v Overall cimensions Lx BH ‘ah z Sin of heaviest package UxBxH om v vid Weight of heaviest package i v ‘i.a_| Transport Limitation v 12__| ev wincing i) ourcyoctc v iv) Range of variation % v = [notes i "cna Lod antes dS ttn 7° | WW 7 ieeoma eure to eleetreyeon \ Guaranteed impedance (Base MVA t rnc tp) s oT Tolerance * opr wi Impedance atecreme tapings 2) Mor. Vokage tap * ¥ ‘ ) Min. Voltage tap % v Tolerance * ‘ vi Regulation at flload 0.8 pfat 75°C winding temperature % v | will) Guaranteed No Load Loss (Max) kw id 1) Galevated anoss aw ¥ 2 Calclated imp Loss aw v ||) Guarantee Asian Loss a8 aw Q | [a Guaranteed manimun Magneting Curentatted Vonage | % v | [idan at ratea 63 unity PF * v |__| peatoaatoraedram eficner car 15 | Anylinitatons in the pertormance ofthe required test ey || [es State kmtatins 16 _| Deviations from specifications (if any) v B, MAGNETIC SYSTEM 1 | core type v 1) 3 Phase 3 Limo (8 wound Lins) ly 3 Phase 5 Limb (3 wound Limbs) |i) 1 Phase 2 Limb (2 wound Limbs) iv) 1 Phase 3 Lim (1 wound Lim) W) 1 Phase 4 Limb (2 wound Limbs) 4 Phase 5 Limb (3 wound Limbs) 2 _| pe of Core Joint v 0 ated 1 Step tap 3 | cro 2) Thickness mm x | b) Max. Specificlossat 1.7 T, SMe we ¥ | 4 | core botts in Limb/Yoke [yes/tvo v | 8 | Minimum Gross Area of Care/Limby/Yoke/Unmound Limb cm v (May be verified during manufacturing tage) 6 | Stacking Factor Lx ¥ igema eure7._| Voltage per Turn v | Apparent Core Density for Weight Calculation | Minimur Net Weight of Silicon Stee! Lamination CRGO a (ay be verified during manutacturing stage by calculation using put from ser-3) 10 | Max-uxcensty at Ratea Voltage and Frequency ‘i (ray be veies during manufacturing stage by calculation) 12 _| Weg at working fux density w 12 | Building Factor considered 14 | Calculated No Load Loss at rated voltage and Frequency vow (Net Weight x Wk x Buliing factor 15 _| Maximum Sound Level e 17 _| Core lolaton test w CONDUCTING SYSTEM Rr nae 1 | Type of winding | Heicat/Disc/Layerinterwound if 2 | Type of Conductor v PICC/CTC/CTCE/CTCEN/BPICC 2 | Minimum Yield Strength of Conductor We? x (0.2% elongatiors 4 _| Maximum Current density at any tap Ale? v 5 | are weight of copper without paper insulation and lead ke Y (Mini 6 _| Per Phase Maximum resistance of winding at rated tap @ 75°C | ohm ¥ 7 | Number of Turns/Phase v 9 | bielecti Shielding used ¥ iyIntereaved winding || iyWounain iets in Others| 10 | magnetic Shieaing Used v 1) Yoke Shunt on core clamp |) Magnetic shunt on tank |_| i) Electromagnetic (Copper/Aluminur) shield on tank I 1) others ieema YikesD. COOLING SYSTEM Type of Cooling 1) ONAN i) ONAN/ONAF i) ONAN/ONAF/OFAE NJ ONAN/ONAFI/ONAF2 vj ONAN/ONAF/ODAF i OFAF vi) COAF vil) OFWE >) ODWE Cee (oR Percentage Rating Corresponding to Cooling Stages (HV/IV/LY) T Guaranteed Maximum Temperature rise at 1000m altitude 1) Top Ollby Thermemeter * 1) Average Winding by resistance % Ii) Winding Hot Spot * ‘ype of Cooler 1) Radiator Bank 1 OlltoAirHeat Exchanger li) Oilto Water Cooler (Single Tube) 'v) Oilto Water Cooler (Double Tube) ¥) Tank Mounted vi) Header Mounted! vil Separately Mounted Cooling Fans ) pe 1) Size tipRating (kw) kW iy) Supply Voltage Quantity (Running + Standby) No. il Pumps i) Type 1 Size lip Rating (om andy lpm ki |v) Supply votage ¥| Quantity Running + Standby) No. Coolers (Oto Al) |) Quantity (Running + Stanty) No, Type iy RatingCoolers (Oil to Water) |) Quantity Running + Stanaty) ype and Rating ipolilow rate by water flow rate \ Nominal Cooling rate i) Material of tube Radiators Width of elements ‘Thickness Leng Numbers E DIELECTRIC SYSTEM Geometric Arrangement of winding with respect to core e.g: Core LV HV-Reg Coarse-Res Fine Regulating Winding 1) Body Tap Separate HY Line Esit point in winding I T6p ‘Center Varistors used across Windings tyes, ave details Insulation Levels 1) 1.2/50 ysimpulse ' Chopped impulse |i) Switching Impulse ivy AC (Shart duration / Long duration) Max level at 15 PU sro sectF ACCESSORIES. cee Ont ee ioe: Tap Changers 1 Control ¥ a-Manual b-tutomatic eRemate d-Local ‘Voltage Class and Current Rating of Ta Changers Ti) Make and Model v v IW Makeand Type of AVR vo v ) Power Supply for contral motor (No of Phase/Vattage/Frequencys ‘Rated Votage for eentrolcrcut y 4 (No of Phasa/Voltage/Frequency\ 2 Tan ] | k |) Tank Cover: Conventianal/Bell/Bottom Plate | v Tank cover: Bolted /Welded ip Plate thickness side, bottom, cover om ii) Rai Gauge AE iH mm ov iv) Minimum Clearance height fram al forliting Active Part | mn | vi Wheels: numbers/Fane/Fienged/Un-Directonal/ v { BLDiectional/Locking Details Vacuum withstand Capability mm of He v vi) Tank/Radlators/ConservatorAccessories| vil) Radiator fins / conservator plate thickness om Vv 3 Bushings wv [iv [ow | evnavn i) Termination Type 3-Outdoor b-Cable Box (oi/Ai/SF,)c-Plug in Type i Type of Bushing: PorcelaivOrr/RIP i) Bushing housing -Povcelain/ polymer i ated Volane Css Ww |__| ated curene a | vi) Rated 1.2/50 us Impulse Withstand kVp v viy v | vi Rated One minute AC withstand, ry ims ix) Make and Model ¥) Terminal Pad detais 0) BCT Requirernents | | ieema Jar ink eect,eee ca 4 Indicative 1) Wining temperature thermometer 19 Oiltemperature thermometer {iy Temperature sensors by Fibre optic 1W)Oilactuated/gas operated relay 1 Pressure Relief Device ‘v) Dahydrating Breathers vi) Conservator Baglaircell vi) Ol evel Indicators Nain Conservator OLTC Conservator in) OF Sight Window | Main Tank ‘Main Conservator LTC Conservator 2) Tap Changer protective device x) Bushing CTs 5 Transformer Oil i) Grade as per EEMA spec [see Chapter 6 of this Manual)/ vec60295 Inhibited / Uninhibited v 1) Spare oll as percentage of fist filing ip Manufacturer 6 Press Board Make ¥ Type 7 Conductor insulating Paper (irate paper, thermally upgraded Kraft paper, Nomex) ¥ icema Your linet stectretyANNEXURE 1.1 Legendt NLL - No Load Loss in AW; FLL-FullLoad Loss in KW; AL Auxiliary Loss in kW a SiNo va IMPEDANCE: HIGH LOSS. LOWLOSS.— = % RLUALUAL NULLA 1 75 8.35 85/45 138 2 0 0 1a 8570 3 125 7 10 1a/100/- 10/80/- 4 16 7 10 1s/1O- 1/100/- 5 20 0 1730 ator 6 25 iE 10 18/140/- 14/115 /- 7 315 vs | 20/150 wei25/- 8 40 - 125 25/185/- 2ort40/- 9 30 25 30/200 25/160/- 0 @ Bs 3272405 mnsora 1 80 125 | 4027576 32/230/5 = 2 ait ET Se Sino Ma, WPEDANCE Higuioss LowLass % NUUALL/aL MAU FLLAL 1 50. 12.5 “33/215/ 26/160/- 2 80 Bs 44728076 3555/5 3 100 125 55/320/8 45/270/7 | 4 125 5 s0rs7078 55/300/8 15 74/45/11 64/365/10 _2sSK0 CLnsS TRANSFORMERSIGT) cae SiNe! wa IMPEDANCE High Loss Low Loss % NUURLL/AL NUUFLL/A, 1 140 as 0400/10 340/10 2 250 EB 4 130/600/13 110/500/12 3 35 14 140/750/16 130/650/15 4 60013+200) 1“ roova50r14 a0/380/12 pg inne ,_ at AS NORM OL SiN va IMPEDANCE HigHLoss Lowtoss % NUALLAL NUALLAL 1 100 | 12.5 30/240/6 25/2106 2 160 25 38/3508 35/008 3 200 6 5430/12 40/330/12 igema orl tocecteky| IMPEDANCE High L055 Lowioss % NLLFLUAL SUELIAL 1 | toomoonsers3 | 125 s0va0078 30/250/8 2 | zoouoorazaa | 125 80/400/10 65/225/10 3 | sisuooroan | 125 95/565/15 75/5205 2 | soowoorzz0a3 | 125 150/700/18 20/8506 5 31105 25 sors? 40/165/8 6 3918667 15 ea/2s0/12 soraio/t2 7 3°200 125 65/300713 60/260/13 8 3250 “128 787360035 To/310715 9 100 125 45730078 207708 10 200 as TeAD00 e/380/10 1" 25 125 95/550/13 7a/a4o/13 2 500 28 1407600/16 s/600/16 2 38108 25 3795/6 3185/6 | 4a 3166.7 125 48/27/11 42/250/11 5 3*200 25 eo/3s0ri2 s5/a20/12 125 70/4205 60/380/%5 16 3250 ae B20 CLASS TRANSFORMERS (GT [ sino wa, | Pepanc vii toss LowL0ss " nen en 1 250 145 raore00/14 cwovssorta 2 35 ms Trs/es076 re0ve00714 3 3200 “ 1a0isian2 10/3602 a 3250 mas ‘a/s0078 rasgors 5 388 5 175156 iwovse0rt6 Te cates raronvins wuron, SSS wa areDANcE wc L055 ‘ow i055 * Mera AURAL 1 38 4 wsi075 ss0078 3500 is en/6s076 ez/sort0 = TEST Tt TST ahow inde wansFonviension Tae eee SLNo Ma. imPeDaNce. wih loss LowLOss = MUTUAL une 1 3200 ri 7564/35 7a780/10 2 3260 5 2/5/40 ozauona Le = a 725680740 1595/12 eneANNEXURE 1.2 Peano eo Crore Ma roe 220K fou Two Winding 132/33kv. | 220/86:., : ~ Trensformets 4orsomva_| 1001va Auto Transformers | 132/66KV, | 20/1326, 400/220/33 4, 768/37 a00Nv3 40/50MVA | 100Mva, 30 315MVA, 308 333 MWA,1 500MVA, 30 s00MvA, 18 tazvaziey, | 2z0a2k, 400/220/33 kv 25/315 Ma | 160MVA, 30 167 MVA.10 | | Generating 1575/2395 kv.30 1575/4200, 27658, | Transformers S15 vA a15MvA, 30 260 MVA, 105 21204, 2UT76SHN, 2O0NWVA, 18, 333A, 10 2182010, 260 MVA, 10 21a20bv, = 333MvA, 10 ieemaList of applicable Standards for Transformers 1. APPLICATION GUIDES ANNEXURE 1.3 Transformers 0076-8 edt.0 Converter Tanstarmers 613783 ‘Tap Changers 602142 ‘Transformers using High Temp. Insulation Materials 6076-14 edi.0-2013, IEE 1276-1997 Transformers connected te Generators c57.116-1989 Transformers for non-sinusoidal currents (loads with Harmonics) c57.110-2008 Loss Evaluation Guide €57.120-1991 Phase shifting transformer (pplication, Specification, Testing Guide) 62022 62.0 57.135.2012 Terminal Marking & Connections TR6DGI6-1978 €57.105-1978 (Connections) €57.12,70-2000 Terminal markings) Apparatus Bushings 57.19.100-1985 Standard Terminology 6050-421 £57.12.80-2010 “Through fault current duraton- (Equipment damage curves) Dry 5712.59-2001 oirfiles 57121091993 Insulation coerdination 0071-1,2,3, 1313.1-1993 (Definition & principles) {60668-1 [Low voltage) 1313,241998 Application guide) Preferred Voltage Ratings 50038-2003 13121903 ‘Transformers for Nuclear Generating station 638-1992 Bay coding of Distibution transformers 1e5712.35-2007 Selection of insulators for polluted eevronments ‘Ts60815-2008, Permissible temperature ise forterminal 60943-1998 Bushings Seismic Qualification ‘T561463:2000 Seismic Guide for Transformers & Reactors 57.114-1990 (withdrawn in 1996) Recommended Practice for Seismic design of substations 693.2005 Direct connection detals ttorstormers & GIS 61639-1896 icemMG Jour inktotactehyAsan Determination of sound level {60076-10-1 (2005)ed1.0 €57.136-2000 Guide for sound abatement c571258-1991 ‘Cleaning of Insulators 957-2008 Occurrence and Mitigation of Switching transients induced by transformers ¢ 57.142/ 2010 ‘Standard Terminology .60050-421-1990 €57.12.80-2010 Metric conversion of wansformer standards | “Transient Voltage Analysis of Dry ype transformer Coll c57.144.2008 57.12.58-1991 Determination of masimum winding temperature rise in quid filled ansformers TEEEStd 1538-2000, Electrical Power System Device Function Numbers, Acronyms, Contact designations | e1a507-4 37.2208 Recommended electrical clearances in air Insulated sectical power substations TEE Ste 14272005, Guide for protecting Transformers 37.91.2008 Guide for protection of network Transformers 37108-2002 (Guide fr Protection of Shunt Reactors Application of CTs used for Protecive €37.109-2006 Relays ca7.t10-2007 Salety oF Transformers -EMC requitements 2041 e02.0:2010 | 2. Specifications Parente Ee fe Gilfiled 60076-1€63.0-2011 €57.12.00-2006, Dry 0076-11 edi 9 €57.12.01-2005 Self protected liquid filed transformer 0076-13 ed1.0 “SF filed 0076-15 “Converter transformer (613781 ed 2.0(2011-07) 57.18.10-1998 HVDC transformer 613782 57.129-2007, ‘Traction transformer 60310-2004 Phase shifting transformer 62032-2005 Transforers < 230, 1-10 MA single phase, | 08-100 MVA 3 Phase | 57.12.10-1997 Overhead distribution transformers | <500 KVA, 34.5/13.816V €57:12,20-2005Particular Pad mounted 3 Phase OT <2.5MVA34.5/0-48kY ics Bue 5712.22-1993 Paclmounted single Phase DT < 167 kVA 34.5/0.48KV |with separable HY Connector (¢5712.25.1990 Paclmounted 3 Phase DT-with insulated HV connectors <2.5MVA34.5/___kVwithseparable HY connector ¢57.12.26-1992 ad Mounted Compartmenta ype Single Phase Disiibution Transformers (HV 34.5 kV/lV 240-120 5167 KVA) 57.12.211992 Pag mounted 3 Phase DT =5MVA345/0.0810 57.12.34-2004 Enclosure ntegrty-Pad maunted €5712,28-2005 Enclosure integrty-Pad mounted for coastal environments (€5712.26-2005 Enclosure integrity Pole mounted ¢57.12.31-2002 Enclosure Integrity Submersible equipment 57.12,32-2002 Electrons Power Transformers IEEE Std295-1969 and vault type Liquid immersed distribution substation c57.12.36-2007 transformers Secondary network transformers subway - 57.12,40-2006, ‘Secondary network protectors 57.12.46-2005, Ventilated, Dry type power transformers 41-500 kVA single phase 15-500 kVA3 phase ¢s7:12.51-1981 Sealed, dry power transformers 20.5 MVA3 phase 34.5 kV 57.12.524981 Diy ype transformers used in unit substations 5742.55-1987 ‘Transtormers for Wind Turbine applications 0076-16 ed 0(2011-06) Stop Voltage Regulators_standard requirements terminology and test code ‘50076-21 edt.0 (2011-12) Design testing and application of quid immersed transformers using high temperature insulation 0076-4 edt.0 2013) PCS7.154/09.1.2012-06 ieema riko lc3. Testng Testing sore et “Gene Dy 4onfomer cs1aze12001 “Genera o ied cSriaao-2010 “HVE ertorer corias-2007 Dielectric tests. 60076-3 d3.0-2013 (C57.12.90-2006 I { ‘ipa viet oore20i30-2011 ‘ore 571290206, Daasttit ie 3382000 Deeminatonafhot soot tenneraie of eari3e200 dev gpetartoner Imps sviching surge test sore 0 esrasasa feeommended price or ple et of Gsrias 1998 Secon tasfomer | | mine | Loss measurement 571232010 | Tempra est for Oven . cs73182001 ftesing se270.2000/ 60076-32000 ore esranaiso ae estizraoor Boy tansfomer csriast9e1 Testorteal evaluation oy csraaso1998 type transformers (Cast resin & Resin encapsulated) Test for thermal evaluation of dry type c57.12.56-1986 transformers (Ventlated dry type) Test for thermal evaluation of dry type |eEE 259.2004 transformers (Ory type specialty and ‘peneral purpose} Guide for determination of maximum “ IEEE 1538-2000 winding temperature ise in iqud lee transformers Test procedure for thermal evaluation of “ cs7400-2011 Insulation systems for liquid immersed transformers Measurement of frequency response 6076-18 e41.0(2012-07) 57149-2012 Determination of uncertainties in loss 6007619 edt 012013) ink eeceelyrer 4, Transformer Oil ‘Mineral 0 Specifications 60296-2012 ASTM 03487-08, Mineral Oi-Recycled Of 62701 ed1.0.2013 Silicone it Specifications 60836-2005 ASTM 4652-1987 Natural Ester O1ts 62770e61.0-2013 ganic ste OF Speteatons 1099.19 sya Aomatca pects 08575995 pera sence sou22.2008 csra06-203 Nora sto marenance csr 2008 icon ahenaes sosaat388 csnastase9 ‘etc organc Enter Maintnance ciz03.1992 ‘Hydrocarbon fluid maintenance 57121-1998 Samar soxrsasra sm 082357 soser2n0s Ast p361398 BDV E 60156-1995 ASTM D1816-97 fi o877-00 uidaton say ona asi 02400 sSrortioo1 econo ose Asti o1593-05 DG-ntrreation fests cosse-1988 cs7304-2008 DGA- Bushings 3614641998 oGA-ouTe 57139-2012 DGA-During fectorytest 1181-2007 pcs7.130/D172006 DGA-Samping 605672005 DGA-Test method ASTM D 361201 GA Silicone cil filed transformers ¢57.146-2005 Reciamation of i! \EFE 637-1985 (R207) DGA-Ester Fluids PCs7.155D4 L your nko electey5. Accessories Dey ype series Tap changers 0214-4 57131-2012 Bushing General 601372008 ¢5719002000 HVDC Bushings €5719.03-1996 Dimensions * 5719.012000 Terminals 60518-1975 Bushing Application Guide 57:19,000-1985 Bushings - Seismic Qualification 1361463-2000 Reactors Specifications (C57.21-2008 (Shunt) esting 60076-6 5716-1996 Smaathing reactors for HVDC \Ge£ 1277-2000 Induction voltage regulator 5715-1999 Controt Cabinet es714B.2011 6. Raw Materials ‘Winding Wires: Paper tape covered Rectangular Wire 60317 eda.0-2013 Magnetic Materials Part8-7 Specifications {or individual materials (Cold-alled grain- oriented electrical steel strip and sheet delivered in the fully processed state) 61061-34 Nonimpregnated densified laminated ‘wood for electrical purposes Pert Definitions Part 2.Methods of Test Part 31 Specifications for Shoets Part 32 Spectfieations for ings 160404-8.7 ed3,0—2008 Electrical Papers Part 1 Definitions Part2 Methods Of Test Part 3-1Geneeal Purpose Paper Part 3 2Capacitor Paper Part’3-3 Crepe Paper Part3-4 Electrolytic capacitor paper Part3-5 Special Papers Non cellulosic Electrical Paper Part3-3 Unflled aramide(aromate polyamide) 0550.1 605502 60554-341 6055432 6055433, 60554:3-4 6055435 60819-3-3¢d3.0-2011 ieema {earlierPressboard and press paper for electrical purposes Part 1 Specifications s0eat-t Part 2 Methods of Test c064t2 part 3-1 Press Board 0881-3-ted2.0-2008 Part 3-2.ress Paper ‘0641-32 Laminated Press Board Part 1Definitons 66076341 ed2.0-2010 Part2 Methods of Test 61628-2 edi.1-2007 Part 3-1 Laminated pre compressed Press 0763-41 ed2.0-2010 Board 7. Installation, Operation & Maintenance Guide for Transportation of Transformers Reactors 57150-2012 Installation & maintenance Cilfiled Transformer 5793-2007 ‘by type Transformer ¢57.94:1982 Loading side i filed Transformer 600767 ed1.0(2005-12) c57.912011 Dey type transformer (60076-12 edi.0(2008-11) €57,95-1999 Falluce investigation . 5725-1981 Reporting falure data csr.1t7-1986 valuation and Reconcitoning of oi files transformers | Diagnastc field testing 5740-2006 ¢57.1522013 Monitoring of transformers & accesseries 57143-2012 | sunstation-Fire protection Containment sconrel of ol ois in substations 97919941R2008) 980-1934{R2001) [Guide forthe design, construction and ‘operation of Electric Power substations for ommunity acceptance and environmental compatiolty| s1a7-1998 sortinkto eect8. Operation & Maintenance: chure ri ee 256-2006 Recent developments inthe interpretation of GA. 342-2008 SRA 343-2008 Recommendations for Condition Monitoring and condition assessment facilities for transformer 1414-2010 Dielectric response methods for transformer windings 4420-2010 Life Time Condition Assessment 4436-2010 Experiencesin service with new Insulating Liquids 4443-2010 DGA on non-mineral ol and Orr ait, 444-2010 Guide lines on unconventionat PO measurements 1494-2012 Furanie Compounds for Diagnosis Operational | 170.2000 static Election 57912011 Loading Guide foro | 60077-2005 Problems | 2282002 Aging Process immersed Loading Guide 323.2007 ageing of Cellose Transformers {ori immerses 349.2008 Moisture Equlbrum and €5796999L0adng GudeforDy | Tansformers ‘migration i nsation system TypeTranstomers "| 60305-1987 378-2009 Copper side mnslation Loong Guide 393.2008 Therma performance of ‘erry type Transformers Transornes 4452012 Maintenance | Life 227-2003 Life Management Techniques: (C57.93-2007 Installation & | 60422-2005 | Assessment | 248-2004 Economics of Management Maintenance of Maintenance | 298-2006 .fe tme Gata Management Transformers Fo | 415-2010 01 regeneration and 57106-2002 Maintenance of Ci Denslogenation 57340-2008 Evalunton & Reconditioning | 637-1985(R2007 Reclamation of Of Diagnoses | 254-2002 Dielectric Response 6241995 (R2005) DagnostcFieid | 60076-18-2012 Testing of Transformers E Reactors €57,104-2008 DSA of Ol (C57.117-1985 Guide for reporting failure data of transformers €57.125-1991 Guide for Site failure investigation of Transformers €57.146:2005 DGA of Slicon Oi filled Transformers 1€57.200-2000 PD detection by Accoustics PC'57139012-2009 DGA FOLIC! PC57:143 021-2010 Transformer Monitoring SRA 60567-2011 Sampling of gasestor DGA 50599-1999 Ga Imerpretation eure electric8, CIGRE Brochures for Asset Management of T&D equipment: ee cutee Product fe 7 eta 22 ears 8s a cc Rue Condition — | 393 083, 300 226 Assessment | 436 259 320 437, 385 ‘& Monitoring we 381 3.06 00 Endoftite | 227 165 ass [ass | 252 422 26+ Issues 358 403 au | ak 248 : - 300 303 azo | secs ‘Management a7 27 340,383 and abt 422 | Decision Malang ria 335 a | 176 Development 336 Maintenance | as 259 27a |230 | 380 Processes 319 ‘Decision Making Collection | 298 7 - - $C 85: 329 of Asset $c 02.341 Data and | Inforation icemMGaChapter - 2 Design and Engineering features ee (1) Architectural Features, General Arrangement Drawings & Accessories Working Group Members Mr. M. Vijayakumaran — ALSTOM Ltd Mr. P. Ramachandran — ABB Ltd Mr. ¥. V. Joshi - GETCO Mr. M.M, Goswami POWERGRID Mr. T. Vijayan ~ TAR Ltd {ur ik to lecreyieema yartintodecony peer aeCHAPTER - 2 DESIGN AND ENGINEERING FEATURES Part 1 - Architectural Features, General Arrangement Drawings & Accessories INTRODUCTION rege ocess of standardisation of wansformer from procurement to commissioning, architectural features do have Tae role. present, same rating/lass transformers are being designed differently even for came user Seer ve ‘rere eciications, manufacturer reviews design for successive tender considering prevailing mathetecralinny {hereby make changes in transformer architectural features and general arangermante, The reviewing activity not even leads to increase in design & manufacturing cycle time, cost, human efforts and inventerie er noe keep user Ta fesolve all these issues and to define standard architectural features and accessories, this Working Group Terme ar teneetings and discussions in the subject matter. However, standardisation refers to lat he vercaen Sehonanayout general arrangements, interchangeably accessories selection guide including Gata sheer drawings, Schematic, mounting arangement/nterface with tan, critical check points for instalation ara conse ing, etc Craraeeeeablty has been referred here mainly to transformers of siniar rating, voltage and ethet technical Scars, even when they are being purchased from cfferent suppliers unde diferenteortrects oo een ofa Varstorns re tind in order tainerease avalablity and reduce costs by minimising the outage tine in cee may ransformer having tobe removed frm service and replaced by spare/new transiotmes area concept {12Y apply for separately cooler bank mounted transformer in which cese the requirement of interchangeabiity can be even made applicable to the main transformer excluding cooler bank. Tis Policy wil reduce the complenty of the purchaser's stack of transformers, bushings, fittings, tap changer components, etc and will minimize maintenance practice and costs *Geaihetic (Appearance) of Transformer: Mounting of fittings tobe sameas faras possible, mounting & location over bank, Conservator et. shall be atstandard position. Atypical plan & section drawing showing accessories, tke Bushings, Tan changer, conservator, LTC Drve!Mechanism, Neutral Carthine ‘arrangement, Marshalling box, Can bee get in this Manuel, Tank mounted racfatrs ere recommended, fortatings up to 100 WWa eee, ‘can be separate for higher than 100 MVA. * Tank Type: Belltybe, Bolted ‘Welded construction, Conventional & Form Ft type eee yee in thickness of radiator willbe minimum 1.0 mm. Only 4 heighs ae proposed (2.0 M,2.5M, 3.0 M Fer oa with number of elements tobe 20, 24 & 26, Radiator lexteral shale Hot ti cahecoedn: painted 2s realtor pneat of Radiator given inthis Manual. Frinteral surface galvanizing is natreconmrasd ear resistant paints may be applied on galvanized surface for better appearance, oe orided fr ral, However, Transformers are recommended to put rect an plnih other tie &roller Renee oriarbe Standardised, Only ane setofroleis recommended foreach substation Since Rates eo hence only Raller assembly is needed to be galvanized, "Malis Schedule: Valve specification type & application shal be standardised, This willbe reviewed with exper and finalized, *Gprgenvator: Main conservator shouldbe with Aircel OLTC conservator shallbe separatota avoid intermixing of OF Maintenance free ype detycratng sca gel breather may be provided in remote operation adore ieemeinternal Farthing of Metal Parts: Earting point shall be robust and made accessible forthe inspection tothe extent possible Painting: Tank, Radiator & Fltings may be of diferent shades. Epoxy coating to be avoided for outermost lave Poiana only. Casting parts not necessary painted for matching shade. Any fabricated accessory should tether gavanized or outer sie PU. Powder coating may be accepted provided it shoud be un laht/ outaoot oe oy reastant Beng nt Eco-friendly, Zinc Chromateisnottobe used, Bottom pate f tank may be accepted 1 ith voter based paint. Intemal paint shal be ol resistive with thickness of 25 to 40 micron only. Hardware /Bolts:MaterialwilbeMS with grade. Toavoid bending igh Tensile Ste! (HTS) salsorecommended Stainless Steel should not be used in the main tank joint. Gasket: Since one side of gasket is exposed to the transformer oll of ciferent quality (old, new, inhibited, casi tritcd, Paraffin base ol, Naphthenic base oll vegetable oil ec.) & other sie is water, moisture, hurieia, snrigen, olidon, saline etc, hence gaset to be reliable & suitable for these appicatios, Chotd (ive Beer range joints are recommended. Top cover of tap chenger tobe suitable for O-Ring or chord with interchangeable with older one. Marshaling Box / Common Matshaling Box: The enclosure (shel) shal be made of cod rlled sheet and Mevanized/ painted. Stainless steel and Aluminum may also be considered for Marshallng Box 07 & WTI: Switches shall be Mercury ree, preather: Coats @ banned material, hence not recomtmended to use, Size of silica gels to be standardised, erat it can be one of 100% or ta af 100% in parallel. Valve over breather isnot recommended. pressute Release Device (PRD): PRD shall be mounts an top cover. One PRD is recommenad nex every 40K ae. Tne oll discharge chamber and ternal Uox ofthe PRD shall be water tight with Protection class IP56 or better as perlEC 60529. Ladder: Ladder (Fixed type) with safety locking device tobe provided. Provision for xing safety bares Sh be frovided ontop tank cover. Ladder for conservator may be provided considering safety for working height fire Protection System (FPS) Povsion af FPS Is recommended in fine wth CEA reguation ie for 10 MVA & above. Itis recommended to keep provision in each transformer. Heath, Safety and Environment (HSE): Al the HSE aspects shal be covered while preparing standard GA aaa equate wotking space ontop of ansformer with suitable rang for safety hall be provide atings of Transformer: Standard ratings considered are as per Annexure 1.2, pall gauge shal be standard (1676 mm). Pith mounted tank design may be adapted. as a specific requirement Rating wise all gauge are standardised as below: 1. 765 KV & 400 kV, 1-Phase Generator Transformer (having two rails or three rails) 2.765 KV & 400 KV, Phase Auto Transformer (having four alls) Note: 3-Phase ratings for above also to be considered depending on size and transportabiiy. {400 kV, 3-Phase Auto Transformer (having four rails) 1400 KV & 220 kV, 3-Phase Generator Transformer (having two rails) 5, 220 kV & 132 KV, Power Transformer (having two rails) ro Location of OLTC: The nurnver and location willbe as per OLTC type &its specication. interchangeetlity & Common Architecture: The OGA is prepared inthe form of block tharem & ol! MmperteTE fitings posttionsare shown (Annexure2.1).Marshaling Bax, Coolercontrol cabinet ane om othercabinetreauired {or aby moritoring devices wil be tank mounted. Grounding inter phase fs considered to minimize Jacking: 4 nos. of jacks shal be provided. ‘cooler bank foundation: Modular block foundation ist house any make raciator in the standard foundation. ‘Maximum Height of Conservator tobe standardised to make the firewall uniform. “The tertiary and neutral bushing shal be provided on top of the tank cover. The provision onside wal f he The torte Zcommende in view to ave lowering of ol evel incase of bushing relacemert which Is ine consuming. ue to winding capacitances, the tertiary winding faces transfered surge voltages during impuise application on Put wring: Therefore, the bushings of 52 kV rating are provided for 33 KV teary winding york oetectretyCooler Bank Design: * _Protisin for connecting cooling bank on both sce shall be provided. Pipe work on main tank to be designed in such a way that position of the cooler bank, conservator etc. can be changed at site by simple reconnection * Specification for separately mounted radiator bank distance (for ll pipe connection) from main tank to be kept anard or minimum. Position of cooling fan to be bottom of radiator bank but cooler fan support from ground isnot recommended, * Modular block foundation will be explored to house any make of radiator inthe standard foundation, * Tank mounted Unit cooler option for Generating / Large transformers can be considered, * If more than one unit is provided, the breather for main tank shal be in parallel + No. of OLTC and its iocation willbe as per OLTC type & its specification * Jacking: 4 Jacks shall be provided and their locations tobe decided by the manufacturer such that itwillnot foul ‘all, rollers or other accessories. + Height of Conservator & HY bushing shall be same, * Hat dp galvanized with a minimum thickness of 70 um and painting as perth following specification eo foes eect en pod ree a Main ark. pipes, |] Shot Blast | Epenybase | Enoxyhightutd | aliphatic | minimum | RAL7035 conservatortank, | cleaning | Zinc primer | Micacaousiron | poyurethane | Seam ailstoragetank "| Sazve* | (30-40um) | oxide Bo) | uy etc. (extemal (5 um) {Mioirum surfaces) 50pm) ‘Main tank, piges | Shot Blast Hot oil Minimum | lossy white or {above BON). | cleaning | resistant, 304m | pane consenvetoriank, | 522i* | nonorrosve Mae oil storage tan varnish or 40um etc. (intemal paintor epoxy surfaces) carergOtemal | Chemica | Eporrbase | Enorynasezne | Pupain | atmimun | Matching shede surtacos) Shor Blast | Zinc primer | primer(30-40 um) | (minimum | 00um” | sreanigen cleaning | (30-40 pm) sum rentshede sain aesthetcaly matching ta tank Radiatorana | chemical | Hot olproot, | - | Piesupto gona | cieaning,t | low viscosity Girteral surfaces) | required | vemish Contrlestinev | Seventank | zincehtomate EPoKY paint | Minimum | RAL7035 shade marshaling box | processas | primer two withFUta | Bum" | for extenor end | peris:s618 | coats) coat interor | aisss005; I Note * Indicates Sa 2¥: as per Swedish Standard SIS 055900 of $0 850% Part Ti als of paint should be such that ts colour should not facie during vapor phase drying process and shallbe able to withstand temperature up to 120°C, *Ffanstorme shale put on pith but provision of roller shall be provided. The nos. of jacking points/ pads and {ing bollards / haoks / devices shall be 4 only. Lacation shall be such that it should hot interiors ath loading and unloading from trailer, YourlietaeecrietyInternal arrangement drawing of the active part and lead exit to be provided in te Instruction Manual by aateactrer for beter assessment of probable aut location when reflected in abnormal DGA results. for core, care clamp and tank earthing diagram shall be provided inthe Instruction Manu + Line diagram: and optical fiber termination shall be on the same = Location of OLTC Driving mechanism box, Marshaling box, side. +The main and OLTC conservator shal be Integr height with no pressure difference. In the case canbe separate. sated type with separate compartments so that they are at same ‘of separate cooler bank orif there i difficulty, OLTC conservator iChapter - 2 Design and Engineering features (2) Power Transformer Fittings and Accessories - OLTC Working Group Members Mr. V. K. Lakhiani ~ T&R Ltd. Mr. R. V. Talegaonkar = - CTR Mfg. Ind. Ltd. Mr. S. Rajan ~ CTR Mfg. Ind, Ltd. Mr, R. Prakash ~ Easun, MR Mr. Vijayakumaran — - ALSTOM Ltd. Mr. R. K. Shukla - On Load Gears Mr.M.M. Goswami - POWERGRID Year net eectyoortinkto ectPart 2 - Standard On-Load-Tap Changers for Power Transformers INTRODUCTION On Load Tap changers (OLTC) are the most important equipment used in the power transformers for changing the ‘ap of a winding (to vary effective transformation ratio ofthe transformer) whilst, the transformer is energized or s ‘on load. Performance requirements of these OLTCs for use in transformers and their routine and type tests are described ir IEC 60214-1, Selection criteria of the OLTC, their various types, fittings and accessories etc, ae covered in the IEC 60214-2 “Application Guide”. CBIP Manual on transformers (Publication 317) in ‘Section GG" gives guidelines for voltage control of Pov ‘Transformers employing OLTC. ‘Asa general practice, end.user af the transformer gives the requirement of voltage regulation (on HV or LV side), range ‘of percent voltage variation (from maximum voltage to minimum voltage, expressed as % of rated voltage), nu of steps, 9% impedance of transformer at maximum voltage and minimum voltage tap positions in case of ‘operation with existing transformer and other contral schematic requirements, ‘Transformer manufacturer, meeting the above requirement, decides the lacation of tapping winding (physic as electrical, based on his design philosophy and experience and estimates the current and voltages seen by the tapping winding (across range, between steps, to earth and between phases). Based on this data, OLTC supplier provides a suitable tap changer from his available range. This IEEMA standard on OLTC purports to define the specification requirements and selection criteria of OLTC and recommends the standard parameters of OLTC to be usedin transformers of prevalent standard ratings inthe coun’ standardised by CBIP, score This standard covers specification requirements and selection of On Load tap changers for Power Transformers. the country 1.0. General requirements for selection of OLTC parameters: 11, Standards Applicable ‘The tap changer shall conform to latest edition of IEC 60214 Partt: Performance Requirements & Test Methods; and IEC 60214 Part 2: Application Guide. 1.2. Tap Changer Specification Forcomprehensive specification of OLTCs, certain data need be specified by the transformer manufacturers ‘depending upon the transformer design & construction, apart from the specifications provided by the end users. These specification requirements are therefore divided in to two parts 1.2.1. Specification requirements from end users (Utilities) 4.24.1 Transformer Details ‘+ Number of Phases: Single phase or three phase + Rated Power: MVA + Rated Voltage: HV KV/ LV kV ‘Winding Connection: HV LW (eg. Star, Delta, Star Auto) + 56 Tapping range of rated winding voltage: (4....%6 to) .....% for HV (or LV] variation + Number of tapping positions (No. of steps and % step voltage) + Direction of Power flow: Unidirectional/Bidirectional = Over Loading requirements (if different from IEC 60076-7), leema Your nto elecry