PART 1

GENERAL SPECIFICATIONS/REQUIREMENTS FOR OIL IMMERSED POWER

TRANSFORMER (ENERGY EFFICIENT – LEVEL 3)

1.0 SCOPE:
This section covers specifications applicable in general to oil immersed (energy
efficient – level 3) power transformers. Unless conflicting the requirements of this
section shall be in addition to the specific requirements set out in Part II.

2.0 STANDARDS:
Except where modified by this specification, all materials and equipments shall conform
to the requirements of the following standards (latest editions).

i) Transformer : IS 2026/1180
ii) Bushings : IS 2099
iii) Transformer oil : IS 335
iv) Current transformer : IS 2705
v) Fittings and accessories for power
transformers : IS 3639
vi) Climate proofing : IS 3202
vii) Loading of oil immersed trans-
formers : IS 6600
viii) Degree of protection for control
gear : IS 2147
ix) Routine tests : IS 2026
xi) Buchholz relay : IS 3637
xii) Electrical insulation classified
by thermal stability : IS 1271
xiii) Specification for on load tap
changers : IS 8468-77
xiv) Dimensions for porcelain
transformer bushings : IS 3347

3.0 CONSTRUCTIONAL FEATURES:

3.1 General

3.1.1 Similar parts, particularly removable ones, shall be interchangeable.

3.1.2 All materials used shall be as per the specifications and in accordance with the
specified Indian Standards and shall be new.
3.1.3 Screws, studs, nuts and bolts shall be as per Indian Standards and passivated to prevent
from rust.
3.1.4 The design and manufacture of all electrical & mechanical equipments shall be such that
they can be transported and installed without any damage and give satisfactory
operation under specified site conditions.
3.1.5 Nuts, bolts & pins used inside the transformers and tap changer compartments shall be
locked.
3.1.6 Exposed parts shall not leave pockets where water can collect.
3.1.7 Internal design of transformer shall ensure that air is not trapped in any location. When
such air pockets cannot be avoided, they shall be connected to pipe between buchholz
relay and tank and suitable air release vents shall be provided.
3.1.8 Facility shall be provided for lubrication of bearings and mechanisms. Mechanisms
shall be constructed of non corrosive materials.
3.1.9 Materials in contact with oil shall be such as not to contribute to the formation of acid in
oil. All bolts and nuts shall be galvanised or cadmium coated.

3.2 Core:
3.2.1 The magnetic circuit shall be of `Core Type' construction. The core shall be built out of
high grade, non-ageing low loss and high permeability, cold rolled grain oriented silicon
steel laminations. Core material shall be M4 or better. Sample testing shall be carried
out by the department.
3.2.2 The Yoke shall be designed for boltless construction.
3.2.3 After being sheared, the laminations shall be treated to remove all burrs.
3.2.4 The finally assembled core shall be free from distortion. It shall be rigidly clamped to
ensure adequate mechanical strength and to prevent vibrations during operations.
3.2.5 The core clamping structure shall be so designed to minimise eddy current loss.
3.2.6 The core shall be provided with lugs suitable for lifting the complete core and coil
assembly.
3.2.7 The core and coil assembly shall be so fixed in the tank that dislocation shift will not
occur during transport or short-circuit
3.2.8 All steel sections used for supporting the core shall be thoroughly sand blasted after
cutting, drilling & welding.
3.2.9 Core and winding assembly shall be mounted on the bottom of the tank. It shall not be
supported from tank cover.
3.2.11 Frame core clamps shall be electrically insulated from the core. Class-F insulation shall
be used for this purpose.
3.2.12 No-load current shall not exceed 3% of full load current and will be measured by
energising the transformer at 433 volts, 50 Hz on the secondary. Increase of voltage of
433 volts by 12.5% shall not increase the no-load current by 6% (maximum) of full
load current.
3.2.13 The transformers core shall be suitable for over fluxing (due to combined effect of
voltage and frequency) up to 12.5% without injurious heating at full load conditions
and shall not get saturated. The bidder shall furnish necessary design data in support of
this situation.

3.3 Internal earthing:

3.3.1 All internal metal parts of the transformer, with the exception of individual lamination
and their individual clamping plates shall be earthed. Core clamps shall be insulated
from the core by Class-F insulation unless other Class insulation is approved by the
purchaser.
3.3.2 The top clamping structure shall be connected to the tank by a copper strip. The bottom
clamping structure shall be earthed by one or more of the following methods.

a) By connection through vertical tie-rods to the top structure.

b) By direct metal to metal contact with the tank base.
c) By a connection to the top structure on the same side of the core as the main earth
connection to the tank.

3.3.3 The magnetic circuit shall be connected to the clamping structure at one point only,
through a link placed in an accessible position beneath an inspection opening on the
tank cover. The link shall be on the same side of the core as the main earth connection.
3.3.4 When the magnetic circuit is sub-divided by oil ducts or insulated barriers above 0.25
mm. thick, tinned copper strip bridging pieces shall be inserted to maintain electrical
continuity between circuits.
3.3.5 Coil clamping rings of material at earth potential shall be connected to the adjacent core
clamping structure on the same side as the main earth connection.

3.4 Windings:
3.4.1 Windings shall be subjected to a shrinking and seasoning process, so that no further
shrinkage occurs during service. Adjustable devices shall be provided for taking up
possible shrinkage in service.
3.4.2 Coils shall be supported at frequent intervals by means of wedge type insulation spacers
permanently secured in place and arranged to ensure proper oil circulation. To ensure
permanent tightness of winding assembly, the insulation spacers shall be dried and
compressed at high pressure before use.
3.4.3 Windings shall not contain sharp bends which might damage the insulation or produce
high dielectric stresses.
3.4.4 Materials used in the insulation and assembly of the windings shall be insoluble, non-
catalytic and chemically inactive in the hot transformer oil and shall not be softened,
unless otherwise affected under the operating conditions.
3.4.5 All threaded connections shall be locked. Leads from the windings to the terminal
board and bushings shall be rigidly supported to prevent injury from vibration. Guide
tubes shall be used where practicable.
3.4.8 Winding conductor shall be of high conductivity & high purity annealed copper only.
3.4.9 Dial type Oil and Winding temperature indicator with alarm and trip facility should be
provided. Further one no Pt100 temperature sensor shall be provided for oil temperature
indication.

3.5 Insulation: Unless otherwise specified in specification, uniform insulation to earth shall
be provided for windings which are required to withstand highest system voltage up to
12kV rms. Winding insulation materials shall be Class-A
3.5.1 Suitable coil clamping rings shall be provided.
3.5.2 Permanent current carrying joints in the windings and loads shall be welded or brazed.
Clamping bolts for current carrying parts inside oil shall be made of oil resistant
material which shall not be affected by acidity in the oil. Steel bolts, if used, shall be
suitably treated.
3.5.3 Pre compressed press boards shall be used during coiling of the winding assembly.

3.6 TANK :
3.6.1 The tank shall be made from good commercial grade low carbon steel. All seams,
flanges, lifting lugs and other permanent parts attached to the tanks shall be welded. All
joints which may have to be opened from time to time in the course of operation shall
be of a design to permit them to be easily made oil tight after re-assembly. The tank
should be free from distortion.
3.6.2 Tank shall be designed to permit lifting, by crane or jacks of the complete transformer
assembly filled with oil. Suitable jacking pads and lifting arrangements should be
provided outside the tank.
3.6.3 Transformer main tank shall be suitable to withstand vacuum of 760mm of mercury.

Tank together with radiators, coolers, conservator, bushings, vessel & other fittings
shall be designed to withstand without permanent distortion the following
conditions:

a) Full vacuum of 760 mmof Hg for filling with oil by vacuum.

b) Mechanical shocks during transport.

3.6.4 Suitable guides shall be provided in the tank for positioning the core and coil assembly.
Core & coil assembly shall be fixed in the tank and not on the top cover.
3.6.5 Adequate space shall be provided at the bottom of the tank for collection of sediment.
3.6.6 The transformer top shall be provided with a detachable cover with a bolted flanged
gasket joint. Lifting lugs shall be provided for removing the cover.
3.6.7 The material used for gasket shall be cork-neoprene or approved equivalent. Gasket
joints for tank and manhole cover bushings and other bolted attachments shall be so
designed that the gasket will not be exposed to the weather. Mechanical steps to
prevent crushing shall be provided for compressible gaskets.
3.6.8 The transformer tank and its fitting shall be designed to withstand the pressure which
will be encountered in normal operation & during abnormal conditions such as short
circuit etc.
3.6.9 An inspection hole with matching cover shall be provided on the tank cover to facilitate
inspection.
3.6.11 Tank top cover shall be provided with suitable slope to avoid stagnation of rain water.
3.6.11 Equalising pipe shall be provided between tank and oil filled disconnecting chamber
with isolating valve.
3.6.12 Core and coil assembly shall be dried out under vacuum and oil in the transformer tank
shall also be filled under vacuum condition.
3.6.13 Two earthings studs shall be provided on base channel at diametrically opposite ends to
terminate 2 Nos.50x6 mm copper strips.
3.6.14 Cable boxes shall be provided on sides. Wherever applicable, location of conservator,
OCTC, marshalling box shall be such that MOG, plain oil level gauge, WTI, OTI are
easily visible from the front gate side.
3.7 BASE :
The transformer base shall be provided with flanged type bi-directional rollers.

3.8 OIL :
Transformer and associated oil filled equipments shall be supplied with first filling of
oil plus 11% extra in non- returnable drums. The oil shall conform to IS 335. No
inhibitors shall be used in the oil.

3.9 CABLE BOXES AND DISCONNECTION CHAMBERS :

3.9.1 When connection is by cable (please refer specific requirements) disconnection chamber
shall be provided for disconnecting and moving away the transformer without unsealing
the cable or draining oil from the main tank, leaving the cable box or chamber behind on
purchaser's external supports. The cable box & disconnecting chamber shall be
fabricated out of sheet steel of adequate thickness and shall be of the phase segregated
type. The fault withstand capacity of the cable box and disconnecting chambers shall be
as per data sheet.
3.9.2 The cable box shall be provided with gasket wherever covers are provided. Front &
bottom covers fitted with bolts. Size of boxes shall be suitable for carrying out Raychem
type end terminations subjected to approval by the purchaser. The gland plate shall be
of 6mm thick.
3.9.3 The disconnecting chamber when specified shall be oil insulated as specified in data
sheet. Bushings, oil filling hole with cap, drain plugs, copper flexible and relief vent.
Level glass and removable cover shall be provided for the disconnecting chamber. The
disconnecting chamber shall be provided with equalising pipe connected to tank through
valve. An isolating valve with facility to lock it in both open and close positions shall
be provided in this pipe. Plates through which high current carrying conductors passes
shall be non-magnetic unless otherwise approved by the purchaser.

3.11 TRANSFORMER COOLING EQUIPMENTS BUILT ON RADIATORS:

Tank mounted radiators shall be of the detachable type with bolted flanged
connections. The following accessories shall be provided for each radiator. Radiator
sheet shall be minimum 1.2mm thick.

a) Shut off valves (butterfly type) and blanking plates on transformer tank at each
point of connection.
b) Top and bottom shut off valves and blanking plates on each radiator.
c) Lifting lugs.
d) Top oil filling hole with cap.
e) Air release vent at top.
f) Oil drain plug at bottom.

Special care shall be taken to ensure that all flanged joints of the radiator are absolutely
leak proof. Valves shall also be leak proof. Make of the radiators shall be subject to
 purchaser’s approval. Radiators shall be cleaned by shot blasting & provided epoxy
painting.

3.11 PAINTING :
3.11.1 The interior of all transformers tanks and other oil filled chambers and internal
structural steel work shall be cleaned of all scale and dust by shot blasting. These
surfaces shall be painted with not less than two coats of heat resistant oil insoluble and
insulating varnish.

3.11.2 Steel surface exposed to the weather shall be thoroughly cleaned by shot blasting and
applied a primary coat of zinc chromate. The second coat shall be weather resistant
nature, preferably of distinct colour from the primer and finish coats. The final coat
shall be of glossy oil and weather resisting non-fading paint polyurethane paint shade
631 as per IS-5. If felt necessary additional coat of enamel based paint may be given to
entire assembly including radiators, conservators etc.
3.11.3 All exposed bolts, nuts and washer shall be of galvanised steel.
3.11.4 Metal parts not accessible for painting shall be made of corrosion resistant material,
machine finished and bright surface shall be coated with suitable compound & wrapped.
3.11.5 Interior surface of mechanism chambers and kiosks shall be provided three coats of
paint, after proper cleaning. The final coat shall be of light coloured anti-condensation
paint.

4.0 MARSHALLING BOX:

4.1 The marshalling box shall be rugged and of welded construction fabricated out of sheet
steel having thickness of 2.5mm or more provided with water tight hinged doors with
padlock arrangement, neoprene gasket all around door to make enclosure water and
dust protected (IP-55). Two Nos. suitable brass earthing studs with double nuts shall
be provided on side at bottom for earthing box. The sheet metal treatment shall be
similar to external surface of the tank. The marshalling box shall be with canopy at the
top for protection from rain and bottom removable plate.

4.2 Mounting: The marshalling box shall be mounted on the tank. Necessary angles with
holes shall be accordingly welded on the tank for bolting the marshalling box on the
tank. Location of marshalling box shall be such that WTI/OTI is easily visible from the
front.

4.3 Space heaters:

Strip type space heaters of adequate capacity shall be provided inside each marshalling
box to prevent moisture condensation. Space heaters shall be rated for 240V, 1Phase 50
Hz supply. Heaters shall be complete with rotary type `ON/OFF' switch, 2 pole MCB
and a thermostat to control switching of the heater.

4.4 Lighting and socket:

A suitable lamp to light the inside of cabinet along with switch and MCB should be
provided. A 11A, metal clad 250V 2 pin & earth socket outlet with controlling switch
and MCB+ 30mA ELCB combination should be provided inside the cabinet.
4.5 Cable glands:
Suitably rated cable glands shall be provided at the bottom of the marshalling box to
receive purchaser's control and power cables. The number and size of cables will be
intimated afterwards. Undrilled detachable gland plate to be provided. The gland plate
shall be non-magnetic type (Aluminium 3 mm thick). Minimum distance between gland
plates to terminal strip should be 200mm.

4.6 Wiring:
4.6.1 Marshalling box shall be supplied completely wired, ready for purchaser's external
connections at the terminal blocks. All wirings shall be carried out with 650/1110 V
grade PVC insulated stranded copper conductors. Power circuits if any shall be wired
with stranded copper conductors of adequate sizes to suit the rated current. The
minimum size shall be 2.5sq.mm. Control, alarm and indication circuits, shall be wired
with stranded copper conductor of sizes not smaller than 2.5 sq.mm. CT circuits shall be
wired with stranded copper conductor of size not smaller than 2.5sq.mm. For control
alarm and indication circuits, wires shall be of different colours for easy identification.
4.6.2 Engraved core identification ferrules marked to correspond with the wiring diagram
shall be fitted at both ends of each wire. Ferrules shall fit tightly on the wires and shall
not fall off when the wire is removed. Spare auxiliary contacts of all relays etc. shall be
wired to terminal blocks using solder less crimping type of tinned lugs. Insulated
sleeves shall be provided at all the wire terminations. Wiring shall be neatly bunched
and cleated without affecting access to equipment mounted within the box. Necessary
schematic connection diagram/chart for wiring shall be pasted inside marshalling box.
4.6.3 Elemex/connectwell type terminal blocks (disconnecting type) complete with insulated
barriers, between each terminal with identification number shall be used. 650V grade
terminal blocks complete with insulated barriers, terminal studs, washers, nuts and lock
nuts and identification strips shall be used. Terminals for power connections shall be
adequately rated for the circuit current and the rating of other terminal blocks for control
indication etc. shall not be less than 16A.
4.6.4 Terminal blocks shall be numbered for identification and grouped according to function.
Terminal blocks for CT secondary leads shall be provided with short circuiting &
earthing facilities. Location of terminal blocks and clearances shall be subject to
purchaser's approval.
4.6.5 Control wiring for trip and alarm circuit shall be carried out on separate terminal blocks.
Two spare terminals shall be left blank between any two strip connections so as to keep
a minimum of 25 mm. gap.
4.6.6 The terminal block shall be covered with transparent cover & shall not be easily
accessible for shorting from the front or sides.
4.6.7 A minimum of 40% spare terminals shall be provided for control wiring.
4.6.8 All alarm and control devices shall be ungrounded.
4.6.9 A ground copper bus of 30x6mm size shall be provided on one side along the height of
the control cabinet for connection to circuits which require grounding.
5.0 FITTINGS AND ACCESSORIES :

5.1 List of fittings, accessories and meters.

All oil immersed transformers shall be provided but need not be limited to the following
fittings and accessories.
5.1.1 Inspection cover : 1 no.
5.1.2 Rating plate : 1 no.
5.1.3 Terminal marking plate : 1 no.
5.1.4 Two earthing terminals
5.1.5 Lifting lugs : As per manufacturer’s design
5.1.6 Drain valve with plug or cover plate : 1 no.
5.1.7 Top filter valve and bottom filter valve : 1 no. each
5.1.8 Oil sampling valve : 1 no.
5.1.9 De-hydrating breather : 1 no.
5.1.10 Oil filling hole and cap : 1 no.
5.1.11 Conservator : 1 no.
5.1.12 Conservator drain valve with plug : 1 no.
5.1.13 Valve between the gas and oil actuated relay and conservator : 1 no.
5.1.14 Air release device : 1 no.
5.1.15 Jacking lugs: As per manufacturer’s design
5.1.16 Explosion vent and Pressure relief valve : 1 no.
5.1.17 Magnetic oil level gauge with low level alarm contact : 1 no.
5.1.18 Plain oil level gauge with low level marking: 1 no.
5.1.19 Marshalling Box : 1 no.
5.1.20 Radiators with valves : 1 no.
5.1.21 Shut off valves on transformer tank at each point of connection : 1 no. each
5.1.22 Top & bottom shut off valve on each radiator : 1 no. each
5.1.23 Equaliser pipes: As per manufacturer’s design
5.1.24 HT & LT disconnecting chambers – 1 no. each
5.1.25 Bidirectional roller as per manufacturer’s design
5.1.26 Air cell for conservator shall be provided – 1 no.
5.1.27 Additional Pt100 temperature sensor for sensing oil temperature along with
conventional OTI – 1 no.

5.1.28 Dial type thermometer: All transformers shall be provided with a 150mm diameter
dial type thermometer for top oil temperature indication. The thermometer shall have
adjustable, electrically independent ungrounded alarm and trip contacts, maximum
reading pointer & resetting device. This shall be housed in marshalling box.

5.1.29 Winding Temperature Indication:

Winding temperature indicator of 150mm dia with adjustable ungrounded electrically
independent alarm & trip contacts shall be provided. The winding temperature
indicator shall be responsive to & shall indicate the hot spot temperature of the
winding.
 Temperature detecting equipment shall consist of a heating coil, a resistance coil and a
current transformer all wired and mounted inside the transformer tank. Two number of
additional contacts shall also be provided.

5.1.30 Gas and oil actuated relay (buchholz relay):

(a) A double float type buchholz relay and as per IS:3637 shall be provided on each
transformer. All gas evolved in the transformer shall collect in this relay. The relay
shall be provided with a test cock suitable for a flexible pipe connection for checking its
operation. A copper tube shall be connected from the gas collector to a valve located
about 1.25M above ground level to facilitate sampling with the transformer in service.
The device shall be provided with two electrically independent ungrounded contacts,
one for alarm on gas accumulation and the other for tripping on sudden rise of pressure.

5.1.31 Explosion vent with diaphragm/pressure relief valve:

Explosion vent with diaphragm shall be mounted along with equalising pipe between
conservator and explosion vent. Not required in case pressure relief valve is used.

5.1.32 Extra thermometer pocket.

One extra thermometer pocket shall be provided with cap.

5.2 The following valves and accessories shall be provided. These have been already
covered under different paragraphs.

a) Conservator drain valve with plug - 1 no

b) One valve between the gas and oil actuated relay and the conservator.
c) One top filter valve with blanking plate.
d) One bottom filter valve with blanking plate.
e) One oil sampling valve with plug.
f) One oil drain valve with plug.
g) Radiator valves (shut off valves on transformer tank and on each radiator)
h) Equalising pipe isolating valves for each equalising pipe.
i) Valve for fire prevention.
a) Manual gate valve at about 120mm below the top cover for oil drain : 1 no.
b) Gate valve on tank side for Nitrogen injection : 1 no.
c) Gate valve on pipe between consumption tank and buchholz relay for fixing
PNRV : 1 no.
d) Pressure relief valve with limit switch : 1 no.

Note: Quantities of all accessories/fittings mentioned above shall also be as per standard
manufacturer’s design.

Note: Graphite or other (conducting) material that could be injurious to oil shall not be
used in valve stem packing.
5.3 LOCATION OF FITTINGS/TERMINALS:
The relative positions of fittings and terminals shall be approved by the purchaser.

5.4 UNDER CARRIAGE:

The transformer shall be equipped with four sets of bi- directional plain type rollers.
The wheels shall be provided with proper locking arrangement to facilitate the locking
of transformer in its final position to prevent accidental movement of the unit.

5.5 Ladder:
Suitable G.I. ladder shall be provided.

6.0 TESTS:
The transformer shall be demonstrated capable of performing satisfactorily. The
transformer shall be offered for inspection at various stages of manufacture apart from
the final inspection and testing of the transformer. Certain tests during the stage
inspection as indicated below in 6.2 shall be conducted. During the final stage
inspection the firm shall offer transformer for all routine and type tests as indicated
below. All the routine and type tests are indicated below, including repeated tests and
inspection that may be necessary owing to the failure to meet the tests specified. The
bidder shall quote accordingly. If transformer fails to pass the tests specified, purchaser
shall have option to reject the unit.

6.1 Stage Inspection :

Transformer shall be offered for inspection at following stages during manufacturing –

a) Visual inspection for tank/ cable end boxes, inspection boxes, marshalling box etc.
after fabrication but before shot blasting, chamber for chemical treatment vacuum
test on tank with a vacuum of 760 mm of Hg.
b) Preliminary core loss measurement and core insulation test on core assembly
before tanking including flux density calculation. Physical check for winding coils
for dimensions of conductor & area and current density verification.
c) Pressure test and vacuum test on transformer tank before sand blasting and
painting.

6.2 Final Inspection:

Final inspection as per following points 6.3 to 6.7 at manufacturer’s works.

6.3 Routine tests :

Before transportation, the transformer shall be subjected to routine factory tests (as per
IS 2026).
a) Ratio on each tapping, polarity, angular displacement and phase displacement.
 b) No load current and no load losses, at rated voltage & higher system voltage (+
10%).
c) Load losses.
d) Impedance voltage (to be measured at all tappings).
e) Resistance of windings at principal and all tappings.
f) Insulation resistance.
g) Induced over-voltage withstand (induced potential).
h) Separate source voltage withstand (applied potential).
i) Polarisation index.
j) Vector group test.
k) Magnetic balance test.

6.4 Type test: .

6.4.1 Temperature rise test on one transformer only. The transformer for testing will be decided
by the purchaser. DGA before and after the temperature rise test shall be carried out.

6.4.2 Impulse Voltage withstand test on one transformer only. The transformer for testing will
be decided by the purchaser

6.5 Special tests:

6.5.1 Zero sequence Impedance Measurement.

6.5.2 Insulation power factor and capacitance for each winding and between windings.

6.5.3 Measurement of Acoustic Noise Level.

6.5.4 Sweep Frequency Response Analysis (SFRA) test

6.6 Supplementary tests:

6.6.1 High voltage withstand test on auxiliary wiring at 2 kV for one minute.

6.6.2 Oil pressure test:

Oil pressure test shall be carried out at 0.35 Kg/cm2 above maximum operating oil
pressure, preferably under hot oil condition. The pressure shall be maintained for 12
hours to detect possible leakages.

6.6.3 No load losses and exciting current shall be measured both at rated voltage, rated
frequency and at 110% voltage.

6.6.4 DGA on oil.

6.7 Tests on associated equipments:

 All associated equipments like winding temperature indicating devices, dial type
thermometers, buchholz relays, OFF LOAD tap changing gears, insulating oil cable
boxes, bushings, neutral CT (if any) etc. covered in the offer shall be tested in
accordance with relevant Indian Standards or other accepted standards.
6.8 All tests shall be performed in the presence of purchaser's representative. The supplier
shall give 15 days advance notice of readiness for inspection of components, parts
and/or before final assembly and tests so that purchaser's representative may witness
such final and acceptance tests before shipment.
6.9 Tests shall be conducted in accordance with Indian Standards in effect at the time of
testing.

7.0 LOSSES: (Energy efficient Transformer, level 3)

7.1 The bidder shall guarantee individually the no-load loss and load loss without any
positive tolerance. The bidder shall also guarantee the total losses at 50% and 100%
load condition (at rated voltage and frequency and at 75 degC).

At 50% Load : Not more than 5900 W

At 100% Load : Not more than 17500 W

No positive tolerance shall be allowed on the maximum losses displayed on the label
for both 50% and 100% loading values.

8.0 SPARES:

Following spares shall be part of the scope of this item. Bidder shall quote
accordingly:

8.1 Complete set of gaskets.

8.2 One set of bushing with metal parts of each type.
8.3 Dial type thermometer.
8.4 Plain oil level gauge.
8.5 Winding temperature indicating equipment.
8.6 Explosion vent diaphragm. (if required)
8.7 Silica gel breather container with silica gel.
8.8 One valve of each type.
8.9 Buchholz relay.
8.10 Magnetic oil level gauge.

INCLUSIONS: The following items shall be deemed to be included in the bidder’s

scope of supply.

Interconnecting cables and cable accessories for connections between the marshalling
box and all electrical measuring, monitoring and protective device mounted on
 transformer. For this purpose stranded copper conductor FRLS PVC insulated and
armoured cables shall be used.
9.1 Glands for control and power cables.
9.2 5 litre of paint for touching up the external surfaces
9.3 The manufacturer shall furnish 4 sets of all test certificates to the department.
9.4 Instruction manuals and as built drawings, Six sets of instruction manuals and as built
drawings shall be submitted to the department. Re-producible & CD of as built
drawings also shall be submitted.
9.5 The supplier shall furnish all the guaranteed particulars as detailed in Part VI.
9.6 The bidder shall furnish full address of their customers list for 2.5 MVA and higher
rated capacity transformers along with their purchase order nos. and name of concerned
engineers.

10.0 Q.A.P: Quality assurance plan shall be submitted for approval and shall be in line with
the attached QAP.

11.0 Evaluation of manufacturer’s works:- The works of the firm shall be visited by
department engineers & evaluation of the firm & their approval subject to the
followings.

11.1 The firm shall have ISO Certification for design & manufacturing.
11.2 The firm shall have either in house core cutting facility or a dedicated vendor for core
cutting approved by the department.
11.3 The firm shall have in house testing facility for testing all raw materials used for
manufacturing of transformers.
11.4 The firm shall have in house winding shop with dust free environment.
11.5 The firm shall have all facilities for routine testing of transformers including heat run
test & special tests.
11.6 The evaluation of the firm shall be for process of manufacturing of transformer in
reasonably dust free environment & also general cleanness. The firm should have
separate design department, quality control, production & testing department.

TECHNICAL DATA TO BE SUPPLIED WITH TENDER

Technical particulars, mentioned below, for each transformer operating at site

conditions outlined in Technical Specification of this tender document, shall be
submitted:

TRANSFORMER

1. Name of manufacturer,
place of :
manufacture and tests offered
full address.
2. Manufacturer's type :
3. Type of construction :
4. Standard according to which :
transformer is to be manufact-
ured and guarantee figures
are given.
5. Type of cooling. :
6. Rated kVA :
7. Rated Voltage.
i. HV :
ii. LV :
8. Rated current.
i. HV :
ii. LV :
11. Rated frequency :
11. Permissible variations
i Voltage :
ii Frequency :
11. Ratio of transformation on :
principal tap.
12. Number of phases :
13. Connections.
i. HV :
ii. LV :
14. Vector group reference :
15. Tapping.
i. Range. :
ii. No. of steps. :
iii.For HV variation/LV variation :

16. Losses
16.1 Guaranteed no-load losses :
on principal tapping
at rated voltage and
rated frequency.
16.2 No-load losses at 111% rated :
voltage and rated frequency.
16.3 Guaranteed load losses at :
principal tapping, rated
current rated voltage and
rated frequency at 75 °C.
16.4 Tolerance on losses. :
16.5 Total losses at normal :
ratio, rated output, rated
voltage, rated frequency and
maximum attainable temp.at site.
17. Percentage impedance at :
rated current and frequency for
 the principal tapping at 75°C.
18. Percentage reactance at :
rated current and frequency.
111. Percentage resistance :
voltage drop at 75°C.
20. No-load current.
i. At rated voltage & rated :
frequency.
ii. At 111% of rated voltage :
& rated frequency.
21. Overload capacity- Short :
time withstand for 150%
with transformer loaded
fully at maximum yearly
weighted average temper-
-ature of 35°C
22. Thermal time constant. :
23. Installation (Indoor/Outdoor) :
24. Temperature rise
i. Top Oil :
ii. Winding :
25. Efficiencies at rated
Voltage rated frequency
and at 75° at UPF.
i. Full load :
ii. 3/4 full load :
iii.1/2 full load :
iv. 1/4 full load :
26. Efficiencies at rated
Voltage rated frequency and at
75° at 0.8 PF lag.
i. Full load :
ii. 3/4 full load :
iii.1/2 full load :
iv. 1/4 full load :
27. Percentage regulation at
full load and 75 °C.
a) Unity power factor :
b) 0.8 power factor lag :
28. Percentage regulation at 50% :
full load at 75 ° C.
a) Unity power factor. :
b) 0.8 power factor lag. :
211. Current density (A/cm2).
i. HV winding. :
ii. LV winding. :
30. Conductor area (mm2)
i. HV winding. :
ii. LV winding. :
31. Highest system voltage for
which transformer windings are
suitable.
i. HV winding. :
ii. LV winding. :
32. Type of winding.
i. HV :
ii. LV :
33. Maximum flux density
i. at rated voltage :
ii. at 111% rated voltage :
34. Lamination details
i. Lamination Thickness
ii. Specific watt loss @1.7T (Watts/Kg)
35. Insulation level
i. Separate source power :
frequency voltage withstand
for HV winding-kV rms
ii. Induced over voltage :
withstand
a. HV winding-kV rms :
b. LV winding-kV rms :
c. Full wave lightning impulse :
withstand voltage for
HV winding - kV peak
36. Polarisation Index :
37. Noise level :
38. Sheet metal treatment and
painting procedure
i. Internal :
ii. External :
311. Maximum operating oil :
pressure (Kg./cm2)
40. Weight of transformer
i. Core and windings (Kg.) :
ii. Oil (Kg.) :
iii.Tank, coolers & fittings(Kg.) :
iv. Total (Kg.) :
INFORMATION TO BE FURNISHED BY THE SUPPLIER AFTER AWARD OF
CONTRACT
The firm shall furnish the following after the award of contract.

1. Drawing
The following shall be submitted for purchaser’s approval within 4weeks of receipt
of the purchase order/letter of intent.
1.1 General outline drawing as submitted at the bidding stage but with binding
dimensions and other details.
1.2 General outline drawings showing plan, front elevation and elevation inner view,
locating dimensions of cable entries, earthing terminals, foundation/floor fixing
details and weights and indicating all the fittings and accessories.
1.2.1 Marshalling box-GA drawings along with all the components layout.
1.2.2 Cable boxes.
1.2.3. Disconnecting chambers.
1.3 Bushings, Plan, elevation, terminal details, mounting details, make and type number,
current and voltage rating, creep age distances and principal characteristics of all
bushings used.
1.4 Rating and diagram plate.
1.5 Marshalling box terminal connections and wiring diagram.
1.6 On load tap changing gear - GA drawings & wiring diagram, components details
drawings for OLTC & RTCC control.
2. List of routine tests to be carried out.
3. Guaranteed vacuum withstand capability of transformer with radiator and other
fittings present during oil filling.
4. Special design features adopted to counter seismic acceleration of 0.2g.
5. Special methods adopted to support radiators on tank such that leaking at flange(
Due to weight of radiator acting on the flanges )is eliminated.
6. Guaranteed vacuum withstand capability of transformer with radiator and other
fittings present during oil filling.

Preferred makes of material: If bidder offer other makes, they are subject to our approval.

1 Buchholz relay M/s Prayog

2 Magnetic Oil Gauge M/s Sukrut.
3 Transformer Oil M/s Apar Pvt. Ltd/M/s Savita (EHV Grade)
4 Radiators M/s CTR/Hitech.
5 Bushing 11 kV/3.3kV M/s WS insulators/CJI/JP/Jayshree
6 WTI/OTI M/s Perfect Controls.
7 Breather M/s Valplex
8 Valves M/s Leader/Elems.
11 Radiator valves M/s Patson/Yogi/BIMAL.
11 Tap switch M/s Paragon
11 Gasket M/s Talbros or other subject to approval.
12 Varnish Dr. Beck
13 Paint M/s Sigma/Berger/Asian
14 Marshalling box
a) Indicating lamp assembly Siemens/ L&T/ Teknic.
b) Selector switches(non cam) Kaycee / Siemens / L&T
c) Push buttons Siemens/L & T
d) Digital voltmeter MECO/ AE
e) Thermostat/space heater Concord/Girish
f) MPCB Siemens / L&T/Schneider
g) Auxi. contactor Siemens / L&T/Schneider (Telemechanique)
h) Control terminal Elmex / Connectwell
i) PVC wire (copper cond.) Finolex/Lapp/Polycab(Daman)/R.R./Uniflex
j) Digital tap indicator. Subject to purchaser’s approval.
k) Bell Target
l) Fuse & fuse fittings GEC/Siemens/L&T
m) MCB Legrand/Siemens/Schneider/L&T

Note: 1) Other makes subject to purchaser's approval.

2) The sheet metal treatment and subsequent painting shall be as per specification.
3) 20% spare terminal in marshalling box shall be provided.
 PART II

SCOPE OF DOCUMENT:- Specific specification for design, fabrication/ manufacturing, inspection, testing and delivery of "2500 kVA,
11kV/433 V Oil filled Transformer" (Energy efficient transformer , level 3)

Note:
1. Bidders have to write full specification offered by them or noted by them. Simply writing the term Noted/ Agreed is discouraged. On such
instances bidders would be asked to submit the document again with full specification, which may cause delay in opening of Part B or even
rejection of technical offer as deemed fit by competent authority.
2. Makes other than indicated below are subject to approval by BARC
3. General specifications and attached QAP shall be followed.

S. No. Parameters Specified by BARC Specification offered by bidder

1 General
1.1 Preferred make Crompton Greaves Ltd, Mumbai/ Areva,
Vadodara/ ABB, Vadodara/ Voltamp,
Vadodara
1.2 Application Distribution transformer
1.3 Type Oil filled, Core Type (2 Winding), Mineral
oil insulating liquid (Energy efficient
1.4 Installation transformer)
Outdoor
1.5 Units Single unit

1.6 Site
1.6.1 Climatic condition Near to sea coast. Atmosphere is laden with
salty spray. Climate is tropical with high
humidity. Annual rainfall is 2000 mm
1.6.2 Maximum ambient temp 45 degC
1.6.3 Humidity (RH) 95% at 45 degC

1.7 Applicable standard IS 2026, IS 1180, IEC 726

2 Rating & performance requirement

2.1 Rated Output 2500 kVA
2.2 No. of Phases Three Phases
2.3 Voltage Ratio 11 kV/433V
2.4 Connection 11 kV - Delta, 433V - Star
2.5 Frequency 50 Hz
2.6 Type of cooling ONAN
2.7 Vector Group Dyn11
2.8 Percentage impedance 6.25%

2.9 Performance requirement

2.9.1 Voltage variation (Primary side) Suitable for voltage variation +5%, -15%
2.9.2 Frequency Suitable for frequency variation +/-5%
2.9.3 Audible sound levels at rated voltage and 62 decibels
frequency
2.9.4 Short circuit withstand capability duration 2 second
2.9.5 Temperature rise limit Not to exceed as per IS 2026/IEC 726

2.10 Auxiliary supply available at site

2.10.1 A.C. supply 240 V, +/- 6% single phase /415V, +/- 6%
Three phase
2.10.2 DC supply 110V, +/- 10%

3 System Voltage
3.1 Nominal Voltage
3.1.1 HV (Primary) 11 kV
3.1.2 LV (Secondary) 415V
3.2 Highest System Voltage
3.2.1 HV 12 kV
3.2.2 LV 460 V

4 Fault Level
4.1 Fault level on HV side 26.2 kA

5 System Neutral Earthing

5.1 HV Effectively earthed
5.2 LV Effectively earthed

6 Core
6.1 Material & Minimum grade of core CRGO annealed steel laminations, M4
grade or better

7 Winding & Insulation

7.1 Winding material HV and LV windings wound from super
enamel covered / Double paper covered
copper conductor/foil winding

7.2 Winding insulation

7.2.1 Material Electrical grade insulation epoxy dotted
Kraft Paper/Nomex and pressboard of
standard make or any other superior
material subject to approval of the
purchaser

7.3 Method of insulation

7.3.1 HV Uniformly insulated
7.3.2 LV Uniformly insulated

7.4 Current density of conductor Not more than 2.8 A/mm2 for copper and
1.6 A/mm2 for aluminium

8 OFF load tap changer

8.1 Tapping on winding HV
8.2 Type of tapping OFF Load. Tap changing shall be carried
out by means of an externally operated self
position switch and when the transformer is
in de-energised condition. Switch position
No.1 shall correspond to the maximum plus
tapping. Provision shall be made for locking
the tapping switch handle in position.
Suitable aluminium anodised plate shall be
fixed for tap changing switch to know the
position number of tap.

8.3 Tapping range ( % ) -5% to + 5%

8.4 Tapping step ( % ) 2.50%
 9 Oil The insulating oil shall comply with the
requirements of IS 335 or BS 148. Use of
recycled oil is not acceptable. The specific
resistance of the oil shall not be less than
2.5 x10^12 ohm-cm at 27 degC when tested
as per IS 6103. Oil shall be filtered and
tested for break down voltage (BDV) and
moisture content before filling. The oil
shall be filled under vacuum. The design
and all materials and processes used in the
manufacture of the transformer, shall be
such as to reduce to a minimum the risk of
the development of acidity in the oil.

10 Insulation levels
10.1 Lightning Impulse voltage
( 1.2/50 Microsecond wave)
10.1.1 HV 95 kVp
10.1.2 LV -

10.2 Power frequency withstand voltage

10.2.1 HV 28kV (RMS)
10.2.2 LV 3 kV (RMS)

11 Temperature rise
11.1 Top oil temperature rise measured by 40 degC
thermometer
11.2 Winding temperature rise measured by 45 degC
resistance method
 12 Percentage Impedance
12.1 Percentage impedance at 75 degC 6.25%

13 Main Tank As per general specs

14 Conservator As per general specs

15 Painting
15.1 Colour shade of final painting Shade 631 of IS5

16 Terminal bushings
16.1 HV
16.1.1 Type of bushing Porcelain bushing
16.1.2 Rated voltage kV 17.5 kV
16.1.3 Current rating 630 A
16.1.4 Impulse withstand voltage kV peak 95 kV (Peak)
(1.2/50 Micro Sec. wave)
16.1.5 Power frequency withstand voltage kV 38 kV (RMS)
16.1.6 Creepage distance 300 mm (Min.)
16.1.7 STC rating 26.2 kA for 2 sec
16.1.8 Minimum clearance in air
16.1.8.1 Phase to phase mm As per IS
16.1.8.2 Phase to earth mm As per IS

16.2 LV
16.2.1 Type of bushing Porcelain/Epoxy
16.2.2 Rated voltage kV 3.6 kV
16.2.3 Current rating 5000 A
16.2.4 Impulse withstand voltage kV peak -
(1.2/50 Micro Sec. wave)
16.2.5 Power frequency withstand voltage kV 5 kV (RMS)
16.2.6 Creepage distance 100 mm (Min)
16.2.7 Minimum clearance in air
16.2.7.1 Phase to phase mm As per IS
16.2.7.2 Phase to earth mm As per IS

16.3 Neutral
16.3.1 Type of bushing Porcelain
16.3.2 Rated voltage kV 3.6 kV
16.3.3 Current rating 4000 A
16.3.4 Impulse withstand voltage kV peak -
(1.2/50 Micro Sec. wave)
16.3.5 Power frequency withstand voltage kV 5 kV (RMS)
16.3.6 Creepage distance 100 mm (Min)
16.3.7 Minimum clearance in air
16.3.7.1 Phase to phase mm As per IS
16.3.7.2 Phase to earth mm As per IS

17 LV.-n C.T. details (For REF)

17.1 Ratio 4000/5 A
17.2 Burden 15 VA
17.3 Class PS
17.4 Knee Point voltage -
17.5 Iext < 30 mA at Vk/2
17.6 Resistance of secondary winding 1 ohm
 18 Terminal details
18.1 HV Bushing shall be provided suitable for
terminating 1 No. 3C x 400 sq.mm XLPE
Al. conductor cable in a cable box. Oil filled
disconnecting chamber on 11 kV side to
facilitate testing of transformer without
disconnecting the cable. The disconnecting
chamber shall have oil filling plug, drain
plug, equalising pipe etc.
18.2 LV Epoxy type suitable for bus duct connection
with flexible copper termination
18.3 LV Neutral Suitable for bare outdoor 3.6 kV
porcelain bushing terminal suitable for
termination of 2 nos. 50x6 mm copper
strip/flat

19 Cable box
19.1 HV Air insulated with oil filled disconnecting
chamber suitable for terminating 1 No. 3C
x 400 sq.mm XLPE Al. conductor cable.
Oil filled disconnecting chamber on 11 kV
side to facilitate testing of transformer
without disconnecting the cable. The
disconnecting chamber shall have oil filling
plug, drain plug, equalising pipe etc.
19.2 LV Air insulated suitable for bus duct
termination

20 Fittings
20.1 Inspection cover To be provided
20.2 Rating plate To be provided
20.3 Terminal marking plate To be provided
20.4 Two earthing terminals To be provided
20.5 Lifting lugs To be provided
20.6 Drain valve with blanking plate To be provided
20.7 Silica Gel breather To be provided
20.8 Thermometer pocket To be provided
20.9 Oil filling hole with cover To be provided
20.10 Conservator with detachable end plates To be provided
and drain valve
20.11 Conservator filling holes To be provided
20.12 Air cell in conservator To be provided
20.13 Air release plug To be provided
20.14 Jacking pads To be provided
20.15 Top & bottom filter valves To be provided
20.16 Rollers Bidirectional plain rollers
20.17 Oil temperature indicator 150 mm, Dial type with contacts
20.18 WTI CT To be provided
20.19 Winding temperature indicator 150mm , Dial type with contacts
20.20 Pressure release device with trip contact To be provided
20.21 Double float Buchholz relay with alarm To be provided
& trip contacts and gas sampling device
20.22 Magnetic oil level gauge for main To be provided, Dial type with contacts
conservator
20.23 Plain oil level gauge for main conservator To be provided
20.25 Top & bottom oil sampling valves To be provided
20.26 Wheels Flanged Bi-directional

20.27 Radiator
20.27.1 Type Detachable type with drain & air release
plugs, bolted flange connection and
isolating valves (Top, Bottom).
20.27.2 Sheet thickness 1.2mm (min.)
20.27.3 Material Commercial grade low carbon steel.
20.28 Radiator valves To be provided
20.31 HT cable box with oil filled disconnecting To be provided
chamber
20.32 LT cable box with air filled disconnecting To be provided
chamber
20.33 HT and LT cable box supports To be provided
20.34 Shut off valve on both sides of Buccholz To be provided
relay
20.35 NCT terminal box To be provided
20.37 Weather proof marshalling box (housing To be provided
devices like WTI, OTI, terminal block,
wiring etc. )
20.37.1 Material 2 mm thick sheet steel
20.37.2 Painting Epoxy based powder coating after seven
tank treatment
20.37.3 Wiring FRLS grade PVC insulated stranded copper
conductor wires
20.37.4 Terminals Screw type elmex connectors suitable for
10A current. 20% extra terminal to be
provided.
20.38 LV Neutral earthing bar To be provided
20.39 Pocket for WTI To be provided
20.40 Pocket for OTI To be provided
20.41 Tapping switch handle with position To be provided
indicator & locking device in OFF load tap
changer
20.43 OFF load tap changer To be provided
20.44 Explosion vent diaphragm To be provided
20.45 Additional Pt100 temperature sensor for To be provided
sensing oil temperature along with
conventional OTI.

21 Gasket
21.1 Cork sheet
21.1.1 Thickness As per manufacturer

21.2 Neoprene
21.2.1 Thickness As per manufacturer

22 Losses (Energy efficient transformer,

level 3)
22.1 At 50% Load (No positive tolerance) 5900 W
22.2 At 100% Load (No positive tolerance) 17500 W

23 Inspection (stage and final) & Testing As per approved QAP in line with the
attached QAP and general specifications

24 Spares
24.1 Complete set of gaskets 1 set
24.2 HT Bushing with metal parts 3 Nos
24.3 LT Bushing with metal parts 3 Nos
24.4 Neutral bushing 2 Nos
24.5 Dial type thermometer 1 set
24.6 Oil level gauge 1 set
24.7 Winding temperature indicator 1 set
24.8 Explosion vent diaphragm 1 set
24.9 Silica gel breather container 1 set
24.10 One valve of each type 1 set
24.11 Buchholz relay 1 No.
24.12 Pressure release device 1 No.
Document Name : QAP for Oil-filled Transformer (11KV/433 V ONAN)

NOTES
A) This document indicates the requirements expected from the prime contractor for the below equipment.
Subsequent to the placement of purchaser order contractor shall submit a quality assurance plan in line
with this document for the approval of BARC.
B) Abbreviations:
V : Verification of test report By
P : Performed By
W : Witnessed By ( After lapse of due notice to BARC, manufacturing may be proceeded)
H : Hold (Unless a written clearance is obtained from BARC, manufacturing shall not be proceeded to next stage
1: BARC or its authorised representative
2: Prime contractor on whom BARC have placed the work order
3: BARC approved sub-contractor/Original equipment manufacturer and their vendor
AD : BARC approved documents (such as tender specifications, tender drawings)
TC : Test certificate/report
FR: Field Report
PS : Original equipment manufacturer's standard approved by BARC based on relevant standards
IS : Indian Standard
IEC : International Electrotechnical Commission
SS : Swedish Standards
ASTM : American Standards for testing materials
IEEE : Institute of Electronics and electrical engineers standards

Page 1 of 29
Document Name : QAP for Oil-filled Transformer (11KV/433 V ONAN)

Sl. No Components/Character Method of Extent of Reference Acceptanc Forma Remarks

istics checked check check document e norm t of AGENCY
record
P V W H

1 RAW MATERIALS .
1.1 Continuously
transposed copper
conductor
1.1.1 Dimensions and visual Measurement Sampling IS 13730 IS 13730 TC 3 1,2 All test
check /PS /PS certificates for
each lot /supply
shall be
submitted to
1.1.2 Tensile strength and Mechanical Sampling IS 13730 IS 13730 TC 3 1,2 BARC
elongation, proof stress /PS /PS
1.1.3 Electrical Elect. Sampling IS 13730 IS 13730 TC 3 1,2
Resistivity/conductivity, /PS /PS
breakdown voltage on
enamelled conductor
1.1.4 Conductor finish Visual Sampling IS 13730 IS 13730 TC 3 1,2
/PS /PS
1.1.5 Chemical analysis Chemical Sampling IS 13730 IS 13730 TC 3 1,2
/PS /PS
1.1.6 Insulation test between Elect. Sampling IS 13730 IS 13730 TC 3 1,2
strands on finished /PS /PS
conductor.
1.1.7 Enamel thickness Measurement Sampling IS 13730 IS 13730 TC 3 1,2
/PS /PS

Page 2 of 29
Document Name : QAP for Oil-filled Transformer (11KV/433 V ONAN)

Sl. No Components/Character Method of Extent of Reference Acceptanc Forma Remarks

istics checked check check document e norm t of AGENCY
record
P V W H

1.1.8 Verification that there is Verification Certificatio IS 13730 IS 13730 TC 3 1,2

no joint within HV & LV of Records n by /PS /PS
Drum. supplier.
1.1.9 Bonding of paper to Visual Inprocess IS 13730 IS 13730 TC 3 1,2
conductor, flexibility and check. /PS /PS
adherence of enamel
covering

1.2 Insulating paper

1.2.1 pH value of paper, Chemical One Sample IS 8504/IS IS 8504/IS TC 3 1,2
density, moisture content from each 11182 11182
consignmen
t
1.2.2 Electric strength of paper Elect. One Sample IS 8504/IS IS 8504/IS TC 3 1,2
in air, conductivity from each 11182 11182
consignmen
t
1.2.3 Tensile / Bursting Mechanical One Sample IS 8504/IS IS 8504/IS TC 3 1,2
strength of paper from each 11182 11182
consignmen
t
1.2.4 Thickness of paper Measurement One Sample IS 8504/IS IS 8504/IS TC 3 1,2
from each 11182 11182
consignmen
t

Page 3 of 29
Document Name : QAP for Oil-filled Transformer (11KV/433 V ONAN)

Sl. No Components/Character Method of Extent of Reference Acceptanc Forma Remarks

istics checked check check document e norm t of AGENCY
record
P V W H

1.2.5 Reaction of hot oil and Test One Sample IS 8504/IS IS 8504/IS TC 3 1,2
paper from each 11182 11182
consignmen
t
1.2.6 Ageing test on paper Chemical Random IS 8504/IS IS 8504/IS TC 3 1,2
11182 11182

1.2.7 Physical condition and Visual In process IS 8504/IS IS 8504/IS TC 3 1,2

cleanliness check 11182 11182

1.2.8 pH of Aquesious extract Elect. Random IS 8504/IS IS 8504/IS TC 3 1,2

11182 11182

1.2.9 Water absorption, air Chemical Random IS 8504/IS IS 8504/IS TC 3 1,2

permeability, ash content 11182 11182

1.3 Paper covered copper

conductor
1.3.1 Dimension and visual Measurement Each drum IS 13730 IS 13730 TC 3 1,2
check (part III) (part III)
1.3.2 Tensile strength & Mechanical One Sample IS 13730 IS 13730 TC 3 1,2
elongation and proof from each (part III) (part III)
stress consignmen
t

Page 4 of 29
Document Name : QAP for Oil-filled Transformer (11KV/433 V ONAN)

Sl. No Components/Character Method of Extent of Reference Acceptanc Forma Remarks

istics checked check check document e norm t of AGENCY
record
P V W H

1.3.3 Electrical conductivity Elect. One Sample IS 13730 IS 13730 TC 3 1,2

and resistance, from each (part III) (part III)
breakdown voltage on consignmen
enamelled conductor, t
insulation test on
bunched conductor
1.3.4 Conductor finish Visual Each drum IS 13730 IS 13730 TC 3 1,2
(part III) (part III)
1.3.5 Chemical analysis / Chemical One Sample IS 13730 IS 13730 TC 3 1,2
composition from each (part III) (part III)
lot

1.3.6 Bonding of paper to Visual Inprocess IS 13730 IS 13730 TC 3 1,2

conductor, flexibility and check (part III) (part III)
adherence of enamel
covering

1.4 Insulation spacers,

press board cylinders,
and insulating supports

1.4.1 Dimension and visual Measurement One Sample PS/IS PS/IS TC 3 1,2
control from each 11182 11182
consignmen
t

Page 5 of 29
Document Name : QAP for Oil-filled Transformer (11KV/433 V ONAN)

Sl. No Components/Character Method of Extent of Reference Acceptanc Forma Remarks

istics checked check check document e norm t of AGENCY
record
P V W H

1.4.2 Tensile strength, Mechanical One Sample PS/IS PS/IS TC 3 1,2

elongation and oil from each 11182 11182
absorption consignmen
t

1.4.3 Physical condition and Visual 100% PS/IS PS/IS TC 3 1,2

cleanliness 11182 11182
1.4.4 Electrical strength in oil Elect. One Sample PS/IS PS/IS TC 3 1,2
from each 11182 11182
consignmen
t

1.4.5 Density, thickness, Mechanical One Sample PS/IS PS/IS TC 3 1,2

moisture from each 11182 11182
content,Cohesion consignmen
between plies, t
compressibility, chemical
properties, pH value,
conductivity, shrinkage
1.4.6 Reaction with hot oil Chemical One Sample PS/IS PS/IS TC 3 1,2
from each 11182 11182
consignmen
t

Page 6 of 29
Document Name : QAP for Oil-filled Transformer (11KV/433 V ONAN)

Sl. No Components/Character Method of Extent of Reference Acceptanc Forma Remarks

istics checked check check document e norm t of AGENCY
record
P V W H

1.5 CRGO (HI-B- Laser

Etched) Silicon sheet
steel laminations
1.5.1 Specific loss before and Elect. One Sample IS /PS IS /PS TC 3 1,2
after ageing test from each
consignmen
t
1.5.2 Stacking factor Measurement Random IS /PS IS /PS TC 3 1,2
1.5.3 Magnetizing Elect. Critical IS /PS IS /PS TC 3 1,2
characteristics/ Induction
at 800 A/m
1.5.4 Ductility Elect. Random IS /PS IS /PS TC 3 1,2
1.5.5 Grade of steel & Measurement Random IS /PS IS /PS TC 3 1,2
Thickness
1.5.6 Ageing test Chemical Type test IS /PS IS /PS TC 3 1,2
1.5.7 Chemical analysis Chemical Random IS /PS IS /PS TC 3 1,2
1.5.8 Edge burr & Waviness Measurement Random IS /PS IS /PS TC 3 1,2
1.5.9 Insulation resistivity Elect. Random IS/PS IS/PS TC 3 1,2
1.5.10 Dimensions of Measurement Random IS /PS IS /PS TC 3 1,2
laminations during
setting of
shearing of
each size of
laminations

Page 7 of 29
Document Name : QAP for Oil-filled Transformer (11KV/433 V ONAN)

Sl. No Components/Character Method of Extent of Reference Acceptanc Forma Remarks

istics checked check check document e norm t of AGENCY
record
P V W H

1.6 Mild steel plates and

sections
1.6.1 Chemical and Chemical 100% IS /PS IS /PS TC 3 1,2
mechanical properties
(Tensile strength and
percentage elongation)
1.6.2 Dimensions Measurement 100% IS /PS IS /PS TC 3 1,2
1.6.3 Identification of certified Chemical 100% IS /PS IS /PS TC 3 1,2
raw materials

1.7 Welding requirements

1.7.1 Welding procedure & Mechanical 100% IS /PS IS /PS TC 3 1,2
welder's qualification
1.7.2 Mechanical and Mechanical/ 100% IS /PS IS /PS TC 3 1,2
Chemical properties of Chemical
electrodes
1.7.3 Visual checks on weld Visual 100% IS /PS IS /PS TC 3 1,2
properties and welds

1.8 Gaskets ( As per IS-

4253)
1.8.1 Visual (Shall be smooth Visual 100% IS/PS IS /PS TC 3 1,2
and free from all harmful
defects)

Page 8 of 29
Document Name : QAP for Oil-filled Transformer (11KV/433 V ONAN)

Sl. No Components/Character Method of Extent of Reference Acceptanc Forma Remarks

istics checked check check document e norm t of AGENCY
record
P V W H

1.8.2 Specific gravity, Chemical Type test IS /PS IS /PS TC 3 1,2

Thickness, Hardness, /Physical
Compressibility at 28Kg/
Sq.cm & 60Kg/Sq.Cm,
recovery at 28 and 60
Kg/Sq.Cm, tensile
strength before oil
absorption, compression
set and flexibility.
1.8.3 Change in acidity after Test Type Test IS / PS IS / PS TC 3 1,2
ageing in transformer oil

1.9 Polyster resin

impregnated weft less
unidirectional glass
1.9.1 tape
Width, thickness and Measurement One Sample IS /PS IS /PS TC 3 1,2
length of Roll from each
consignmen
t

Page 9 of 29
Document Name : QAP for Oil-filled Transformer (11KV/433 V ONAN)

Sl. No Components/Character Method of Extent of Reference Acceptanc Forma Remarks

istics checked check check document e norm t of AGENCY
record
P V W H

1.9.2 Tensile strength, Mechanical One Sample IS /PS IS /PS TC 3 1,2

Polyester resin content, from each
sealing solder test, warp consignmen
yarn,softnening point of t
resin,breaking load at
room temperature,
elongation at break at 20
deg C and arc resistance
of cured tape.
1.9.3 Shelf life Chemical each roll IS /PS IS /PS TC 3 1,2

2 Components
2.1 Gas operated relay
(Reed type with
magnetic operated
2.1.1 switches)
Pressure withstand test, Verification 100% IS /PS IS /PS TC 3 1,2
operation of
floats(manual), 2KV test
for 1 minute.
2.2 Bushings
2.2.1 HVBushing

Page 10 of 29
Document Name : QAP for Oil-filled Transformer (11KV/433 V ONAN)

Sl. No Components/Character Method of Extent of Reference Acceptanc Forma Remarks

istics checked check check document e norm t of AGENCY
record
P V W H

2.2.1.1 Visual inspection and Visual sample IS 8603 IS 8603 TC 3 1,2

dimensional
check(creepage and lead
length)
2.2.1.2 All routine tests as per Test 100% IS-2099 IS2099 TC 3 1,2
Clause No.11.2.3 of IS-
2099
2.2.1.3 All type tests as per Test Type test IS-2099 IS 2099 TC 3 1,2
Clause No.11.2.1 of IS-
2099.

2.2.2 LV and Neutral

2.2.2.1 bushing
Visual inspection and Visual sample IS 8603 IS 8603 TC 3 1,2
dimensional
check(creepage and lead
length)
2.2.2.2 All routine tests as per Test 100% IS-2099 IS2099 TC 3 1,2 LV & Neutral
Clause No.11.2.3 of IS- bushing voltage
2099 rating is 3.6 KV.
So applicable IS
is 2099

Page 11 of 29
Document Name : QAP for Oil-filled Transformer (11KV/433 V ONAN)

Sl. No Components/Character Method of Extent of Reference Acceptanc Forma Remarks

istics checked check check document e norm t of AGENCY
record
P V W H

2.2.2.3 All type tests as per Test Type test IS-2099 IS 2099 TC 3 1,2 LV & Neutral
Clause No.11.2.1 of IS- bushing voltage
2099. rating is 3.6 KV.
So applicable IS
is 2099

2.3 Axles and wheels

2.3.1 Dimensions and finish Visual and 100% IS IS TC 3 1,2
measurement
2.3.2 Mechanical properties Mechanical Test on IS IS TC 3 1,2
sample

2.4 Winding temperature

indicator (WTI )
2.4.1 Accuracy, operation of Calibration 100% IS /PS IS /PS TC 3 1,2
contacts, calibration & 2 and electrical
KV power frequency HV
test between all terminals
and earth & sensor
resistance
2.4.2 Degree of protection Mechanical Sampling IS IS TC 3 1,2

2.6 Oil temperature

indicator (OTI)

Page 12 of 29
Document Name : QAP for Oil-filled Transformer (11KV/433 V ONAN)

Sl. No Components/Character Method of Extent of Reference Acceptanc Forma Remarks

istics checked check check document e norm t of AGENCY
record
P V W H

2.6.1 Accuracy, operation of Calibration 100% IS /PS IS /PS TC 3 1,2

contacts, calibration & 2 and electrical
KV power frequency HV
test between all terminals
and earth & sensor
resistance
2.6.2 Degree of protection Mechanical Sampling IS IS TC 3 1,2

2.7 Current Transformers

2.7.1 Ratio error, magnetizing Elect./ 100% IS 2705 IS 2705 TC 3 1,2

characteristics, Dimensional
Secondary Winding /Visual
resistance, HV tests, as
per IS-2705 visual and
dimensional checks.

2.80 Marshalling box

2.8.1 Finish, adhesion and Visual 100% PS PS TC 3 1,2
painting (shade 631 of IS-
5)
2.8.2 Electrical and Electrical / 100% IS /PS IS /PS TC 3 1,2
mechanical operation as Mechanical
per approved schematic
drawing

Page 13 of 29
Document Name : QAP for Oil-filled Transformer (11KV/433 V ONAN)

Sl. No Components/Character Method of Extent of Reference Acceptanc Forma Remarks

istics checked check check document e norm t of AGENCY
record
P V W H

2.8.3 2 KV insulation Elect. 100% IS /PS IS /PS TC 3 1,2

withstand test for 1
minute between all line
terminals to earth & IR at
500 V & functional test
at rated voltage
2.8.4 Degree of protection test Mechanical Sampling IS IS TC 3 1,2
2.8.5 Wiring & its routing, Visual 100% PS PS TC 3 1,2
ferruling, labelling
2.8.6 Visual check and Measurement 100% PS PS TC 3 1,2
dimensional check

2.9 Pressed steel Radiators

2.9.1 Visual check and Visual 100% Drawing As per TC 3 1,2

dimensional check approved
drawing.
2.9.2 Leakage Test Test As per PS PS TC 3 1,2
CBIP
2.9.3 Vacuum test Test As per PS PS TC 3 1,2
CBIP
2.9.4 Finish and painting Visual 100% PS Good TC 3 1,2
(shade 631 of IS-5) finish

2.10 Terminal connectors

Page 14 of 29
Document Name : QAP for Oil-filled Transformer (11KV/433 V ONAN)

Sl. No Components/Character Method of Extent of Reference Acceptanc Forma Remarks

istics checked check check document e norm t of AGENCY
record
P V W H

2.10.1 Dimensional and visual Visual / 100% PS PS TC 3 1,2

control Measurement
2.10.2 Tensile test Mechanical Sampling PS PS TC 3 1,2
2.10.3 Resistance test Electrical 100% PS PS TC 3 1,2

2.11 Oil level gauge (MOG)

2.11.1 Calibration check at Test 100% Manufactur pass test TC 3 1,2

empty, 1/4, 1/2, 3/4th & er's
full marking at ambient catalogue.
temp.
2.11.2 Leak proof/pressure test, Test 100% Manufactur pass test TC 3 1,2
2KV test between er's
terminals and earth & catalogue.
operation.
2.11.3 Dimensional and visual Visual 100% Manufactur To be TC 3 1,2
check. er's satisfactor
catalogue. y.
2.11.4 Degree of protection Mechanical Sampling IS IS TC 3 1,2

2.12 Pressure relief device

2.12.1 Air pressure Test 100% PS PS TC 3 1,2
test(Operating Pressure)
2.12.2 Leakage test( Liquid Physical 100% PS PS TC 3 1,2
pressure test)
2.12.3 Contact operation Visual 100% PS PS TC 3 1,2

Page 15 of 29
Document Name : QAP for Oil-filled Transformer (11KV/433 V ONAN)

Sl. No Components/Character Method of Extent of Reference Acceptanc Forma Remarks

istics checked check check document e norm t of AGENCY
record
P V W H

2.12.4 2 KV HV test Elect. 100% PS PS TC 3 1,2

2.12.5 Finish and dimension Visual / 100% PS PS TC 3 1,2
Measurement
2.12.6 Degree of protection Mechanical Sampling IS IS TC 3 1,2

2.13 Valves
2.13.1 Oil / Water tightness test Pressure test 100% IS / PS IS / PS TC 3 1,2
2.13.2 Oil seepage test in open Pressure test 100% IS / PS IS / PS TC 3 1,2
condition
2.13.3 Dimensions as per Measurement 100% IS / PS IS / PS TC 3 1,2
approved drawing of
BARC
2.13.4 Checks on verticality and Measurement 100% IS / PS IS / PS TC 3 1,2
parallelness of flanges

2.14 Silica gel breather

2.14.1 Pressure test at 0.35 Test 100% IS/PS IS/PS TC 3 1,2
Kg/sq.cm. for 30 minutes
by blanking oil cup end

2.14.2 Visual and dimensional Visual / 100% IS / PS IS / PS TC 3 1,2

check Measurement
2.14.3 Rusting Visual 100% IS / PS IS / PS TC 3 1,2

Page 16 of 29
Document Name : QAP for Oil-filled Transformer (11KV/433 V ONAN)

Sl. No Components/Character Method of Extent of Reference Acceptanc Forma Remarks

istics checked check check document e norm t of AGENCY
record
P V W H

2.14.4 Operational test Physical 100% IS / PS IS / PS TC 3 1,2

2.15 Tap changer

2.15.1 OFF Load Tap
Changer
2.15.1.1 Contact resistance (Milli Test 100% PS PS TC 3 1,2
volt drop test)
2.15.1.2 IR test Test 100% IS IS TC 3 1,2
8468/IEC 8468/IEC
60214 60214
2.15.1.3 Construction & Test 100% Drawing Drawing TC 3 1,2
dimension check, Visual
inspection as per
approved drawing of
BARC
2.15.1.4 Power frequency HV test Test 100% IS 8468 IS 8468 TC 3 1,2
(Dielectric test).
2.15.1.5 Operational check Test 100% PS PS TC 3 1,2

2.16 Tank, conservator and

other fabricated steel
items.

Page 17 of 29
Document Name : QAP for Oil-filled Transformer (11KV/433 V ONAN)

Sl. No Components/Character Method of Extent of Reference Acceptanc Forma Remarks

istics checked check check document e norm t of AGENCY
record
P V W H

2.16.1 Welding procedure & Mechanical 100% ASME IX 3 1,2

welder's qualification
2.16.2 Dimensions as per Visual / 100% PS PS TC 3 1,2 1,2
approved drawing of Measurement
BARC and visual checks
on welds.
2.16.3 Air Pressure test on Test As per PS PS TC 3 1,2 1,2
transformer tank at CBIP
fabrication stage
2.16.4 Full Vacuum test on Test / As per PS PS TC 3 1,2 1,2
transformer tank at Measurement CBIP
fabrication stage
2.16.5 Air Pressure test on Test As per PS PS TC 3 1,2 1,2
conservator CBIP
2.16.6 Air Pressure test on Test As per PS PS TC 3 1,2
piping CBIP
2.16.7 Cleanliness of surface Visual 100% PS PS TC 3 1,2
(Grit Blasting)
2.16.8 Film thickness of oil Measurement Sampling PS PS TC 3 1,2
insoluble varnish/ paint
2.16.9 Wheel dimensions, Dimensions 100% PS PS TC 3 1,2
proper turning of wheels
through 90degrees and
further dimensional
checks

Page 18 of 29
Document Name : QAP for Oil-filled Transformer (11KV/433 V ONAN)

Sl. No Components/Character Method of Extent of Reference Acceptanc Forma Remarks

istics checked check check document e norm t of AGENCY
record
P V W H

2.16.10 Physical proper ties of Physical Sampling PS PS TC 3 1,2

materials for lifting and
jacking pads
2.16.11 DP tests on load bearing NDT 100% PS PS TC 3 1,2
welds ( pulling eyes,
lifting hooks, and jacking
pads)
2.16.12 Check for flatness of Measurement 100% DRG/Mater V/SV TC 3 1,2
gasketing surface. ial Spec. IR/TC
2.16.13 Leak proofness of oil Testing 100% Process V/SV TC 3 1,2
filled compartments. spec /CBIP IR/TC
2.16.14 Verfication of tank Visual& 100% Approved V/SV TC 3 1,2
profile as per approved Measurement DRG. IR/TC
drawing of BARC
2.16.15 Paint type and shade. Visual Sampling Approved V/SV TC 3 1,2
DRG. IR/TC
2.16.16 Paint thickness Measurement Sampling Approved V/SV TC 3 1,2
DRG. IR/TC
2.16.17 Uniformity of finish. Visual Sampling Process V/SV TC 3 1,2
Spec. IR/TC
2.16.18 Paint adhesion test. Testing Sampling Process V/SV TC 3 1,2
Spec. IR/TC

2.17 Core with core clamps.

Page 19 of 29
Document Name : QAP for Oil-filled Transformer (11KV/433 V ONAN)

Sl. No Components/Character Method of Extent of Reference Acceptanc Forma Remarks

istics checked check check document e norm t of AGENCY
record
P V W H

2.17.1 Dimensions & Measurement 100% PS PS TC 3 1,2

straightness and / Visual both
roundness of core, during and
suitability of clamps, after assembly
position of oil ducts,
tightness of core
clamping bolts, and core
binding tape and stack
height.
2.17.2 Overlapping Visual 100% PS PS TC 3 1,2
2.17.3 Core loss and Hot spot at Measurement Type test PS PS TC 3 1,2 1,2
100% excitation
2.17.4 Visual inspection and Visual 100% PS PS TC 3 1,2 1,2
dimensions
2.17.5 Insulation test between
2.17.5.1 core to yoke bolts Electrical 100% PS PS TC 3 1,2 1,2

2.17.5.2 core to core clamps Electrical 100% PS PS TC 3 1,2 1,2

2.17.5.3 core clamps to yoke bolts Electrical 100% PS PS TC 3 1,2 1,2

2.17.5.4 core to core (on split Electrical 100% PS PS TC 3 1,2 1,2

core only)

2.18 HV and LV windings

Page 20 of 29
Document Name : QAP for Oil-filled Transformer (11KV/433 V ONAN)

Sl. No Components/Character Method of Extent of Reference Acceptanc Forma Remarks

istics checked check check document e norm t of AGENCY
record
P V W H

2.18.1 Dimensions and visual Measurement 100% PS PS TC 3 1,2

check ( HV and LV
winding details shall be
checked by BARC
engineer as per approved
drawing of dynamic
short circuit calculations)

2.18.2 Terminal location Visual 100% PS PS TC 3 1,2

2.18.3 Shorting between Continuity 100% PS PS TC 3 1,2
parallel strands using
Megger
2.18.4 Spacer and its spacing Visual 100% PS PS TC 3 1,2
2.18.5 Number of turns, Visual / 100% PS PS TC 3 1,2
continuity and shorting Electrical
by buzzer test
2.18.6 Tightness (clamping Measurement 100% PS PS TC 3 1,2
pressure) of HV and LV
windings
2.18.7 Coil stack height Measurement 100% PS PS TC 3 1,2

2.20 Core Coil Assembly

2.19.1 Lead arrangements Visual / 100% PS PS TC 3 1,2
Measurement
2.19.2 Oil ducts and push bolt Visual / 100% PS PS TC 3 1,2
arrangement Measurement

Page 21 of 29
Document Name : QAP for Oil-filled Transformer (11KV/433 V ONAN)

Sl. No Components/Character Method of Extent of Reference Acceptanc Forma Remarks

istics checked check check document e norm t of AGENCY
record
P V W H

2.19.3 Cleanliness and absence Visual 100% PS PS TC 3 1,2

of dust
2.19.4 Grinding of sharp points Visual 100% PS PS TC 3 1,2
2.19.5 Inspection of joints Visual 100% PS PS TC 3 1,2
(Crimped joints)
2.19.6 Inspection of joints ( Visual 100% PS PS TC 3 1,2
brazing shall be done by
qualified brazers)
2.19.7 Torque on coil clamping Measurement 100% PS PS TC 3 1,2
bolts/tightness of coils.
2.19.8 2 kV for 1 min Test 100% IS-2026 pass test TC 3 1,2
withstand test
2.19.9 10 kV for 1 min Test 100% IS-2026 pass test TC 3 1,2
withstand test
2.19.9.1 Core to Tank Electrical 100% IS-2026 pass test TC 3 1,2

2.19.9.2 Clamp plates to tank Electrical 100% IS-2026 pass test TC 3 1,2

2.19.9.3 Core to Clamp plates Electrical 100% IS-2026 pass test TC 3 1,2

2.19.10 Insulation test of core Elect. 100% PS PS TC 3 1,2

earthing.
2.19.11 IR value in air after Elect. 100% PS PS TC 3 1,2
drying
2.19.12 Ratio test. Elect. 100% PS PS TC 3 1,2

Page 22 of 29
Document Name : QAP for Oil-filled Transformer (11KV/433 V ONAN)

Sl. No Components/Character Method of Extent of Reference Acceptanc Forma Remarks

istics checked check check document e norm t of AGENCY
record
P V W H

2.19.13 Electrical joints between Visual 100% PS PS TC 3 1,2

bus bars
2.19.14 Shrinkage of coils Visual 100% PS PS TC 3 1,2

2.2 Drying & Oil

impregnation
2.20.1 Temperature, IR value, Test / 100% PS PS TC 3 1,2
Vacuum, tan delta and Measurement
duration
2.20.2 Filling of oil for test Visual 100% PS PS TC 3 1,2
purpose (Total oil qty
filled shall be recorded
separately and to be
included in the cost).
2.20.3 Characteristics of oil
used for first
impregnation of winding
as per IS-1866/IS 335
2.20.3.1 BDV (minimum 50 KV) Electrical 100% PS PS TC 3 1,2

2.20.3.2 Water content ( Physical 100% PS PS TC 3 1,2

maximum 10 ppm)
2.20.3.3 Resistivity at 90 ºC ( Electrical 100% PS PS TC 3 1,2
minimum 6 x 10 ^12
ohm cm)

Page 23 of 29
Document Name : QAP for Oil-filled Transformer (11KV/433 V ONAN)

Sl. No Components/Character Method of Extent of Reference Acceptanc Forma Remarks

istics checked check check document e norm t of AGENCY
record
P V W H

2.20.3.4 Tan delta at 90 °C Electrical 100% PS PS TC 3 1,2

(Maximum 0.010)
2.20.3.5 Interfacial Tension Physical 100% PS PS TC 3 1,2
(0.035 N/m (minimum))
2.20.4 Completeness of drying Measurement 100% PS PS TC 3 1,2

2.21 Tanking
2.21.1 IR value between Elect. 100% PS PS TC 3 1,2
internal body and tank
before connecting earth
lead
2.21.2 Dimensions and Measurement 100% PS PS TC 3 1,2
insulation clearances
2.21.3 Looseness of Visual 100% PS PS TC 3 1,2
connections
2.21.4 Insulation clearance Measurement 100% Drawing Drawing TC 3 1,2
between high voltage
leads, earth and other
live parts.

2.22 Hardware
2.22.1 Visual control Visual Sampling IS IS TC 3 1,2
2.22.2 Routine tests Test Sampling IS IS TC 3 1,2

3 Final inspection &

Testing

Page 24 of 29
Document Name : QAP for Oil-filled Transformer (11KV/433 V ONAN)

Sl. No Components/Character Method of Extent of Reference Acceptanc Forma Remarks

istics checked check check document e norm t of AGENCY
record
P V W H

3.1 Inspection of completed

fully assembled
transformer

3.1.1 Conformity with Visual / 100% PS PS TC 3 1,2

approved drawing Measurement
3.1.2 Provision of all fittings & Visual / 100% PS PS TC 3 1,2
accessories as per Measurement
approved drawing
3.1.3 Finish and dimensions Visual / 100% PS PS TC 3 1,2
Measurement

3.2 Testing of Transformer Tests 100% IS 335 IS 335 TC 3 1,2

Oil

3.3 Painting
3.3.1 Material, shade, number Visual 100% IS IS TC 3 1,2
of coats (shade 631 of IS-
5)
3.3.2 Quality of paint, Dry Verification 100% IS IS TC 3 1,2
film thickness.(DFT)
3.3.3 Paint adhesion test. Mechanical Sampling IS IS TC 3 1,2
3.3.4 Peel test & Scratch test Mechanical Sampling IS IS TC 3 1,2

3.4 Testing at
manufacturer's works

Page 25 of 29
Document Name : QAP for Oil-filled Transformer (11KV/433 V ONAN)

Sl. No Components/Character Method of Extent of Reference Acceptanc Forma Remarks

istics checked check check document e norm t of AGENCY
record
P V W H

3.4.1 Routine tests

3.4.1.1 Terminal/ Tapping Visual 100% IS: 2026 IS: 2026 TC 3 1,2
markings.
3.4.1.2 Rating Plate details Visual 100% IS: 2026 IS: 2026 TC 3 1,2
3.4.1.3 Voltage Ratio test Electrical 100% IS: 2026 IS: 2026 TC 3 1,2
3.4.1.4 Winding resistance at all Electrical 100% IS: 2026 IS: 2026 TC 3 1,2
taps.
3.4.1.5 No load Loss & current Electrical 100% IS: 2026 IS: 2026 TC 3 1,2
at rated & 110% voltage
& rated frequency.
3.4.1.6 Impedance Voltage/ Electrical 100% IS: 2026 IS: 2026 TC 3 1,2
short circuit impedance
(Principal Tap) & Load
Loss.
3.4.1.7 Induced Over Voltage Electrical 100% IS: 2026 IS: 2026 TC 3 1,2
withstand Test
3.4.1.8 Power Frequency Electrical 100% IS: 2026 IS: 2026 TC 3 1,2
separate source voltage
withstand test
3.4.1.9 Insulation Resistance & Electrical 100% IS: 2026 IS: 2026 TC 3 1,2
P.I. Test
3.4.1.10 Voltage Vector Electrical 100% IS: 2026 IS: 2026 TC 3 1,2
relationship
3.4.1.11 Magnetic balance test Electrical 100% IS: 2026 IS: 2026 TC 3 1,2

Page 26 of 29
Document Name : QAP for Oil-filled Transformer (11KV/433 V ONAN)

Sl. No Components/Character Method of Extent of Reference Acceptanc Forma Remarks

istics checked check check document e norm t of AGENCY
record
P V W H

3.4.1.12 Tests on OFF-load tap- Electrical 100% IS/PS IS/PS TC 3 1,2

changer.

3.4.2 Type tests

3.4.2.1 Heat run test (Temp. rise Electrical On 1 No. of IS: 2026 IS: 2026 TC 3 1,2
test) transformer
of the
ordered
quantity

3.4.2.2 Impulse Voltage Test. Electrical On 1 No. of IS: 2026 IS: 2026 TC 3 1,2
transformer
of the
ordered
quantity

3.4.2.3 DGA before & after Electrical On 1 No. of IS/PS IS/PS TC 3 1,2
temp. rise test. transformer
of the
ordered
quantity

3.4.3 Special Tests.

Page 27 of 29
Document Name : QAP for Oil-filled Transformer (11KV/433 V ONAN)

Sl. No Components/Character Method of Extent of Reference Acceptanc Forma Remarks

istics checked check check document e norm t of AGENCY
record
P V W H

3.4.3.1 Zero Sequence 100% 100% IS: 2026 IS: 2026 TC 3 1,2
impedance measurement
test.
3.4.3.2 Acoustic Noise Level 100% 100% IS: 2026 IS: 2026 TC 3 1,2
measurement.
3.4.3.4 Short circuit withstand Electrical Test IEC-60076 , IEC-60076 TC 3 1,2
test certificate IS-2026 . , IS-2026
of similar
voltage but
rating either
similar or
different
transformer
not
necessarily
from the
scope of the
transformer
s

4 Pre-shipment checks
5.1 Verification of final Visual 100% PS PS TC 3 1,2
checking

Page 28 of 29
Document Name : QAP for Oil-filled Transformer (11KV/433 V ONAN)

Sl. No Components/Character Method of Extent of Reference Acceptanc Forma Remarks

istics checked check check document e norm t of AGENCY
record
P V W H

5.2 Check for proper loading Visual / 100% PS PS TC 3 1,2

of transformer on road mechanical
trailor/railway wagon,
proper bracing &
anchoring.
5.3 Proper packing of Visual 100% PS PS TC 3 1,2
accessories & fittings
5.4 Oil.
5.4.1 Drum quality, leak Visual Sampling PS PS TC 3 1,2
tightness and oil

6 End documents
6.1 Test certificate of raw - As As As - - -
material/bought out indicated indicated indicated
materials indicated above

6.2 Test certificate of in - As As As - - -

process inspection indicated indicated indicated
indicated above
6.3 Test certificates of final - As As As - - -
testing indicated above indicated indicated indicated
6.4 O&M - 100% - - -
Manuals/Catalogues of
panels/all bought out
items
6.5 As fabricated drgs - 100% - - -

Page 29 of 29