SECTION 4.

3 - TRANSFORMERS specification

1.0.0 INTRODUCTION

This specification covers the requirements of 11/0.433 kV oil type service transformers and
solid grounding system for the River water intake System.

2.0.0 CODES AND STANDARDS

The equipment to be furnished under this specification shall be in accordance with the
applicable section of the latest version of the following Indonesian Standards, except
where modified and /or supplemented by this specification.

IS 335 New insulating oils.

IS 2026 Power transformers.
IS 3639 Fittings and accessories for Power
transformers.
IS 4257 Dimensions of porcelain transformer bushings for use in normal and
lightly polluted atmosphere.
IS 10028 Code of practice for selection, installation and maintenance of
transformers
IS 11171 Specification for Dry Type Power
Transformers

3.0.0 DESIGN REQUIREMENTS

3.1.0 The power transformers shall be suitable for outdoor installation in a hot, humid and tropical
climate. The power transformers shall be oil-immersed type capable of operating
continuously at its rated output without exceeding the temperature limits specified.

The service transformers shall be Dry type Transformers suitable for indoor
installation.

3.2.0 The transformers shall be suitable for connection to the system having short circuit level and
short circuit duration as specified. The transformers shall be capable of withstanding without
injury, the thermal & magnetic stresses caused by faults on any of the winding /through faults.

3.3.0 The transformers shall be capable of delivering the rated output at any particular tap without
exceeding the specified temperature limits under the following operating conditions.

Voltage variation of ± 10% of rated voltage of that particular

tap. Frequency variation of ±5% of rated frequency.
Combined voltage and frequency variation of 10% (absolute
sum).

3.4.0 The transformers shall be free from annoying hum and vibration when it is in operation, even
at 110% rated voltage.

3.5.0 The noise level at rated voltage and frequency shall be as per NEMA-TR1 standard.

3.6.0 The transformers shall be suitable for overfluxing (due to combined effect of voltage &
frequency) up to 10% on any tapping without injurious heating at full load condition. The
maximum flux density in any part of core and yoke under such condition shall not exceed
1.9
Tesla.

3.8.0 Salient parameters of the service transformers are as follows:

 Nominal system voltage (HV / LV) 11/0.433

kV
 Vector group Dyn1
 Type of cooling ONAN
 Class of insulation Resin cast, Class
H
 Temp rise in winding Class F
limits
 415 V System fault level 50kA for 1
sec
 415 V Neutral Solidly
grounded
4.0.0 CONSTRUCTIONAL FEATURES OF SERVICE TRANSFORMER

4.1.0 Tank

The transformer tank shall be of welded construction and fabricated from low carbon steel of
adequate thickness. All seams or joints shall be continuously welded. The tank shall be
designed and tested for a vacuum and pressure as per the guidelines indicated in CBIP
manual. The tank cover shall be bolted on the tank with weather proof, hot oil resistant,
resilient neoprene gasket in between for complete oil tightness. Inspection openings
of sufficient size shall be provided in the tank cover to give access to leads, bottom terminals
of bushings, taps and testing earth connections.

4.2.0 Core & Windings

4.2.1 The core shall be made from low loss, grain oriented, cold-rolled, and silicon steel laminations.
The coil shall be manufactured from electrolytic copper of suitable grade and shall be
properly insulated and stacked.

4.2.2 The core assembly shall be connected to the transformer tank for effective core earthing.
The insulation structure for the core to bolts and core to clamp plates shall withstand a
voltage of 2 kV AC for one (1) minute. The core shall be provided with lugs suitable for lifting
the complete core and coil assembly.

4.3.0 Transformer Oil shall be new conforming to the latest revision of IS 335.

4.4.0 Conservator Tank

Oil preservation shall be done by means of conservator tank. Conservator shall be ‘aircell’
type. The conservator shall be fitted with a magnetic oil level gauge with alarm contacts. A
Silicagel breather shall be provided in the airside vent line at about 1400 mm above ground
level.

4.5.0 Pressure relief device

Spring loaded type pressure relief device shall be provided and shall have potential free trip
contacts. Suitable means shall be provided to direct the major flow of oil downwards away
from the transformer when pressure relief device operates.

4.6.0 Temperature Indicators

4.6.1 For top oil measurement, 150 mm dia dial type oil temperature indicator (OTI) with
adjustable potential free alarm and trip contacts, maximum reading pointer and resetting
device shall be provided. Temperature sensing element shall be connected to OTI by means
of capillary tubing. Accuracy class of OTI shall be +/- 2C or better.

4.6.2 For measuring hot spot temperature in the winding, 150 mm dia dial type winding
temperature indicator (WTI) with adjustable potential free alarm and trip contacts, maximum
reading pointer and resetting device shall be provided. Temperature sensing element shall
be complete with image coil, bushing CT etc. Accuracy class of WTI shall be ±2°C or better.

4.7.0 Buchholz Relay

A double float buchholz relay with isolating valves, test cock and gas sampling valve shall be
provided. The device shall have potential free alarm and trip contacts.
4.8.0 Bushings

4.8.1 All bushings shall be homogenous, non-porous porcelain type, uniformly glazed and free
from blisters, burns and other defects complete with suitable terminal connectors of adequate
capacity. Bushings located inside cable boxes flanges can be epoxy-molded types.

4.8.2 Bushing CTs shall be provided as per system requirement. Secondary leads of CTs shall be
wired upto-marshalling box. The arrangement shall be such that the CT can be removed
from the transformer without removing the tank cover. Current transformers shall be cast
resin type with Class E or better insulation.

4.9.0 Terminal Arrangement

4.9.1 For cable termination, terminals of transformer shall be brought out through side wall
mounted bushings to a detachable cable box with disconnect link . The cable box shall be
suitable for cable termination kits and shall be self supporting, weather proof, air filled type
complete with all hardware such as gland plates, etc.

4.9.2 Cable box shall have IP 55 degree of protection.

4.10.0 Marshalling Box

4.10.1 Marshalling box shall be sheet steel enclosed with IP 55 degree of protection alarm & trip
contacts of all the fittings & accessories and secondary leads of CTs shall be wired up to
marshalling box. Cable gland plate shall be of removable type.

4.10.2 The marshalling box shall have isolating switch & MCB for incoming power supply. Cubicle
illumination lamp with door switch and space heater with thermostat and ON/OFF switch
shall be provided.

4.10.3 The marshalling box shall have 10% additional set of control terminals.

4.11.0 Grounding

4.11.1 Two grounding pads, located on the opposite sides of the tank, shall be provided for
connection of station ground mat for each transformer. Grounding pads shall have clean
buffed surface with tapped holes. M10 GI bolts, nuts and spring washers.

4.11.2 Two ground terminals each shall be provided on marshalling box & cable box.

4.11.3 For neutral connection, cable box shall be provided for connecting to Neutral grounding
resistor.

4.12.0 Cooling

Tank mounted radiator banks shall be provided with required valves. Radiators shall be of
pressed sheet CRCA steel.

4.13.0 Off Circuit tap Changer

Off Circuit tap changers shall be provided on HV winding with +2.5 % to -7.5% range of taps
insteps of 2.5%. The tap changing shall be effected by an external 3 phase gang operated
tap change switch. The operating handle shall be padlocked at any position. The mechanism
shall be provided with a mechanical tap position indicator, mechanical stop to prevent over
cranking of mechanism etc. A warning plate indicating ’For denergised operation only’ shall
be fitted.
4.14.0 Valves

Valves shall be of gunmetal type for drain, filter, sampling and air release application. For
‘shut off ‘application valves can be of cast iron type. They shall be of fullway type with
screwed ends. Every valve shall be provided with position indicators. Bottom valves shall
have means for pad locking in open/close positions. All valves shall be provided with flanges
having machined faces. Oil tight blank flanges shall be provided for the following.

- Valves opening to
atmosphere.
- For each connection for use when any radiator is
detached.

4.15.0 Wiring and Terminal Blocks

4.11.1 All control cabinets, marshalling boxes, etc shall be fully wired at the factory to ensure
proper functioning of the control, protection and interlock schemes. All spare contacts of
switches, relays and other devices shall be wired upto the terminal block.

4.11.1 Wiring shall be done with flexible 650V grade HR PVC cables with stranded copper
conductor of minimum size 2.5 sq.mm. Wiring shall be identified at both ends with ferrules
bearing wire numbers as per approved drawings. Wire termination shall be made with
crimping type connectors with insulating sleeves. Wires shall not be spliced between
terminals.

4.11.1 Terminal blocks shall be of 650 V grade suitable for terminating required cable size.
Terminals for CT secondary shall have provision for shorting. Not more than two wires shall
be connected to any terminal. 10% spare terminals shall be provided.

4.15.4 All devices and terminal blocks within the panel shall have identification numbers as per
schematic diagram.

4.16.0 Neutral Grounding Resistor

Neutral shall be grounded through resistor wherever specified / required. The neutral
grounding resistor shall be mounted in respective cubicles near the transformers and
connected by cables. The cubicles shall be factory assembled metal clad, hot dip
galvanized, suitable for outdoor installation with IP 33 degree of protection.

The resistor elements shall be of stainless steel or steel alloy, rust proof, corrosion and acid
resistant type limiting hot spot temperature to 250° C. The resistors shall be designed to
carry earth fault current of 300 A for 10 s.

4.17.0 Nameplate

Each transformer shall be provided with a nameplate of weather-resistance material fitted in

a visible position showing all the ‘information and additional information’ as per IS 2026-I.

4.18.0 Fittings & Accessories

Each transformer shall be supplied with the following as a

minimum:
1 no. Oil conservator with set of
valves
1 no. Silica gel breather with oil seal &
charge.
1 no. Double float Buchholz relay with isolating valves, test cock & sampling
valve.
1 no. Magnetic oil level
gauge.
1 no. Pressure relief
device.

1 no. Thermometer pocket with mercury in glass

thermometer
1 no. Winding temperature
indicator
1 no. Oil temperature
indicator
1 no. Drain valve.
2 nos. Sample valve (top and
bottom).
2 nos. Filter valves (top and
bottom)
 Set of Radiator banks with isolating valve & drain
valves.
1 no. Air release
devices.
4 nos.hauling lugs
4 nos. Jacking Pads
4 nos. Rollers /flanged
wheels
4 nos.Cover lifting
eyes
2 nos. Grounding pads for transformer tank, cover and radiator banks, cable box and
marshalling box.
Two nos. Stainless steel Rating and diagram plate (Hindi &
English).
1 no. Stainless steel Valve diagram
plate
1 no. Marshalling box
1 no. off circuit tap
changer
3 nos. HV Bushings with terminal connectors in Cable
box
3 nos. LV Bushings with terminal connectors in Cable
box
1 no. LV Neutral Bushing with terminal connectors in Cable
box
1 set LV Neutral Bushing CTs
2nos.Inspection
covers.
1 Lot Interconnecting
cables.

6.0.0 TESTING AND INSPECTION

Transformer and all its fittings should have been type tested and proven type. Type test
certificates shall be furnished for Owner’s review. Transformer and all its fittings shall be
subjected to routine tests as per applicable Indonesian Standard. In addition, any special
test required shall also be performed. Test reports shall be submitted for approval.

7.0.0 PAINTING

Cleaning and painting shall be as per clause 1.6 of section-A of CBIP manual. After
preparation of the under surface the equipment shall be painted with epoxy based paint. Oil
resistant paint shall be applied as required. The final thickness of paint film on steel shall not
be less than 100 microns and shall not be greater than 150 microns. Final shade shall be
RAL
7032.

8.0.0 DRAWINGS, DATA AND MANUAL

8.1.0 To be submitted after the award of

contract: Completely filled in technical
Schedules
Dimensional General arrangement drawing for the transformer indicating disposition of
various fittings & accessories
Cable box & Marshalling
box
Schematic & wiring diagram for Marshalling
box
Properties of transformer oil
List of valves indicating material &
size. Quality Plan
Test certificates
Operation & Maintenance
Manual
Details of Erection, Testing and Commissioning at
Site.