HeadOffice Uploading Date And Time::::: Wednesday, September 30, 2015 5:48:24 PM

DCPL Volume IV: Ch 05: Isolated Phase Bus Ducts and

Neutral Grounding
Electrical Works
Equipment
Sheet l 5 of 21

than capacitive KVA to ground.For determining capacitive KVA to ground

capacitance, equipment such as Generator, Generator Busduct, GT & UAT
LV windings and surge capacitor will be considered.

3.09.00 Gaskets will be of neat, water and dust proof material.

3.10.00 Outdoor runs of the busducts will be weather proof; and solar heating effect will
be considered while sizing the busduct sections. In addition the outdoor section
shall withstand the wind loading as indicated elsewhere in bid document.

3.11.00 Busduct and auxiliary equipment will be capable of withstanding the mechanical
forces and thermal stresses of the short-circuit currents without any damage or
deterioration of material. Bus conductor support insulator span will be chosen
considering minimum safety factor of 2.5 for cantilever strength under short
circuit condition. Whenever busduct penetrates RCC walls, TG foundation block
or run in the vicinity of RCC framework etc, necessary arrangement e.g in the
form of provision of shield of non magnetic material of adequate width or any
alternative arrangement if required shall be provided to ensure there is no undue
heating on the concrete structure due to leakage flux.

3.12.00 Busducts and supporting structures will be designed and constructed so as to

withstand without any damage, the horizontal/vertical ground acceleration due
to an earthquake.
A slit of 10-20 mm shall be kept between enclosure and generator flange.
Suitable covering shall be provided on the slit to prevent escape of hydrogen
and avoid dust entry inside the common chamber.

3.13.00 Bidder shall furnish the following calculations for main run delta and tap off
run bus duct.

(a) Temperature rise at rated current considering effect of solar radiation.

(1) Conductor size

(2) Guaranteed KW losses in conductor & enclosure
(3) Supporting span
(4) Dynamic and static forces transferred to TG foundation.

3.14.00 Generator Transformers and Unit Transformers shall be handled on the rail
track from Main Plant side/ Switchyard side. The contractor shall
transformers removal, after opening the terminations, but without dismantling
busduct run or supporting structure.

4.00.00 SPECIFIC REQUIREMENTS

4.01.00 GENERAL

i. The busduct rated more than 6000A shall be continous isolated phase
type (bonded enclosure), natural air cooled, positive pressure type
(+100mm water column) to prevent entry of dust and moisture.

ii. The layout of the busduct shall be generally in accordance with tender
drawings. The details shown, however, are only typical. Bidder may
propose changes to suit the particular design. Number of flexible,
bolted and welded joints shall be provided as per requirement.

Obra “C” 2x660 MW Thermal Power

Extension Project
Bidding Doc. No. : 14A22-SPC-G-0001
HeadOffice Uploading Date And Time::::: Wednesday, September 30, 2015 5:48:24 PM

DCPL Volume IV: Ch 05: Isolated Phase Bus Ducts and

Neutral Grounding
Electrical Works
Equipment
Sheet l 6 of 21

iii. All parts and accessories shall have appropriate match mark and
part numbers or easy identification and installation at site.

iv. Design of the busduct and its supporting structure shall be such
that it will permit transformer removal after opening of the
termination but without dismantling busduct run or supporting
structure.

4.02.00 Temperature Rise

For continuous operation at rated current under specified site conditions, the
temperature rise shall not exceed the limits as defined under technical
parameters. The Bidder has to ensure high standards of design. The process
and workmanship of silver plating shall be approved by the Purchaser.

4.03.00 Enclosure
i. Each phase shall be enclosed in a weather proof, dust tight, non-
magnetic metal (Aluminum alloy) enclosure. The enclosure shall be
designed for welded connection.
ii. The enclosure shall be of minimum flux type to permit not more than
five (5) percent of total, magnetic flux outside enclosure.
iii. The enclosure cross-section, connecting members between enclosure
section, flexible and rigid joints between phase enclosures shall be
adequate to allow the flow of longitudinal current corresponding to the
rated continuous current of the bus without over-heating.
iv. Metallic bellows along with necessary flexible links ( to ensure
required X-section) shall be provided in bus duct run. Rubber bellows
shall be provided on equipment termination.

v. Flexible joints shall be provided in enclosures at all points where the

busduct terminates at equipment to withstand vibration,
expansion/contraction and at suitable intervals in any straight run
of the busduct where expansion and contraction would otherwise
result in stresses in the supporting structures
vi. Phase enclosures shorting links rated for continuous current shall be
provided at bus duct termination on generator, GT,UT, tap off and
excitation transformer (if applicable).
vii. The enclosure shall be insulated at the connections to various
equipment as listed above so that the longitudinal current will not flow
through or be transmitted to any connecting equipment. The insulation
shall be non-deteriorating and shall be clearly indicated on the
Contractor’s drawings.
viii. The bidder should ensure that no load is transferred on electrical
equipments transformers, generator terminals etc. by the bus ducts.
ix. Inspection opening/ split covers shall be provided to allow easy access
for installation, inspection, replacement or repairs of the insulators,
disconnects, bus connections, terminations and current transformers.
Inspection covers/ split covers should be connected electrically to the
main duct by flexible braids for proper earthing. The inspection/ split
covers shall have reliable sealing arrangements with neoprene
rubber/synthetic rubber bonded cork gaskets in grooves, to ensure air
tightness.
x. Wall frame and support plates shall be provided where the bus duct
penetrates the building wall. It should be ensured that no loads are
imposed on building wall/ structure.
xi. Seal of bushings shall be provided at

Obra “C” 2x660 MW Thermal Power

Extension Project
Bidding Doc. No. : 14A22-SPC-G-0001
HeadOffice Uploading Date And Time::::: Wednesday, September 30, 2015 5:48:24 PM

DCPL Volume IV: Ch 05: Isolated Phase Bus Ducts and

Neutral Grounding
Electrical Works
Equipment
Sheet l 7 of 21

a) Generator End.
b) Generator Transformer End,
c) Unit Transformers end.
d) Excitation Transformer End etc.

xii. Filtered drain tapping with dual stop cocks shall be provided for
drainage of condensate at the lowest point and at such other locations
where accumulation of condensate can be expected. In particular a
drain valve shall be provided at the lowest point of transformer end
termination. The contractor shall be required to add drainage points if
required during installation. Contractor has to take care of proper
draining arrangement even though busduct is pressurized.
xiii. The enclosures of all three phases shall be rigidly supported by cross
members to maintain parallel alignment.

xiv. Shipping length of the busduct shall be as long as practicable

within transport limitation to reduce field assembly work.

4.04.00 Bus Conductor

i. The Bus Conductor shall be of high conductivity, painted aluminium
alloy as per IS:5082 supported on wet process porcelain insulators.
ii. The bus conductor shall be designed for welded connections except at
equipment terminations, bolted disconnect links, and bolted flexible.
Detailed welding procedure adopted by the manufacturer should be
furnished during detailed engineering and approved by the Owner.
iii. Flexible connections shall be provided between bus sections to allow for
expansion and contraction of the conductor. Flexible connections shall
also be provided at all equipment terminations.
iv. All contact surfaces shall be silver plated. All connection hardware shall
be non-magnetic and shall have high corrosion resistance.
v. The bus conductor shall be sufficiently corona-free at rated voltage to
eliminate the possibility of igniting the potential accumulation of
hydrogen gas

4.05.00 Insulators
i. Bus support insulators shall be interchangeable, high creep and high
strength, fine glazed porcelain manufactured by wet process, or high
strength cast resin insulators and shall be suitable for heavily polluted
atmosphere.
ii. Insulator shall be mounted in such a way so as to permit its easy
removal or replacement without disassembly of the bus.
iii. The conductor shall be fastened on the insulator through fixed and
sliding joints so as to allow conductor expansion or contraction without
straining the insulator. Positive contact shall be made between end
caps of the supporting insulators and the conductors.
iv. All ferrous metal part of the insulator shall be hot-dipped galvanized.
v. Additional support insulators shall be provided at bend, at tap offs for
withstanding all possible forces.

4.06.00 Disconnect Link

i. Removable bolted disconnect link shall be provided in the bus for
isolation of the transformers and auxiliary equipment.

Obra “C” 2x660 MW Thermal Power

Extension Project
Bidding Doc. No. : 14A22-SPC-G-0001
HeadOffice Uploading Date And Time::::: Wednesday, September 30, 2015 5:48:24 PM

DCPL Volume IV: Ch 05: Isolated Phase Bus Ducts and

Neutral Grounding
Electrical Works
Equipment
Sheet l 8 of 21

ii. Disconnect link shall consist of a removable section of conductor and

shall be so constructed as to permit easy removal or reinsertion
without alignment difficulties.
iii. The bus on both sides of the link shall be rigidly supported so that the
disconnect link is equal in mechanical strength to any other section of
the bus.
iv. A minimum clearance of 300 mm. (12") shall be provided between the
disconnected bus sections with the link removed.

4.07.00 Connections & Terminations

i. All matching flanges, seal off bushings, gaskets, fittings, hardware and
supports required for termination of the bus duct at Generator,
Transformers and other equipment shall be furnished under the scope
of this specification. Bus duct lengths for payment purposes shall be
measured from matching flanges.
ii. Flexible connections both for conductor and enclosure shall be
furnished:
At all equipment termination to take care for misalignment up to
25mm (1”) in all directions.
A) Between bus duct supported from building steel and that
supported by turbine foundation to prevent transmission
vibrations.
iii. The equipment terminal connections shall be readily accessible and
shall provide sufficient air gap for safe isolation of requirement during
electrical testing.
iv. If the material of bus conductor and that of the equipment terminal is
different, then suitable bi-metallic connectors shall be provided
by the contractor.
v. Seal off bushings / Isolation barriers shall be provided at the generator
end of the busduct, tap off to PT cubicles and N,.G. cubicle and
Excitation Transformer Cubicle (in case it is provided).
vi. The space above the barrier at the generator side shall be ventilated
through filtered opening in the enclosure wall.

4.08.00 Shorting Link

i. Pre-fabricated shorting links rated same as the continuous

amperage of busduct main run shall be furnished complete with all
hardware for connections.

ii. The links shall be suitable for shorting bus conductors/enclosures of

three (3) phases after generator phase current transformers in a
prefixed location as shown on drawing.

iii. The links shall be so designed with flexible connections that the bus
insulators will not be unduly stressed due to expansion/ contraction
during dry out or short circuit tests.

4.09.00 Grounding
The electrically continuous bus enclosure shall be used as the grounding bus.
All parts of the bus enclosure, supporting structure and equipment frames
shall be grounded to earthing mat by the contractor.
Ground pad shall be bolted type to accommodate 75x10mm. galvanized
steel flats at following locations :

Obra “C” 2x660 MW Thermal Power

Extension Project
Bidding Doc. No. : 14A22-SPC-G-0001
HeadOffice Uploading Date And Time::::: Wednesday, September 30, 2015 5:48:24 PM

DCPL Volume IV: Ch 05: Isolated Phase Bus Ducts and

Neutral Grounding
Electrical Works
Equipment
Sheet l 9 of 21

(a) Generator end of the bus

(b) Generator transformer end of the bus.
(c) Unit transformer end of the bus.
(d) Voltage transformer and surge protection cubicles.
(e) Neutral grounding cubicle.
(f) Excitation transformer cubicle (if applicable).

4.10.00 Supporting Structure

i. All supporting structure required for hanging and/or supporting the
complete bus duct shall be furnished. These include all members,
indoor/outdoor posts, bolts, shims, base plates, hangers, brackets,
bracings and hardware.
ii. All bus ducts shall be adequately supported and braced to successfully
withstand normal operation, vibrations, thermal expansion, short
circuit forces and all specified design loads. Supporting calculations
shall be furnished to establish adequacy.
iii. Supports shall be designed to provide tolerance of ±12mm (1/2”) in
the horizontal and vertical directions.
iv. All steel members shall be hot dipped galvanized after fabrication. All
hardware shall be of high strength steel with weather resistant finish.
v. Concrete foundation, building steel, inserts/plates in concrete will be
provided by the Contractor.
vi. The indoor support shall be in general of hanger supports while
outdoor shall be generally supported from the ground.
vii. Arrangement of support steel work shall be such as to prevent heating
of structures caused by circulating currents.
viii. The EPC Contractor shall co-ordinate with the Owner/Purchaser for
necessary & timely approvals of designs, documents & drawings etc.
ix. Hinges of all inspection Covers shall be strapped across with flexible
earth connections.

4.11.00 Hot Air Blowing Equipment

i. To avoid condensation of moisture inside busduct during shut-down

of the generator, suitable facility for blowing hot air inside the bus
enclosure shall be provided.

ii. Hot air blowing system shall be of open loop type, capable of
blowing hot air simultaneously in the indoor and outdoor portions of
the busduct. The system shall be portable type, mounted on a
wheeled carriage, so that the same can be used for different Unit as
and when required.

iii. The system shall be furnished complete with motor-blower unit,

combination starter, washable filters, piping, valves, heaters,
thermostats, controls, instrumentation and monitoring.

iv. A control cabinet shall be furnished with mounted and wired control
v. & monitoring devices, indicating lights etc. Auxiliary contacts shall be
provided for remote ON/OFF indication of hot air blowing operation.

vi. Ambient air will be drawn in through inlet damper and dry air filter
and forced through thermostat-controlled heaters. Hot air will be
distributed by a set of properly sized ducts and dampers to the
indoor and outdoor portion of the busduct. Hot air will be let out

Obra “C” 2x660 MW Thermal Power

Extension Project
Bidding Doc. No. : 14A22-SPC-G-0001
HeadOffice Uploading Date And Time::::: Wednesday, September 30, 2015 5:48:24 PM

DCPL Volume IV: Ch 05: Isolated Phase Bus Ducts and

Neutral Grounding
Electrical Works
Equipment
Sheet l 10 of 21

from busduct through suitably directed outlet provided at each

equipment termination.

vii. The system will be put in operation only before start-up and shall be
sized to complete the drying operation in about one to one and half
hour. (Minimum rating of the Blower : 1250 m3 /hour , 120 mm WC
and Heating Capacity: 9675 K.Cal/Hour) Once the drying up is
complete, the system will be shut down. The dampers and hot air
outlets are to be kept closed when the system is not in operation.

viii. Means shall be provided so as to prevent circulation of longitudinal

current through hot air system piping.

4.12.00 Air Pressuring

i. Each busduct shall be provided with air pressurization system

consisting of two (2) 100% capacity oil free type air compressors
with motors, necessary filters, valves, driers,piping, solenoid
valves, transmitters, drains, pressure switch and gauges, fittings
and necessary controls to ensure a continuous supply of clean and
dry pressurized air to the busduct enclosure maintaining a positive
air pressure (100 mm water column) inside the enclosures to
prevent any ingress of moisture from atmospheric air.
ii. The bidder shall guarantee and demonstrate at site the air leakage rate
of not more than 5% of total enclosure volume per hour after
installation.
iii. The Bidder shall offer a compete arrangement for pressurization of bus
duct with compressed instrument air supply which shall be at 5.0 to 7.0
kg/sq.cm. Bidder shall include equipment for pressure reduction,
drying, bus duct internal pressure indication, dust filters control, safety
valves and alarms for failure of pressurization and excessive leakage.
iv. To prevent ingress of foreign matter into the bus duct enclosure during
plant shut down or maintenance, aluminum end caps shall be provided
for the following locations:
(a.) Generator transformer and
(b.) Unit transformer end
v. A tee-off connection with non-return valve and isolating valve,
pressure reducer etc shall be provided for a stand-by connection to
station compressed air supply header by EPC contractor. The
pressure range of the station compressed air system will be suitably
decided by the EPC contractor with owner/purchaser’s approval.

vi. The allowable air leakage shall be less than 5% of the total
enclosure volume per hour. The contractor shall demonstrate this
guaranteed figure during factory test as well as during site
acceptance test.

vii. In order to avoid any excess over pressure due to any abnormality
the unit shall be equipped with safety valves calibrated to open the
circuit at about 2-3 times the design pressure. All materials shall be
designed to withstand more than twice the safety valve set pressure.

viii. One number control panel shall be provided for each air
pressurization unit to house motor starters, push buttons, interlock,
protection and monitoring, alarm and annunciation system. The

Obra “C” 2x660 MW Thermal Power

Extension Project
Bidding Doc. No. : 14A22-SPC-G-0001
HeadOffice Uploading Date And Time::::: Wednesday, September 30, 2015 5:48:24 PM

DCPL Volume IV: Ch 05: Isolated Phase Bus Ducts and

Neutral Grounding
Electrical Works
Equipment
Sheet l 11 of 21

control system shall perform automatic function with manual start

stop facility. Local as well as remote monitoring facility shall be
provided for both mechanical and electrical systems.

ix. The complete details of air drying plant shall be furnished along with
the offer/bid.
x. The Bidder shall furnish the following details clearly in his bid:
1. Parameters of clean air
2. Requirement of air in m3/hr at NTP.
3. Scheme/ method to calculate the leakage rate.

4.13.00 Current Transformer

i. The current transformers shall be epoxy cast-resin, single core ring

type, mounted within the bus duct enclosure and suitable for operation
at an ambient temperature existing within the bus duct enclosure
which may be in range of 90 deg. C to 100 deg.C. Mounting
arrangement of CT shall be so designed so as to avoid equalizing
connections between live conductor and CT inner surface.
ii. The bus design shall permit removal or replacement of C.T.s without
dismantling the bus run or supports
iii. The C.T.s shall have polarity markings indelibly marked on them.
iv. The terminal boxes shall be dust_tight, weather_proof, fabricated from
aluminum alloy and complete with screwed cover for access to
terminals and removable gland plate for Owner/Purchaser's cable
connections.
v. CT secondary leads shall be brought out through non-magnetic metallic
conduits to a marshalling box (MB) with degree of protection IP-55
(IS:13947 Pt.1).
vi. The MB shall be provided with removable aluminium gland plant. The
facility for shorting and grounding shall be provided at the terminal
blocks.
vii. In addition to above the marshalling box having termination of line side
CT’s, the transducers as listed at Annexure-B to this chapter shall be
provided to facilitate interface of generator busduct CT’s/PT’s with
ECP/DDCMIS. Accordingly the interconnection from VT panels to this
marshalling box shall also be provided, This marshalling box housing
transducers shall be located near PT & SP Cubicle.
viii. Transducers for all electrical parameters like current, Voltage, VAR,
Watt, frequency, power factor, phase angle difference etc. shall be
provided by the bidder. The transducers shall provide 4-20mA dual
output. The terminal blocks in transducer panels shall be provided
suitable for signals form CT/PT. Proper segregation shall be done to
ensure isolation between incoming high level signals and low level
output signal of transducers.

ix. The bidder shall hookup 220 V DC power supply to this transducer
panel with automatic changeover scheme. Suitable local and remote
annunciation to DDC MIS (for power supply failure) shall be provided.
Further, each transducer shall be fed through independently fused
power supply feeder.
x. All transducers shall be of tested quality as per IEC 600-688 (for
impulse test etc.) and SWC test as per ANSI C-37.90.1-1989 or
equivalent.

Obra “C” 2x660 MW Thermal Power

Extension Project
Bidding Doc. No. : 14A22-SPC-G-0001
HeadOffice Uploading Date And Time::::: Wednesday, September 30, 2015 5:48:24 PM

DCPL Volume IV: Ch 05: Isolated Phase Bus Ducts and

Neutral Grounding
Electrical Works
Equipment
Sheet l 12 of 21

xi. Each transducers shall provided to decouple 4-20 mA outputs, one for
driving electrical meters and the other for wiring to DDCMIS. The
accuracy of transducer shall be +/- 0.2 scale or better.

4.14.00 Voltage Transformer and Surge protection Cubicles

i. The V.T and S.P cubicles for each phases shall be metal clad, dust and
vermin proof, free standing, dead front assemblies housing VTs,
surge capacitor, lightning arrester, V.T. L.V. side fuses etc.
ii. Each phase cubicle shall house three (3) voltage transformers, one (1)
lightning arrestor and one (1) surge capacitor, in separate
compartments Each VT and SP cubicle shall have seal off busing at the
terminations of tap-off bus duct to cubicle.
iii. Lightning arrester shall be Gapless type station class, hermetically
sealed, connected between line and ground, specifically suitable for
generator protection as per technical parameters given elsewhere in
the specifications.
iv. A discharge counter shall be provide for each lightning arrester. The
discharge counter register shall be visible without having to open the
compartment door.
v. Mineral oil filled/Askarel (PCBS) filled surge capacitor shall not be
acceptable.
vi. The voltage transformer shall be epoxy cast-resin type, suitable for
nominal voltage operation, connected from line to ground, and for 1.73
times rated line to ground voltage under sustained emergency
condition.
vii. The voltage transformer along with secondary fuses shall be mounted
on draw out type carriage. Suitable guide slots and stops shall be
provided to ensure easy withdrawal and positioning. The fixed and
draw out contacts of voltage transformer primary shall be tinned or
silver plated.
viii. In the disconnected position, the voltage transformer primary and
secondary circuits shall be automatically disconnected. The draw out
frame shall be grounded at all times. A reliable automatically operated
shutter mechanism shall be provided for isolating and shrouding the
bus bar live parts when the VT is in drawn out position.
ix. The high voltage winding of the voltage transformer shall be protected
by current limiting fuse mounted on top of the primary bushing. The
fuse will be accessible only in fully drawn out position
x. The secondary leads from the voltage transformer shall be extended to
two separate fuses for dual accuracy PT and terminal cabinet flush
mounted in the compartment.
xi. From phase cabinets the VT secondary leads shall be brought to
marshalling box having sufficient number of terminals with 20% spare,
to accommodate all VT leads. Facility of making star points and
undrilled gland plate for Purchasers cable connections shall be provided
in the marshalling box.
xii. VT and CT secondary neutral or common lead shall be earthed at one
place only at the terminal blocks, provided in the instrument
transformer marshalling boxes. The facility for connecting Purchasers
earthing grid, shall be provided by the contractor through suitable
connectors in the marshalling box, with isolating links for testing of
instrument transformers.

4.15.00 Neutral Grounding Cubicle

Obra “C” 2x660 MW Thermal Power

Extension Project
Bidding Doc. No. : 14A22-SPC-G-0001
HeadOffice Uploading Date And Time::::: Wednesday, September 30, 2015 5:48:24 PM

DCPL Volume IV: Ch 05: Isolated Phase Bus Ducts and

Neutral Grounding
Electrical Works
Equipment
Sheet l 13 of 21

i. The transformer and resistor shall be located in separate cubicles/

compartment adjacent to each other. The cubicles shall have hinged
access doors capable of being pad locked.
ii. The transformer cubicle shall be made of sheet steel construction with
formed sheet sides. The resistor cubicle shall be made of with hot dip
galvanized screen sides. The neutral grounding equipment shall be
completely assembled, wired and connected to the neutral bus tap
through seal-off bushing.
iii. The neutral grounding transformer shall be dry type cast epoxy resin,
ring type natural air cooled single phase connected between generator
neutral and ground.
iv. The loading resistor shall be formed of non-aging, corrosion resistant
punched stainless steel grid element provided with necessary insulation
and designed for indoor service for a temperature rise not exceeding
300 deg.C.
v. All alarm, protection and indication leads shall be wired up to terminal
blocks that shall be mounted in a IP: 52 enclosure suitable for flush
mounting and having a fully hinged cover with lock.

4.16.00 Cubicle Construction (V.T. & S.P., N.G. Cubicle Etc.)

i. All cubicles except NG cubicle shall be fabricated from cold rolled sheet
steel for minimum 2mm thick suitably reinforced to ensure structural
rigidly. NG cubicle shall be of aluminum alloy. The degree of protection
for all indoor cubicle shall be IP:52 except for neutral grounding
resistor enclosure which shall be minimum IP:23.
ii. Space heater, Illumination and Grounding
iii. Each cubicle shall be equipped with space heater with thermostat,
internal illumination lamp, 240 V AC, 5A receptacle.
iv. Space heater and lamp shall be provided with individual ON-OFF
switches.The space heater shall be provided with thermostat.
v. Space heater shall be so sized and located as to maintain the
temperature within cubicle at least 5ºF above dew point.

vi. The ground bus shall have provision for receiving plant grid’s ground
connections - two numbers 75 x 10mm galvanized steel
4.17.00 Wiring

All wiring shall be done with insulated stranded copper conductor of not less
than 2.5 sq.mm cross-section with suitable lugs on both sides.

The wiring inside the bus duct enclosure (i.e. for CT etc.) shall be suitable for
operating in the ambient temperature existing inside the bus duct.

Not more than two wires shall be connected to a terminal. Spare terminals
equal in number to 20% of active terminals shall be furnished and these shall
be uniformly distributed through out the cubicle CT terminal blocks shall be of
stud type and suitable for round type lugs with a facility for isolation, shorting
and grounding.

Terminal blocks shall be box_clamp type suitable for 2x2.5 Sq.mm copper
conductor with marking strips

4.18.00 Name Plate

Obra “C” 2x660 MW Thermal Power

Extension Project
Bidding Doc. No. : 14A22-SPC-G-0001
HeadOffice Uploading Date And Time::::: Wednesday, September 30, 2015 5:48:24 PM

DCPL Volume IV: Ch 05: Isolated Phase Bus Ducts and

Neutral Grounding
Electrical Works
Equipment
Sheet l 14 of 21

Name plates shall be furnished for each equipment, disconnect link, voltage
transformer compartment, lightning arrester compartment and fuse block,
current transformer TB, Air pressurization cubicles etc.

Material for name plat shall be plastic/lamicoid 3mm thick using white letters
on black background.

4.19.00 Finish
i. Except for supporting steel structures which shall be galvanized, all
equipment including bus duct enclosure shall be finished with an under
coats of high quality primer followed by two coats of synthetic enamel
paint which shall have a thickness not less hant 50 microns.
ii. The interior surface finish shall be as per manufacturer's standard.
The shade of exterior surface shall be shade RAL 5012 for busduct
and equipment. The shade of interior surface of cubicles shall be
glossy white. The identification tag shall be signal red shade ISC 537
or RAL 3001.
iii. Pre-treatment consisting of degreasing, derusting etc. shall be done on
all fabricated parts before painting of cubicles, cabinets, marshalling
boxes and galvanization of steel structures.
iv. Paints shall be carefully selected to withstand heat and weather
conditions. The paint shall not scale-off or crinkle or get removed
by abrasion due to normal handling.
v. Sufficient quantities of all paints and preservatives required for
touching up at sites shall be furnished

5.00.00 TYPE TESTS

5.01.00 the contractor shall carry out the type tests as listed in the “LIST OF TESTS TO
BE CONDUCTED” on the equipment mentioned therin. The Bidder shall
indicate the charges for each of these type tests separately. The type test
charges shall be paid only for the test(s) actuall y conducted successfully
under this contract and upon certification by the Employer’s Engineer.

5.02.00 The type tests shall be carried out in presence of the Purchaser’s
representative, for which minimum 15 days notice shall be given by the
contractor. The Contractor shall obtain the Purchaser’s approval for the type
test procedure before conductingthe type test. The type test procedure shall
clearly specify the test set-up, instruments to be used. Procedure,, acceptance
norms, reconrding of different parameters, interval of recording, precautions
to be taken etc. for the type test(s) to be carried out.

5.03.00 In case the contractor has conducted such specified type test(s) within last
five years as on the date of bid opening, he may submit during detailed
engineering the type test reports to the owner for waival of conductance of
such type test(s). These reports should be for the tests conducted on the
equipment similar to those proposed to be supplied under this contract and
the test(s) should have been either conducted att an independent laboratory
or should have been witnessed by a client. The owner reserves the right to
waive conducting of any or al lthe specified type test(s) under this contract. In
case type tests are waived, the type test charges shall not be payable to the
contractor.

Obra “C” 2x660 MW Thermal Power

Extension Project
Bidding Doc. No. : 14A22-SPC-G-0001
HeadOffice Uploading Date And Time::::: Wednesday, September 30, 2015 5:48:24 PM

DCPL Volume IV: Ch 05: Isolated Phase Bus Ducts and

Neutral Grounding
Electrical Works
Equipment
Sheet l 15 of 21

5.04.00 All acceptance and routine tests as per the specification and relevant
standards shall be carried out. Charges forthese shall be deemed to be include
in the equipment price.

5.06.00 LIST OF TYPE TEST TO BE CONDUCTED

5.06.01 The following type tests shall be conducted on each type and rating of bus
ducts:

a) Heat run test (the set up shall include 3 phase straight run, 90 deg.
Bend, set of flexible connection of each type, , metallic below on
enclosure, CT’s mounted in position, (as applicable), bolted link, and
necessary inspection covers. Milli volt drop across bolted flexible joint
shall be measured.

b) Short circuit withstand test (set up same as for heat run).

c) Impulse withstand test (set up shall incude typical X-section with

flexible connections, 90 degree bend, CT’s in position, seal off bushing,
inspection cover and belows)

d) Air leakage rate

e) Water tightness test

5.07.00 Routine Test

5.07.01 Routine test shall be conducted at manufacturer’s works on each busduct all
other components as per relevant Indian Standards & Quality Asssurance Sub-
section.

5.07.02 Also Radiography Test (RT) shall also be conducted as follows:

1. 2% on circumferential butt weld joint of conductor and 2% on

enclosure (Circumferential and longitudinal Butt weld joints).

2. 2% on flexible conductor

6.00.00 AUXILIARY EQUIPMENT

All component parts and auxiliary equipment such as current transformer,

voltage transformer, neutral grounding transformer, lightning arrestor, surge
capacitor, insulator etc. shall be routine tested as per relevant Indian
Standards.
All cubicles shall be completely wired up at the factory and subject to wiring
check, and power frequency withstand tests on control/ secondary wiring.

7.00.00 TEST WITNESS

Test shall be performed in presence of Owner/Purchaser’s representative so

desired by the Owner/Purchaser. The Contractor shall give at lest fifteen (15)
days advance notice of the date when the tests are to be carried out.

Obra “C” 2x660 MW Thermal Power

Extension Project
Bidding Doc. No. : 14A22-SPC-G-0001
HeadOffice Uploading Date And Time::::: Wednesday, September 30, 2015 5:48:24 PM

DCPL Volume IV: Ch 05: Isolated Phase Bus Ducts and

Neutral Grounding
Electrical Works
Equipment
Sheet l 16 of 21

8.00.00 TEST CERTIFICATES

Certified reports of all the tests carried out at the works shall be furnished in
six (4) copies for approval of the Owner/Purchaser.

The equipment shall be dispatched from works only after receipt of

Owner/Purchaser's written approval of the test reports.

Type test certificate on any equipment, if so desired by the Owner/

Purchaser, shall be furnished. Otherwise, the equipment shall have to be
type tested, free of charge, to prove the design.

9.00.00 Commissioning Checks

Pre-Commissioning/Commissioning
10% radiography and 100% DP test on all site welded joints of busbar
and enclosure.
Milli volt drop test
Ratio and polarity tests on current and voltage transformers
Insulation measurement of equipment and all wiring
Functional test on pressurization (Tightness test as per ANSI 37.20).
One minute high potential power frequency withstand test at full test
voltage.

DATA SHEET

1. Generator Busduct
a) Type Isolated phase, continuous self- cooled,
pressurized type
b) Service Indoor/Outdoor
c) Rating
Rating Continuous Symmetrical S.C. Momentary peak
KA rms KA
i) Main run 25,000A* During Detailed During Detailed
Engineering Engineering
ii) Delta run 15000A* During Detailed During Detailed
Engineering Engineering
iii) Tap-off for 2250A* During Detailed During Detailed
UT/UAT, VT & Engineering Engineering
STP Cubicle,
and NG
cubicle.
d) Permissible Temp Rise
--Bus conductor 55 C
--Bus enclosure 30 C
2. Current Transformer
a) Type Epoxy cast resin, ring type
b) Service Indoor
c) Mounting Within bus enclosure
Other ratings Accuracy Class
--Low forward power relay,
Acceptance testing, energy 0.2
accounting, audit meters

Obra “C” 2x660 MW Thermal Power

Extension Project
Bidding Doc. No. : 14A22-SPC-G-0001
HeadOffice Uploading Date And Time::::: Wednesday, September 30, 2015 5:48:24 PM

DCPL Volume IV: Ch 05: Isolated Phase Bus Ducts and

Neutral Grounding
Electrical Works
Equipment
Sheet l 17 of 21

d) -- Reverse power relay, AVR, 0.5

EHG and other
measurement
e) Differential Proteciton PS

f) Other Protection 5P20

NOTE: CTs for energy meters for energy accounting and audit purpose shall
be located at a point after the generator stator terminals and before the tap
off to the VATs.

3. Lightning arrester
a) Type Gapless type
b) Service Indoor
c) Rated voltage as per generator Voltage
d) Nominal discharge 10KA
e) Power frequency spark over Surge protection of the generator having
voltage power frequency one minute high
potential test voltage at works of
2U+1kV and BIL of 4U+5kV (peak),
where U is the line to line voltage
4. Voltage Transformer
a) Type Epoxy cast resin, draw out
b) Service Indoor
c) Rated Voltage
- Primary Generator voltage in kV/ 3 V
- Secondary 110 / 3 V
d) Winding connection
- Primary Grounded Wye
- Secondary Grounded Wye
e) Insulation Class E or better
f) Over voltage Factor
- Continuous 1.2
- 30 seconds 1.9
g) Other ratings Accuracy Class VA burden
- Protection 3P 100

- Automatic Voltage 0.5 100

Regulator (AVR)/ Electro
Hydraulic Governor(EHG)/
Synchronization and other
measurements 0.2 100
- Acceptance testing,
energy accounting and
audit meters
5. Neutral Grounding transformers
a) Type Cast resin insulated self cooled
b) Service Indoor
c) Phase Single
d) Voltage ratio Generator Voltage/240V
e) Rated output DDE
f) Duty time rating 5 minutes
g) Insulation class Class F or better
h) Max. Temp. rise 90 C rise above 50 C ambient
6. Neutral Grounding Resistor

Obra “C” 2x660 MW Thermal Power

Extension Project
Bidding Doc. No. : 14A22-SPC-G-0001
HeadOffice Uploading Date And Time::::: Wednesday, September 30, 2015 5:48:24 PM

DCPL Volume IV: Ch 05: Isolated Phase Bus Ducts and

Neutral Grounding
Electrical Works
Equipment
Sheet l 18 of 21

a) Type Grid Type

b) Material Punched Stainless Steel
c) Service Indoor
f) Voltage 250 Volt
g) Duty (Time rating) 5 minutes
h) Max. temp. rise 300 C above 50 C ambient
7. Surge Capacitors 0.125 micro-farad/ Phase, 24 kV
8. Service Voltage
a) Hot air Blowing 415V±10%, 3ph, 50Hz, ±5%, 4wire
b) Space heating cubicle 240V±10%, 1ph, 50Hz, ±5%, 2wire
lighting circuit

“*” - Indicative value. Bidder to decide actual values by calculations.

Obra “C” 2x660 MW Thermal Power

Extension Project
Bidding Doc. No. : 14A22-SPC-G-0001
HeadOffice Uploading Date And Time::::: Wednesday, September 30, 2015 5:48:24 PM

DCPL Volume IV: Ch 05: Isolated Phase Bus Ducts and

Neutral Grounding
Electrical Works
Equipment
Sheet l 19 of 21

ANNEXURE

LIST OF TRANSDUCERS FOR GENERATOR BUSDUCT CT’S/PT’S

S.N Measuring Dual Output Transducer Remarks

o Parameter (Range) Input/Output

1 Generator Voltage (0- 0-110V ac/4-20mA Three (3) nos.

30 KV) RY, YB & BR
Voltage

2 Generator Active 0-110V ac/4-20 mA 0-5A ac

Power
3 Generator Reactive 0-110V ac/4-20 mA 0-5A ac
Power
4 Generator frequency 0-110V ac/4-20 mA
(45-55 Hz)
5 Generator power 0-110V ac/4-20 mA
factor(0.5lead-1-0.5 0-5A ac
lag)
6 Generator Ammeter R- 0-5A ac/4-20 mA
Phase
7 Generator Ammeter Y- 0-5A ac/4-20 mA
Phase
8 Generator Ammeter B- 0-5A ac/4-20 mA
Phase

9 Generator MWH Suitable Range

Obra “C” 2x660 MW Thermal Power

Extension Project
Bidding Doc. No. : 14A22-SPC-G-0001
HeadOffice Uploading Date And Time::::: Wednesday, September 30, 2015 5:48:24 PM

DCPL Volume IV: Ch 05: Isolated Phase Bus Ducts and

Neutral Grounding
Electrical Works
Equipment
Sheet l 20 of 21

C.T. RATINGS
_____________________________________________________________________________________________________________
C.T. Description Current Output Class ISF Knee Point Excitation Secondary
Type Ratio Voltage Vk Current Resistance
A/A VA Volt * mA ** Ohm +
_____________________________________________________________________________________________________________

MAIN RUN C.T.S (Typical)

D2. GEN. Differential 25000*/1 - PS - ---------------Bidder to decide----------

D3. GEN. Differential 25000*/1 - PS - ---------------Bidder to decide----------

F. GEN Metering 25000*/1 Biddet to decide 0.5 <5 - - -

G1. AVR &Load 25000*/1 Biddet to decide 0.5 <5 - - -

Transducer

G2. AVR &Load 25000*/1 Biddet to decide 0.5 <5 - - -

Transducer

TAP OFFS C.T.S (Typical)

A2. Overall Differential 25000*/1 - PS - ---------------Bidder to decide----------

A3. UT Over current 2250*/1 Biddet to decide 5P20 - - - -

H1. UT Differential 2250*/1 - PS - ---------------Bidder to decide----------

I. UT Metering 2250*/1 Biddet to decide 0.2 <5 - - -

Obra “C” 2x660 MW Thermal Power

Extension Project
Bidding Doc. No. : 14A22-SPC-G-0001
HeadOffice Uploading Date And Time::::: Wednesday, September 30, 2015 5:48:24 PM

DCPL Volume IV: Ch 05: Isolated Phase Bus Ducts and

Neutral Grounding
Electrical Works
Equipment
Sheet l 21 of 21

GEN. BUSDUCT NEUTRAL SIDE (Typical)

A1. Overall Differential 25000*/1 - PS - ---------------Bidder to decide----------

B1. GEN. Relaying 25000*/1 Biddet to decide PS - ---------------Bidder to decide---

B1. GEN. Relaying 25000*/1 Biddet to decide PS - ---------------Bidder to decide----------

C. PERF. Test & 25000*/1 Biddet to decide 0.2 <5 - - -
EHG System

NG XFMR SEC. C.T.

M1. Back-up Over current Bidder to decide 5P20 - - - -

M2. Back-up Over current Bidder to decide 5P20 - - - -

_________________________________________________________________________________________________________
“*” - Bidder to decide actual values by calculations.

Obra “C” 2x660 MW Thermal Power

Extension Project
Bidding Doc. No. : 14A22-SPC-G-0001
HeadOffice Uploading Date And Time::::: Wednesday, September 30, 2015 5:48:24 PM

DCPL Volume IV: Ch 06: Interconnecting Auto-

Transformer
Electrical Works
Sheet l 1 of 23

Chapter 6 : INTERCONNECTING AUTO-TRANSFORMER

1.00.00 Scope

Two (2) sets, 765/ 3/400/ 3/33kV, 3X333 MVA, ONAN/ONAF/OFAF single
phase, Yna0d11 auto-transformer shall be installed in the 765kV switchyard to
provide an interconnection between 765kV and 400kV systems so as to enable
bi-directional flow of power.

Both the auto-transformers shall be suitable for running in parallel and their tap
changers shall be controlled by keeping any one as master and other as slave.
The 33kV tertiary winding shall be unloaded.

Two (2) nos. 1050MVA Interconnecting Transformers Bank each comprises of

three (3) nos single phase unit shall be provided for two ICT bays. There will be a
common single phase unit auto transformer of equally rated capacity like other
single phase unit & suitable for live line transfer incase of failure of any one
single phase unit of auto transformer of two ICT-bays. Bidder shall make suitable
arrangement of live line transfer accordingly.

1.02.00 Electrical Performance

1.02.01 Transformer shall operate without injurious heating at the rated MVA at any
voltage within 10 percent of the rated voltage of that particular tap
continuously.

1.02.02 The transformer shall be capable of remaining in operation without injurious

heating when forced cooling has failed at full load for at least 10 minutes.

1.02.03 Transformers shall be capable of withstanding the mechanical and thermal effects
of short circuit resulting from different forms of system faults, including transfer
surges, which could be reflected through capacitor coupling between windings.
The ability to withstand dynamic short circuit shall be demonstrated by the
CONTRACTOR by calculations.

1.02.04 The transformer shall be rated to deliver rated MVA continuously even at the
lowest tap without exceeding specified temperature rise under site conditions.

2.0000 GENERAL

2.01.00 STANDARDS

All equipment provided under the specification shall in general, conform to the
latest issue of the following standards:

Indian
Standards Title
No.
(1) (2)
IS: 2026 Power transformers
IS: 3639 Fittings & accessories for power transformers

IEC: 60296, Insulating oil for transformers and switchgear

BS:

Obra “C” 2x660 MW Thermal Power Extension

Project

Bidding Doc. No. : 14A22-SPC-G-0001

HeadOffice Uploading Date And Time::::: Wednesday, September 30, 2015 5:48:24 PM

DCPL Volume IV: Ch 06: Interconnecting Auto-

Transformer
Electrical Works
Sheet l 2 of 23

IS: 2099 Bushing for alternating voltages above 1000 V

IS: 2705 Current transformers

IS: 325 Three phase induction motors
IS: 3637 Gas operated relays
IS: 4691 Degree of protection provided by enclosure for rotating
electrical
machinery
IS: 13947 Degree of protection provided by enclosure for low
voltage
switchgear & control
IS : 5 Colours for ready mix paints
IS: 1866 Code of practice for maintenance
& Supervision of mineral insulating oil in equipment

IS: 6272 Industrial cooling fans

IS: 6600 Guide for Loading of oil immersed transformers

IS: 3347 Specification for dimensions of porcelain bushing

IS: 8468 On load tap changers

IEC: 60 High voltage test technique
IEC: 71 Insulation co-ordination
NEMA-TR-1 NEMA standard publication for Power transformers

IS: 10596 Code of practice for selection, Installation operation &

maintenance of pumps for industrial
IS: 9434 Guide for sampling & analysis of free & dissolved gas & oil
from oil filled electrical equipment
IS: 12676 Dimensions for OIP insulated condenser bushings
Cigre SC 12 Guidelines for conducting Design reviews for transformers
(working 100MVA and 123KV and above
Group 12.22)

IEC-60076 Ability to withstand S. C. Test (Guidelines for conducting

Part-5 the Design review)
(PointA.3)

2.02.00 The electrical installation shall meet the requirements of Indian Electricity act
2003.

2.03.00 The transformers shall be having constant ohmic impedance between HV and IV
on all taps.

2.04.00 External or internal reactors shall not be used to achieve HV/LV and IV/LV
impedance specified.

3.00.00 PERFORMANCE

(a.) Inter-Connecting Transformer would be used for bi-directional flow of

rated power.
(b.) Inter Connecting Transformers shall be capable of operating under
Obra “C” 2x660 MW Thermal Power Extension
Project

Bidding Doc. No. : 14A22-SPC-G-0001

HeadOffice Uploading Date And Time::::: Wednesday, September 30, 2015 5:48:24 PM

DCPL Volume IV: Ch 06: Interconnecting Auto-

Transformer
Electrical Works
Sheet l 3 of 23

natural cooled condition up to the specified load. The forced cooling

equipment shall come into operation by preset contacts of winding
temperature indicator & the transformer shall operate as a forced
cooled unit initially as ONAF up to specified load and then as OFAF.

(c.) Total cooling system of transformer with oil forced & air forced (OFAF)
cooling shall be so designed that during total failure of power supply to
cooling fans & oil pumps, the transformer shall be able to operate at full
load for at least ten (10) minutes without the calculated winding hot
spot temperature exceeding 140 deg. C. Also stopping of one of the
cooling fan should not have any effect on the cooling system of
transformers.

(d.) The maximum flux density in any part of the core & yoke at the rated
MVA, voltage & frequency shall be such that under 110% continuous
voltage condition it does not exceed 1.9 tesla.

(e.) The transformer & all its accessories including CTs etc, shall be
designed to withstand without injury the thermal & mechanical effects of
any external short circuit to earth & of short circuits at the terminal of any
winding for a period of 3 secs. Contractor shall submit the short circuit
withstands calculations.

(f.) Transformers shall withstand, without injurious heating, combined

voltage & frequency fluctuations, which produce the following over fluxing
condition:
110 % - continuous
125% - for one minute
140% - for five seconds

Bidder shall indicate 150% & 170% over voltage withstand time. Over fluxing
characteristics up to 170 % shall be submitted.

g) The air core reactance of HV winding of transformers shall not be less

than 20%.

h) The transformers shall be capable of being operated continuously

without danger on any tapping at the rated MVA with voltage variation
of 10% corresponding to the voltage of tapping.

i) The transformers shall be capable of being loaded in accordance with IS:

6600/ IEC: 60076-7 up to load of 150 %. There shall be no limitation
imposed by bushings, tap changers etc. or any other associated
equipment.
j) Max oil velocity shall be such that it does not lead to static discharges
inside the transformer.

4.00.00 CONSTRUCTION

The features & construction details of each transformer shall be in accordance

with the requirement stated hereunder.

4.01.00 TANK AND TANK ACCESSORIES

(a.) Tank shall be of welded construction & fabricated from tested quality
Obra “C” 2x660 MW Thermal Power Extension
Project

Bidding Doc. No. : 14A22-SPC-G-0001

HeadOffice Uploading Date And Time::::: Wednesday, September 30, 2015 5:48:24 PM

DCPL Volume IV: Ch 06: Interconnecting Auto-

Transformer
Electrical Works
Sheet l 4 of 23

low carbon steel of adequate thickness. After completion of welding, all

joints shall be subjected to visual examination. In case of doubt
particular weld shall be checked by D.P. Test. However weld joints of
load bearing member shall be left unpainted till carrying out of jacking
test followed by DP Test during final inspection of transformer. Details of
acceptance norms of welding shall be submitted for Purchaser’s
approval which shall include permissible undercut, overlap, surface crack,
porosity, out of alignment of plate surface in butt joints, maximum gap
due to incorrect fit up of fillet joint etc.

(b.) Transformers shall be with bell type tank with the joint at about 500-mm
above the bottom of the tank.

(c.) Each tank shall be provided with :

i) Lifting lug suitable for lifting the equipment complete with oil.

ii) A minimum of four jacking pads in accessible position to enable

the transformer complete with oil to be raised or lowered using
hydraulic or mechanical screw jacks.

iii) Suitable haulage holes shall be provided for transformer wheeling

in all four directions.
(d.) The transformers are to be provided with flanged bi-directional wheels &
axles and shall be mounted on wheels on foundation. Suitable locking
arrangement shall be provided for the wheels to prevent accidental
movement of transformer. The rail track gauge shall be 1676 mm along
longer axis as well as along shorter axis.

(e.) At least two adequately sized inspection openings one at each end of the
tank shall be provided for easy access to bushing & earth
connections. The inspection covers shall not weight more than 25 Kg.
Handles shall be provided on the inspection cover to facilitate lifting.

(f.) All bolted connections shall be fitted with weather proof & hot oil resistant
of ‘O’ ring of Nitrile rubber in between for complete oil tightness. If
gasket is compressible, metallic stops shall be provided to prevent over
compression.

4.02.00 Core
(a.) The core shall be constructed from high-grade non-ageing, cold rolled,
super grain oriented, silicon steel laminations. CRGO silicon steel shall be
HI-B grade or equivalent.
(b.) The insulation of core to tank, clamp to tank & core to clamp plates
shall be able to withstand a voltage of 10 kV (rms) for 1 minute in air.

(c.) In order to ensure prevention of multiple core earthing, core isolation test
at 10 kV for 1 minute shall be done during pre commissioning stage. To
facilitate above, core earthing has to be done outside the tank with
suitable bushing.

(d.) Adequate lifting lugs will be provided to enable the core & windings to be
lifted.

4.03.00 Windings

Obra “C” 2x660 MW Thermal Power Extension

Project

Bidding Doc. No. : 14A22-SPC-G-0001

HeadOffice Uploading Date And Time::::: Wednesday, September 30, 2015 5:48:24 PM

DCPL Volume IV: Ch 06: Interconnecting Auto-

Transformer
Electrical Works
Sheet l 5 of 23

(a.) The contractor shall ensure that windings are made in dust proof &
conditioned atmosphere. The bidder shall furnish details of the
facilities available at his works along with the bid.

(b.) The conductors shall be of electrolytic grade copper free from scales &
burrs.

(c.) All windings of the transformers having voltage less than 66 kV shall be
fully insulated.

4.04.00 Insulating Oil

4.04.01 No inhibitors shall be used in oil. The oil supplied with transformers shall conform
to following while tested at supplier’s premises & shall have following parameters.

Oil property and their permissible values shall be as follows:

S. No. Property Permissible Values

1. Kinematic Viscosity, mm2/s 12.0 at 40
deg. C
2. Flash Point, d e g . C 140
3. Pour point, d e g . C (-)40
4. Appearance Clear , free from
sediment and
5.
Density kg/dm3 at 20 deg. C
0.895
6. Interfacial Tension N/m at 25 d e g . C 0.0
7. Neutralisation value, mg KOH/g
8. Corrosive sulphur Non
9. Water content mg/kg 30
10. Anti oxidants additives Not
11. Oxidation Stability
12. Breakdown voltage As delivered, kV
13. Dissipation factor, at 90 deg. C And
14. PCA content 1%
15. Impulse withstand Level, kVp
16. Gassing tendancy at 50 Hz after 120 5

Subsequently oil samples shall be drawn at:

1) Prior to filling in main tank at site & tested for

i) BDV 60 kV (min)
ii) Moisture content 10 ppm (max.)
iii) Tan delta at 90 deg. C 0.005 (max.)
iv) Interfacial tension 0.04 N/m(min)
2) Prior to energization at site for following properties &
acceptance norms:
i) BDV 60 kV (MIN)
ii) Moisture content 10 ppm (max.)
iii) Tan delta at 90 deg. C 0.05 (max.)
iv) Interfacial tension 0.03 N/m (min)

Obra “C” 2x660 MW Thermal Power Extension

Project

Bidding Doc. No. : 14A22-SPC-G-0001

HeadOffice Uploading Date And Time::::: Wednesday, September 30, 2015 5:48:24 PM

DCPL Volume IV: Ch 06: Interconnecting Auto-

Transformer
Electrical Works
Sheet l 6 of 23

4.04.02 Oil Preservations System

Bidder shall offer air cell type oil sealing in the conservator to prevent
oxidation and contamination of oil due to contact with water. The
requirement of air cell type constant oil preservation system are given
below:

1) Contact of the oil with atmosphere is prohibited by using a flexible

urethane or nitrile rubber reinforced with nylone cloth air cell.

2) The connection of air cell to the top of reservoir is by air proof seal
preventing entrance of air into the conservator.

3) The temperature is likely to rise upto 100 Deg C when the transformer is
in operation. As such air cell used shall be suitable for operating
continuously at 100 deg. C.

4) A silicagel breather shall be provided in the air side vent line.

4.05.00 Terminal Arrangements

4.05.01 Bushings
(a.) The electrical & mechanical characteristics of bushings shall be in
accordance with IS: 2099, IS: 3347 & IS: 12676.

(b.) Bushings for 52 kV & above shall be of the oil filled condenser type &
shall be of draw lead/ rod type to facilitate removal. Bushings of
rating below 52 kV shall be solid porcelain or oil communicating type.

(c.) Condenser type bushings shall be provided with:

1) Oil level gauge
2) Oil filling plug & drain valve (if not hermetically sealed)
3) Tap for capacitance & tan delta test.
(d.) Clamps & fittings shall be of hot dip galvanized steel.

(e.) Bushing & fittings shall be provided with vent pipes that shall be
connected to route any gas collection through the Buchholz relay.

(f.) No arcing horns shall be provided on the bushings.

4.05.02 TERMINAL CONNECTOR

(a.) Bushing terminal shall be provided with terminal connectors of approved
type & size for connection to external part. Terminal connectors
must have been successfully type tested as per IS: 5561.
(b.) Terminal connectors shall be suitable f o r ACSR conductor or Al Tube
bus as per required ampacity and layout requirement. These shall be
suitable for horizontal take off.

(c.) Aluminum alloy if used shall conform to designation 4600 M of IS:

617 or of better quality.

(d.) No part of a clamp shall be less than 10 mm thick.

Obra “C” 2x660 MW Thermal Power Extension

Project

Bidding Doc. No. : 14A22-SPC-G-0001

HeadOffice Uploading Date And Time::::: Wednesday, September 30, 2015 5:48:24 PM

DCPL Volume IV: Ch 06: Interconnecting Auto-

Transformer
Electrical Works
Sheet l 7 of 23

(e.) All ferrous parts shall be hot dip galvanized conforming to IS: 2633.

(f.) For bi-metallic clamp, copper alloy liner of minimum 2-mm thickness
shall be cast integral with aluminum body. Alternatively Bidder may
offer bimetallic connector with loose bimetallic sleeve.

(g.) Flexible connectors shall be made from tinned copper sheets.

(h.) Size of terminal/conductor for which the clamp is suitable & rated
current under the conditions shall be embossed/punched on each
component of the clamp, except hardware.

(i.) Rated current of the terminal connectors shall be same as that of

corresponding bushing. However the short circuit current rating for 400
kV connectors shall be 50 kA for 1 second.

4.06.00 Bushing Current Transformer

(a.) Current transformer shall comply with IS: 2705.

(b.) It shall be possible to remove turret mounted current transformers

from the transformer tank without removing the tank cover. Necessary
precautions shall be taken to minimize eddy currents & local heat
generated in the turret.

(c.) All secondary leads shall be brought to a weatherproof terminal box

near each bushing. These terminals shall be wired out to cooler
control cabinet using separate cables for each core.
4.07.00 Terminal Marking

The terminal marking & their physical position shall be as per IS: 2026 unless
specified otherwise.

4.08.00 Neutral Earthing Arrangement

The neutral of transformers shall be brought through insulated support from
tank to the ground level at a convenient point with copper flat, for
connection to ground network. The connection shall be made by using two
(2) bolted neutral grounding terminals with necessary accessories.

4.09.00 Marshalling Box (M. Box)

(a.) Each transformer shall be provided with one M. Box housing all the
cooler control, OTI, WTI for each winding etc. Each transformer shall
also be provided with OLTC control cabinet, which will house the OLTC
controls & indications.
(b) The sheet steel used for all the cabinet boxes shall be at least 2.5 mm
thick. The gasket used shall be of neoprene rubber. A space heater &
cubicle lighting with on–off switch shall be provided in each cabinet. A
circuit breaker/contactor with thermal overload device for controlling
the AC auxiliary supply shall be provided.

(c.) Terminal Blocks

1) The terminal blocks to be provided shall be fully enclosed with
removable covers & made of molded, non-inflammable plastic

Obra “C” 2x660 MW Thermal Power Extension

Project

Bidding Doc. No. : 14A22-SPC-G-0001

HeadOffice Uploading Date And Time::::: Wednesday, September 30, 2015 5:48:24 PM

DCPL Volume IV: Ch 06: Interconnecting Auto-

Transformer
Electrical Works
Sheet l 8 of 23

material with blocks & barriers molded integrally. The terminal

blocks shall be 650V grade & have 10 A continuous rating.
Terminal blocks for current transformer secondary leads shall be
provided with test links & isolating facilities. Also current
transformer secondary leads shall be provided with short
circuiting & earthing facilities. At least 20% spare terminals shall
be provided on each panel & these spare terminals shall be
uniformly distributed on all terminal blocks.

2) Terminal blocks shall be suitable for connecting the following

conductors on each side:
i) Current transformer circuits - minimum of two No. of
2.5 sq. mm copper wires
each side

ii) Other circuits - minimum of one No. of

2.5 sq. mm copper wire
each side

(d.) The temperature indicators shall be so mounted that the dials are
not more than 1500 mm from ground level. Glazed door of suitable
size shall be provided for convenience of reading.

(e.) Cooler control cabinet / marshalling box of each type for each
rating of transformer shall be suitable for IP 55 protection in
accordance with IS: 13947.

(f.) One dummy terminal block in between each trip wire terminal
shall be provided.

(g.) M. Box shall have two compartments one for AC power supply
arrangement and other for CT and control cable, as high temp.
inside kiosks make CT cables brittle.

(h.) Wiring scheme shall be engraved in a plate and the same shall be
fixed inside the Marshalling box door.

(i.) M. Box shall preferably be Tank Mounted.

4.10.00 Cooling Equipment

The transformer shall be provided with 2x60% cooling banks. Each bank shall be
provided with adequate number of fans, two oil pumps (one in service and other
stand-by) and one standby fan. Each radiator bank shall be provided with uni-
directional bypass valve to permit oil to bypass the pump in the event of pump
failure. It shall be possible to completely isolate any one of the radiator banks for
maintenance, while the transformer is in service. Flexible expansion joints, one
each, on top and bottom pipe connections for each radiator bank shall be
provided. Each radiator bank shall have at least two (2) extra radiators to
facilitate usage of the same in case of leakage in the other radiators. If radiators
are arranged in groups, each group of radiators shall have upper and lower shut
off valves with blanking at either ends. Each radiator to have topmost vent and
bottom most drain plugs & bracings between radiators.

Cooling equipment shall include local and remote cooler control cabinets
complete with controls, indicators etc.
Obra “C” 2x660 MW Thermal Power Extension
Project

Bidding Doc. No. : 14A22-SPC-G-0001

HeadOffice Uploading Date And Time::::: Wednesday, September 30, 2015 5:48:24 PM

DCPL Volume IV: Ch 06: Interconnecting Auto-

Transformer
Electrical Works
Sheet l 9 of 23

4.11.00 Composite Monitoring System (CMS)

The system shall provide supervision, control & communication of various

operating condition and condition monitoring of Inter Connecting auto
Transformer. Individual CMS shall be provided for each ICT.

4.11.01 Salient Technical Features:

i) The measured signals (Analog, Digital, etc) from various sensors shall
be brought to M. Box/CCC and will interact with CMS. The system
should be processor based controller.

ii) CMS shall provide display of real time information through HMI for
calculated winding hot spot temperature, Loss of insulation life,
Overloading capacity, Ageing rate etc. CMS shall also indicated residual
life of insulation based on loading pattern.

iii) Cooling system supervision and control logics shall be built in soft with
local indication display in CMS as given in specification.

iv) Various Output signals & indications from CMS shall be available at
M.Box (for ICT) in the employer’s required format (digital, analog,
potential free etc). Suitable hardware and software shall be provided
to interface these signals with DDCMIS/SCADA through OPC/IEC 61850
protocol.

v) All sensors, acquisition units, cables, processor, software etc. shall be

in scope of bidder.

vi) The CMS shall be provided with 2x100% processors in hot standby
mode. In case a failure of working processor, the standby processor
shall take over the operation automatically by bumpless transfer.
Potential free contacts shall be provided for CMS unit/processor
failure, supply failure and auto changeover in addition to local lamp
indication.

4.11.02 Operating Condition:

a. The CMS system will be installed in outdoor in transformer marshalling box

without any external cooling requirement. The CMS shall be suitable for
operation at 50 deg. C ambient temperature, 85% relative humidity and
industrial environment.

b. The operating voltage for CMS shall be compatible for both DC and AC.

4.11.03 Tests requirements for CMS:

i) Factory acceptance test(Routine): The logics built up & functional

tests in the CMS shall be tested at works .

ii) Test Reports (as per recognized national/international

standards): EMC Tests, Temperature Withstand Tests, Atmospheric
Environmental Tests, Dielectric Tests & Mechanical Stress tests reports
shall be submitted.

Obra “C” 2x660 MW Thermal Power Extension

Project

Bidding Doc. No. : 14A22-SPC-G-0001

HeadOffice Uploading Date And Time::::: Wednesday, September 30, 2015 5:48:24 PM

DCPL Volume IV: Ch 06: Interconnecting Auto-

Transformer
Electrical Works
Sheet l 10 of 23

4.11.04 OLTC control & Remote Electrical group control through CMS

CMS shall also incorporate OLTC control scheme & remote electrical group
control during the parallel operation of transformer. This is in addition to
independent control of OLTC. CMS shall have four modes of selection viz.
master, follower, independent and OFF mode. This shall enable operator to
select modes of OLTC either in master, follower, or independent mode
through SCADA/DDCMIS. CMS system shall be able to function in parallel
operation in Master-Follower mode for upto two transformers. CMS shall also
have provision for OLTC raise/lower control through SCADA / DDCMIS, this is
in addition to the manual control of OLTC raise/lower. Various OLTC input &
output signals/indications/alarms shall be wired upto Transformer’s M. Box
through CMS by the bidder.

4.12.00 Onload Tap Changer (OLTC)

a) OLTC used shall be compatible with tapping winding. The selection criteria
for OLTC w.r.t. rated current, rated voltage, rated short circuit current,
overload withstand capability & dielectric withstand levels shall be submitted
by the supplier for owner’s approval. Recovery voltage calculations shall also
be furnished in case OLTC is provided with reversing switch.

b) The current diverting contacts shall be housed in a separate oil chamber not
communicating with oil in main tank of transformer. The OLTC oil
chamber shall have oil filling drain plug, relief vent & level glass.

c) Tap equipment shall be suitable for local & remote electrical control & local
manual control. The features to be provided with these controls are
detailed below:

1) Manual control

The cranking device for manual operation of OLTC gear shall be

removable & suitable for operation by a man standing on ground level.
The mechanism shall be complete with the following

- Mechanical tap position indicator which shall be clearly visible from

near the transformer.
- Mechanical operation counter.
- Mechanical stops to prevent over cranking of the mechanism beyond
the extreme positions.
- The manual control considered as backup to the motor operated tap
control shall be interlocked with the motor startup during manual
operation. The manual operating mechanism shall be labeled to show
the direction of operations for raising the secondary voltage & vice
versa.

2) Electrical control

This includes the following:

- Electrical local control from M. Box /Drive Mechanism.
- Electrical remote control from DDCMIS/SCADA through CMS

The control scheme shall have following features :

Obra “C” 2x660 MW Thermal Power Extension

Project

Bidding Doc. No. : 14A22-SPC-G-0001

HeadOffice Uploading Date And Time::::: Wednesday, September 30, 2015 5:48:24 PM

DCPL Volume IV: Ch 06: Interconnecting Auto-

Transformer
Electrical Works
Sheet l 11 of 23

- An interlock to cutoff electrical control automatically upon recourse

being taken to manual control.
- Selection of point of control local or remote. It shall not be possible
for any two electrical controls to be in operation at the same time.
- Reinforcement of the initiating impulse for a tap change, ensuring a
positive completion once initiated.
- Step by step operation, ensuring only one tap change for each tap
changing command.
- An interlock to cut off the electrical control when it tends to operate
the gear beyond either of the extreme tap positions.
- An interlock to block a command for reverse tap change during
a tap change until the mechanism comes to rest & resets the
circuit for a fresh operation.

The equipment shall be so arranged as to ensure that when a tap

change has commenced, it shall be completed independent of the control
relays and switches.

3) The auxiliary devices for electrical controls of the OLTC shall be

housed either in the OLTC driving mechanism box or in the transformer
M. Box. OLTC shall be equipped with a time delayed INCOMPLETE
STEP alarm consisting of a normally open contact, which closes, if the
tap changer fails to make a complete tap change. The alarm shall not
operate for momentarily loss of auxiliary power. Each transformer on
load tap shall be equipped with a fixed resistor network capable of
providing discrete voltage step for input to the supervisory system.

d) Remote Electrical group control

Refer above clause for OLTC control through CMS.

e) Interconnecting drawing and cable schedule between CMS and control

panel.

f) Measurement for Tan delta values of OLTC to be done before installing in

the transformer.

5.00.00 Fittings

5.01.00 Following minimum fittings are required to be supplied:

a) Drain & lower filter valve with sampling cock.

b) Top filter valve.

c) Pressure relief device with trip contacts.

d) Flanged bi-directional rollers (4 Nos.).

e) Anti-earthquake clamping device.

f) Atmoseal type conservator with shut-off valves, drain valves and silicagel
breather.

g) Double float Buchholz relay with alarm & trip contacts and 2 Nos. shut-off
valves and gas sampling cocks.

Obra “C” 2x660 MW Thermal Power Extension

Project

Bidding Doc. No. : 14A22-SPC-G-0001

HeadOffice Uploading Date And Time::::: Wednesday, September 30, 2015 5:48:24 PM

DCPL Volume IV: Ch 06: Interconnecting Auto-

Transformer
Electrical Works
Sheet l 12 of 23

h) OLTC oil surge relay with alarm & trip contacts.

i) Top oil dial type temperature indicator with alarm & trip contacts.

j) RTD / Transmitter for remote OTI.

k) Winding temperature indicator with alarm & trip contacts.

l) RTD / transmitter for remote WTI.

m) Magnetic oil level indicator.

n) Transmitter for remote tap position indication.

o) Rating & diagram plate.

p) Jacking pads (4 Nos.).

q) Oil flow indicator.

r) Weather proof marshalling kiosk.

s) Earthing terminals (2 Nos).

t) Lifting lugs (4 Nos.) and hauling eyes (8 Nos.).

u) Foundation bolts.

v) Neutral earthing flats supported along the tank on insulators and brought
down up to about 1 metre from ground level.

w) Manhole & handhold for inspection.

x) Air release pipe.

y) Ladder with safety device.

5.02.00 GASKETS

All the gasket shall be of ‘O’ ring of Nitrile rubber for all valves, flanges, HV, MV,
LV & Neutral Turrets, Bushings, Tank rim, etc. For this, all the flanges shall
be machined.

The gaskets shall not deteriorate during the life of transformer if not opened for
maintenance at site. Supplier shall also recommend quality & make of gaskets to
be used for replacement during maintenance if required. All joints flanged or
welded associated with oil shall be such that no oil leakage or sweating occurs
during the life of transformer. The quality of these joints is considered
established, only if the joints do not exhibit any oil leakage or sweating for a
continuous period of at least 3 months during the guarantee period. In case any
sweating / leakage is observed, contractor shall rectify the same & establish for
a further period of 3 months of the same. If it is not established during the
guaranteed period, the guaranteed period shall be extended until the
performance is established.

Obra “C” 2x660 MW Thermal Power Extension

Project

Bidding Doc. No. : 14A22-SPC-G-0001

HeadOffice Uploading Date And Time::::: Wednesday, September 30, 2015 5:48:24 PM

DCPL Volume IV: Ch 06: Interconnecting Auto-

Transformer
Electrical Works
Sheet l 13 of 23

6.00.00 VALVES

a) All valves upto and including 50mm shall be of gun metal or of cast
steel. Larger valves may be of gun metal or may have cast iron bodies
with gun metal fittings. They shall be of full way type with internal screw
and shall open when turned counter clockwise when facing the hand wheel.

b) Suitable means shall be provided for locking the valves in the open and
close positions. Provision is not required for locking individual radiator
valves.

c) Each valve shall be provided with the indicator to show clearly the
position of the valve.

d) Gland packing/gasket material shall be of “O” ring of nitrile rubber for

all the valve’s flanges. All the flanges shall be machined.

e) Oil sampling shall have provision to fix rubber hose of 100mm size to
facilitate oil sampling.

f) After testing, inside surface of all cast iron valves coming in contact
with oil shall be applied with one coat of oil resisting paint/varnish with
two coats of red oxide zinc chromate primer followed by two coats of fully
glossy finishing paint conforming to IS:2932 and of a shade (Preferably
red or yellow) distinct and different from that of main tank surface.
Outside surface except gasket setting surface of butterfly valves shall be
painted with two coats of red oxide zinc chromate conforming to
IS:2074 followed by two coats of fully glossy finishing paint.

g) All hardware used shall be cadmium plated/electro galvanised.

h) Sampling & drain plug/valves should have zero leakage rate.

7.00.00 INSPECTION AND TESTING

(a.) The Contractor shall carry out a comprehensive inspection and testing
program during manufacture of the transformer. An indication of
inspection envisaged by the Purchaser is given i n C h a p t e r 11 o f Vo l .
I I . This is however not intended to form a comprehensive program, as
it is Contractor’s responsibility to draw up and carry out such a program
in the form of detailed quality plan duly approved by Employer for
necessary implementation.

(b.) The Contractor shall carry out all type tests and routine tests
on the transformers. The tests are listed elsewhere in the specification.
(c.) The charges for conducting each type test to be carried out by the
Contractor shall be indicated separately in the bid.
(d.) The equipment checks to be carried out by the Contractor are given
elsewhere in the specification.
(e.) The requirements of site tests are given elsewhere in the specification
(f.) Each transformer shall be completely assembled with all fittings and
accessories meant for the particular transformer before offering for
Obra “C” 2x660 MW Thermal Power Extension
Project

Bidding Doc. No. : 14A22-SPC-G-0001

HeadOffice Uploading Date And Time::::: Wednesday, September 30, 2015 5:48:24 PM

DCPL Volume IV: Ch 06: Interconnecting Auto-

Transformer
Electrical Works
Sheet l 14 of 23

inspection and testing.

8.00.00 TESTS

8.01.00 Routine Tests

8.01.01 All routine test in accordance with IEC 60076 shall be carried out in all the
transformers.

8.01.02 Measurement of Voltage Ratio & phase displacement (as per IEC 60076-1)

8.01.03 Measurement of winding resistance on all the taps (as per IEC 60076-1)

8.01.04 Vector group and Polarity Check (as per IEC 60076-1)

8.01.05 Magnetic Balance and Magnetising Current Test

8.01.06 Measurement of no load current with 415V, 50Hz AC supply

8.01.07 Measurement of no load losses and current at 90%, 100% & 110% of rated
voltage(as per IEC 60076-1).

8.01.08 Load Loss & Short Circuit Impedance Measurement on principal &
Extreme Taps

8.01.09 IR measurement (As per IEC 60076-1)

8.01.10 10 KV core isolation (core-clamp, clamp-tank, core-tank)

8.01.11 Measurement of capacitance & tan delta to determine capacitance between

winding & earth. (Should not exceed 0.5% at 200 C, also refer Note-iii
below)
8.01.12 Dielectric tests shall be carried out as per IEC 60076-3.

8.01.13 Separate Source Voltage Withstand Test (as per IEC 60076-3)

8.01.14 Lightning impulse (Full & Chopped Wave) test on HV, MV & LV windings (as
per IEC 60076-3)

8.01.15 Switching impulse test (as per IEC 60076-3)

8.01.16 ACLD test as per IEC 60076-3 shall be conducted (for U1 & U2 level refer
Note & Table given below)

8.01.17 Repeat no load current/loss measurement & IR after completion of all

electrical test

8.01.18 Oil leakage test on completely assembled transformer along with radiators.

8.01.19 Jacking test followed by D.P. test

8.01.20 Frequency Response Analysis test

8.01.21 Marshalling Box/Cable box: It shall not be possible to insert a thin sheet of
paper under gaskets and through enclosure joints.

Obra “C” 2x660 MW Thermal Power Extension

Project

Bidding Doc. No. : 14A22-SPC-G-0001

HeadOffice Uploading Date And Time::::: Wednesday, September 30, 2015 5:48:24 PM

DCPL Volume IV: Ch 06: Interconnecting Auto-

Transformer
Electrical Works
Sheet l 15 of 23

8.01.22 IR measurement on wiring of Marshalling Box.

8.02.00 Type Test

8.02.01 ACSD test as IEC 60076-3 (also refer Table-2 given below)

8.02.02 Short circuit test (special test) as per IEC 60076-5. Following shall also be
conducted before & after SC test:
a) DGA
b) FRA

8.02.03 Temperature Rise test at a tap corresponding to maximum losses & at

minimum 110% of rated current of corresponding tap). DGA shall be
conducted on oil sample taken before & immediately after temp. rise test.
Gas analysis shall be as per IS: 9434 (based on IEC: 60567), results will be
interpreted as per IS: 10593 (based on IEC: 60599).

Infra red thermography shall be done during temp rise test. Result shall be
recorded for future reference.

8.02.04 Zero sequence impedance measurement test (Special test)

8.02.05 Measurement of power taken by the fans & pumps (special test)
8.02.06 Measurement of harmonics of no load current (special test)

8.02.07 Measurement of acoustic noise level as per NEMA TR-1 (special test)
8.02.08 Determination of transient voltage transfer characteristics (Special test).
(Measure the transferred surge on LV tertiary winding due to HV lightning
impulse & MV lightning impulse)
NOTE:-

i) All the type/special tests & temperature rise test shall be conducted after
performing Short Circuit Test. If Tank Vacuum & Pressure Test is to be carried
out then it shall be conducted before SC test.

ii) The power factors should not exceed 0.5% (at 20 deg C). However in case of
deviation from limiting values the same shall be resolved in line with IEEE Std-
62.

iii) For ACLD Test U1 & U2 are as follows:-

a) U1=510 kV & U2 = 460 kV

Table-1
Test ACLD/ACSD
Max allowed change in 100 pC
PD after voltage
enhancement
The background noise level shall not exceed
100 pC.

Obra “C” 2x660 MW Thermal Power Extension

Project

Bidding Doc. No. : 14A22-SPC-G-0001

HeadOffice Uploading Date And Time::::: Wednesday, September 30, 2015 5:48:24 PM

DCPL Volume IV: Ch 06: Interconnecting Auto-

Transformer
Electrical Works
Sheet l 16 of 23

Table-2
(Test Voltage for ACSD)
Highest System 420 KV
Voltage (Um)
U1 630 KV
U2 (Ph-Ph) 545 KV
U2 (Ph-E) 365 KV

8.03.00 TANK TESTS

8.03.01 Routine tests

1) Oil leakage test on assembled transformer

All tank and oil filled compartment shall be tested for oil tightness by
being completely filled with oil of viscosity not greater than that of
specified oil at the ambient temperature and applying pressure equal to
the normal pressure plus 35 kN/m2 measured at the base of the tank.
The pressure shall be maintained for a period of not less than 6 hours
during which time no sweating shall occur. This test shall be done on
completely assembled transformer alongwith radiators.

8.03.02 Type Tests

1) Vacuum test

Each type of transformer tank shall be subjected to the specified

vacuum. The tank designed for full vacuum shall be tested at an
internal pressure of 3.33 kN/m2 absolute (25 torr) for one hour. The
permanent deflection of the plate after the vacuum has been released
shall not exceed the values specified below:

Horizontal Length of Flat Permanent deflection

Plate (in mm) (in mm)
Up to and including 750 5.0
751 to 1250 6.5
1251 to 1750 8.0
1751 to 2000 9.0
2001 to 2250 11.0
2251 to 2500 12.5
2501 to 3000 16.0
Above 3000 19.0

2) Pressure Test

Transforer tank of each type shall be subjected to a pressure

corresponding to twice the normal head of oil or to the normal pressure
plus 35 kN /m2 whichever is lower, measured at the base of the tank
and maintained for one hour. The permanent deflection of the plates

Obra “C” 2x660 MW Thermal Power Extension

Project

Bidding Doc. No. : 14A22-SPC-G-0001

HeadOffice Uploading Date And Time::::: Wednesday, September 30, 2015 5:48:24 PM

DCPL Volume IV: Ch 06: Interconnecting Auto-

Transformer
Electrical Works
Sheet l 17 of 23

after the excess pressure has been released shall not exceed the figure
specified above for vacuum test.

9.00.00 Pre-shipment Checks at Manufacture’s Works

a) Check for interchangeability of similar transformers for mounting

dimensions.

b) Check for proper packing and reservation of accessories like radiators,

bushings, dehydrating breather, rollers buchholz relay, fans, control
cubicle, connecting pipes, conservator etc.

c) Check for proper provision for bracing to arrest the movement of core
and winding assembly inside the tank.

d) Gas tightness test to confirm tightness.

e) Derivation of leakage rate and ensure the adequate reserve gas

capacity.

f) Dew point measurement of Dry air/N2 at the time of filling & after 24
hours in the transformer tank. Dew point of Dry air/N2 at the time of
transformer dispatch should be better than (–)30deg.C. Also the Dew
point of Nitrogen Cylinders/Dry Air attached for makeup during
transportation should be better than (–)50deg.C.

g) Functioning of gas dew point and gas pressure recorders in the works.

h) Functioning of impact recorder in the works.

i) To avoid pilferage and tempering with the valves and other accessories
used while dry air/N2 filling, due security arrangements to be ensured
during

10.00.00 Inspection and Testing at Site

The Contractor shall carry out a detailed inspection and testing program
for field activities covering areas right from the receipt of material stage up
to commissioning stage. An indicative program of inspection as
p r e se n t l y envisaged is given below. This is however not intended to form
comprehensive program, as it is contractor’s responsibility to draw up and
carry out such a program duly approved by the Purchaser. Testing of oil
sample at site shall be carried out as specified in Chapter-11 of Volume II.

10.01.00 Receipt and Storage Checks

a) Check and Record reading of impact recorder at receipt and verify the
allowable limits as per manufacturer’s recommendation.

b) Check and record the gas pressure in the transformer tank as well as
in the gas cylinder.

c) Check and record condition of each package, visible parts of the

transformer etc. for any damage.

d) Visual check for wedging of core and coils before filling up with oil

Obra “C” 2x660 MW Thermal Power Extension

Project

Bidding Doc. No. : 14A22-SPC-G-0001

HeadOffice Uploading Date And Time::::: Wednesday, September 30, 2015 5:48:24 PM

DCPL Volume IV: Ch 06: Interconnecting Auto-

Transformer
Electrical Works
Sheet l 18 of 23

and also check conditions of core and winding in general.

10.02.00 Installation Checks

a) Dew point measurement of Dry Air / N2.

b) Inspection and performance testing of accessories like tap changers,

cooling fans, oil pumps etc.

c) 1) Check the direction of rotation of fans and pumps.

2) Check the bearing lubrication.

d) Check whole assembly for tightness, general appearance etc.

e) Oil leakage test on assembled transformer for 24 hrs shall be

repeated as a pre commissioning test at site. The gaskets & flanges
used shall be capable of meeting the requirement as specified
elsewhere in this specification.

f) Check oil sample prior to filling.

10.03.00 Commissioning Checks

a) Check the colour of silica gel in slicagel breather.

b) Check the oil level in the breather housing, conservator tanks,

cooling system, condenser-bushing etc.

c) Check the bushing for conformity of connection to the lines etc. and
tan delta test for bushing at 10 kV (min.)

d) Check for correct operation of protection devices and alarms:

1) Buchhloz relay.
2) Excessive winding temperature
3) Excessive oil temperature
4) Low oil flow
5) Low oil level indication
6) Fan and pump failure protection
7) Oil flow failure
8) Pressure relief valve
9) On line DGA Analyzer

e) Check for the adequate protection on the electric circuit

supplying the accessories.

f) Check resistance of all windings on all steps of the tap changer.

g) Insulation resistance measurement for the following:

1) Control wiring.

Obra “C” 2x660 MW Thermal Power Extension

Project

Bidding Doc. No. : 14A22-SPC-G-0001

HeadOffice Uploading Date And Time::::: Wednesday, September 30, 2015 5:48:24 PM

DCPL Volume IV: Ch 06: Interconnecting Auto-

Transformer
Electrical Works
Sheet l 19 of 23

2) Cooling system motor and control

3) Main windings
4) Tap changer motor and control
5) Tank & turret mounted CTs
6) Core and clamp
- Core to earth
- Core clamp to earth
- Core to core clamp

h) Check for cleanliness of the transformer and the surroundings.

i) Check the following

1) Direction and overload setting of cooling Accessories

2) Buchholz, oil level indicator, pressure gauges, temp indicators

etc. for fitting & operation.

3) Earthing of main tank, marshaling Box, tap changer driving

gear, pump and fan motor etc.

4) Neutral earthing

5) Calibration of WTI and OTI

6) Earthing of bushing test tap

7) Connection of WTI CT with its heater

8) Tightness of CT secondary connection and shorting of unused

CTs

9) All valves for their correct opening and close sequence

j) Phase out and vector group test.

k) Ratio test on all taps.

l) Magnetizing current test (HV winding & IV winding).

m) Capacitance and Tan delta measurement of winding

n) Measurement of noise level.

o) Oil Dielectric strength test-the various test on oil shall be conducted

prior to filling in main tank at site & prior to energization at
site as specified elsewhere in the specification. Oil samples are to
be drawn from top & bottom of main tank, cooling system.

p) DGA of oil before commissioning

q) Check on OLTC

Obra “C” 2x660 MW Thermal Power Extension

Project

Bidding Doc. No. : 14A22-SPC-G-0001

HeadOffice Uploading Date And Time::::: Wednesday, September 30, 2015 5:48:24 PM

DCPL Volume IV: Ch 06: Interconnecting Auto-

Transformer
Electrical Works
Sheet l 20 of 23

1) Visual inspection of equipment

2) Hand operation at all taps
3) Complete wiring of circuit
4) Limit switch
5) Over running device
6) Brake system
7) Remote panel wiring
8) O/L device of driving motor
9) Local operation (electrical)
10) Remote operation (electrical)
11) Tap position indicator
12) Step by step contactor
13) Out of step relay
14) OLTC continuity test
r) Core isolation test

s) Magnetic balance test

t) Short circuit impedance measurement

u) Test on tank/turret mounted CTs

1. IR value between secondary winding & earth and between

windings

2. secondary resistance

3. Polarity

4. Ratio test

5. Magnetization current

v) Test on cooler fan & pump

1. IR Value

2. Starting current

3. Running current

w) WTI and OTI setting for alarm/trip, fan start/stop and pump start/stop

x) FRA Test

y) Final IR Value

1. HV/E+LV

Obra “C” 2x660 MW Thermal Power Extension

Project

Bidding Doc. No. : 14A22-SPC-G-0001

HeadOffice Uploading Date And Time::::: Wednesday, September 30, 2015 5:48:24 PM

DCPL Volume IV: Ch 06: Interconnecting Auto-

Transformer
Electrical Works
Sheet l 21 of 23

2. LV/E+HV
3. HV/LV
4. HV/MV
5. MV/LV
6. MV/E+HV
7. MV/E+LV

z) Infra red thermography shall be done after 12 hours of full load

operation and results will be recorded for future reference.

10.04.00 INITIAL OPERATION

a) Continuously observe the transformer operation at no load for 24 hrs.

w.r.t. Voltage, no load current, temperature rise and noise

b) Gradually put the transformer on load, check and measure increase in

temperature in relation to the load and check the operation with
respect to temperature rise and noise level etc.

11.00.00 TRANSPORTATION

The Contractor shall be responsible to select and verify the route, mode of
transportation and make all necessary arrangement with the appropriate
authorities for the transportation of the equipment. The dimension of the
equipment shall be such that when packed for transportation, it will comply
with the requirements of loading and clearance restrictions for the selected
route. It shall be the responsibility of the contractor to coordinate the
arrangement for transportation of the transformer for all the stages from the
manufacturer’s work to site. All metal blanking plates and covers which are
specifically required to transport the transformer shall be considered part of
the tansformer and handed over to the Purchaser after completion of the
erection. Bill of quantity and relevant drawings of these items shall also be
included in the manual to enable the Purchaser to have it re-manufactured, if
required.

The scope of any necessary modification/ extension/ improvement to existing

road, bridges, culverts etc. shall be included in the scope of the bidder. The
contractor shall carry out the route survey along with the transporter.

The contractor shall dispatch the transformer filled with oil or in an

atmosphere of nitrogen or dry air. In the former case the contractor shall
take care of the weight limitation on transport and handling facility at site.
In the latter case, necessary arrangement shall be ensured by the
contractor to take care of pressure drop of nitrogen or dry air during transit
and storage till completion of oil filling during erection. The total duration
of storage at site with dry gas shall be limited to three months after which
the transformer shall be processed and filled with oil. A gas pressure
testing valve with necessary pressure gauge and adaptor valve shall be
provided. Transformer shall also be fitted with sufficient number of impact
recorders/accelerometer during transportation to record the movement due to
impact in all three directions perpendicular to each other and of which the
main direction shall be in the direction of transportation. The recording

Obra “C” 2x660 MW Thermal Power Extension

Project

Bidding Doc. No. : 14A22-SPC-G-0001

HeadOffice Uploading Date And Time::::: Wednesday, September 30, 2015 5:48:24 PM

DCPL Volume IV: Ch 06: Interconnecting Auto-

Transformer
Electrical Works
Sheet l 22 of 23

shall commence in the factory and shall continue till the unit is installed on
its foundation.

NOTE:

Despite all condition monitoring done by the Owner, the Contractor

shall be responsible to obtain all required inputs such as DGA to evaluate
the transformer. The guarantee and costs of any repair done under the
guarantee shall not be affected by any condition monitoring done or not
done by the Owner during the guarantee period. A full DGA test shall be
completed at the end but before expiry of the guarantee period.

12.00.00 TECHNICAL PARAMETERS

a) Rating HV 333 MVA

MV 333 MVA
LV 111 MVA

b) Cooling ONAN/ONAF/OFAF
c) Rating of Different cooling 60%/ 80%/100%
d) Type Auto Transformer
e) Voltage Ratio 765/ 3/ 400/ 3/33 kV
f) Frequency 50 Hz
g) Phases Single Phase
h) i) Impedance at 75 deg. C at principal tap (HV- 14% (with IEC tolerance)
MV)
ii) HV/LV( Min) 65% External or internal
iii) MV/LV (min) 45% reactors shall not be
used to achieve the
HV/ LV (tertiary) and
MV/LV (tertiary)
impedance
i) Service Outdoor
j) Duty Continuous
K Overload capacity As per IS:6600/IEC 60076-7
l) Temperature rise over 500C ambient temperature
i) top oil measured by thermometer 400C
ii) Of winding measured by resistance method 450C
m) Max. design Ambient temp. 500C
n) Windings HV MV LV
i) System Fault level 40 50 -
(kA)
ii) Lightning impulse 1950 1300 170
withstand voltage KVp
iii) Switching impulse 1550 1050 -
withstand voltage KVp
iv) One min. power - - 70
frequency withstand
voltage (rms)

v) Winding connection Auto Auto Delta

In case of non-uniformly insulated.
o) Vector YNa0d11
symbol

Obra “C” 2x660 MW Thermal Power Extension

Project

Bidding Doc. No. : 14A22-SPC-G-0001

HeadOffice Uploading Date And Time::::: Wednesday, September 30, 2015 5:48:24 PM

DCPL Volume IV: Ch 06: Interconnecting Auto-

Transformer
Electrical Works
Sheet l 23 of 23

p) Tap Changer
i) Tap range Tap changer shall be located on the neutral side of
the winding and shall be designed for tapping range
of 5.5% on HV variation in 22 steps.
ii) Tap Control Full capacity on load tap changer suitable for group
independent, remote/local electrical and local
manual operation and bidirectional power flow.

q) Bushing HV MV Neutral LV
i) Rated voltage (kV) 800 420 17.5 52
ii) Rated current (A) 1250 1250 - 2000
iii) Switching impulse 1550 1050 - -
withstand voltage kVp
iv) Lightning impulse 2100 1425 95 250
withstand voltage
KVp
v) One min. power 880 630 38 95
frequency withstand
voltage kV (rms
vi) Mounting Turret Turret Turret Turret
r) Terminal Details
i) High Voltage ACSR conductor / AL Tube to suit ampacity and
layout requirement

ii) ACSR conductor / AL Tube to suit ampacity and

Medium Voltage
layout requirement
iii) Low voltage(33KV): Bushing brough out open. Suitable insulating caps
for terminals to be provided
iv) Neutral Copper flat
s) Noise level As per NEMA-TR-1

Obra “C” 2x660 MW Thermal Power Extension

Project

Bidding Doc. No. : 14A22-SPC-G-0001

HeadOffice Uploading Date And Time::::: Wednesday, September 30, 2015 5:48:24 PM

DCPL Volume IV: Ch 07: Generator Transformer

Sheet l 1 of 32
Electrical Works

CHAPTER 07 : GENERATOR TRANSFORMER

1.00.00 SCOPE OF SUPPLY

1.01.00 Seven 7 Nos. (6Nos working + 1No spare) - oil filled 800/ 3/* kV (* denotes
rated generator voltage), 275 MVA (minimum), single phase, Generator
transformer with all fittings and accessories, metering and protection, 50 Hz,
ONAN/ ONAF/OFAF cooled, Ynd11 connected, outdoor type, with off circuit taps
in the range of (+) 5 to (-) 5 percent, in steps of 2.5 percent. The rating
specified above is indicative and shall be considered as minimum requirement
for the project. The contractor shall size the GT according to the criteria
specified in this chapter and higher rating shall be provided if required by sizing
calculations.

1.01.00 Each transformer shall be furnished complete with:

(a) OCTC
(b) Fittings and accessori es
(c) Cooli ng & Auxiliary equi pments
(d) First fillin g of oil includi ng 10% extra
(e) Protecti on & metering devices.
(f) On line monitoring system (DGCA)

One set of special tools and tackles.

1.02.00 Mandatory Spare parts

Recommended spare parts for three (3) years operation in addition to

mandatory spares.

1.03.00 All relevant drawings, data and instruction manuals

Any equipment/items though not specifically mentioned above but which are
required to make the transformers complete in all respects for their safe,
efficient, reliable and trouble free operation shall be supplied by the Bidder,
unless they are specifically excluded elsewhere in this specification

2.00.00 CODES AND STANDARDS

All equipment and materials shall be designed, manufactured and tested in

accordance with the latest applicable Indian Standards (IS) and IEC except where
modified and/or supplemented by this specification.

Equipment and material conforming to any other standard, which ensures equal
or better quality, may be accepted. In such case, copies of the English version of
the standard adopted shall be submitted along with the bid.

The electrical installation shall meet the requirements of Indian Electricity Rules
as amended upto date and relevant IS Code of Practice. In addition, other rules
and regulations applicable to the work shall be followed.

Indian Title Internationa

Standards l standards
(1) (2) (3)
IS: 2026 Power transformers IEC: 60076
IS: 3639 Fittings & accessories for power

Obra “C” 2x660 MW Thermal Power Extension

Project

Bidding Doc. No. : 14A22-SPC-G-0001

HeadOffice Uploading Date And Time::::: Wednesday, September 30, 2015 5:48:24 PM

DCPL Volume IV: Ch 07: Generator Transformer

Sheet l 2 of 32
Electrical Works

transformers
IS: 335 Insulating for alternating voltages IEC: 60296,
switchgear BS:148
IS: 2099 Bushing for alternating voltages above IEC:
1000 V 600137,
BS: 223
IS: 2705 Current transformers IEC: 60185
IS: 325 Three phase induction motors IEC: 60034-
1
IS: 375 Marking & arrangement for switchgear bus
bars, main connections & auxiliary wiring.
IS: 3637 Gas operated relays
IS: 10028 Code of practice for selection installation&
maintenance of transformers
IS: 4691 Degree of protection provided by enclosure
for rotating electrical machinery
IS: 8478 On-load tap changer application guide
IS: 2147 Degree of protection provided by enclosure IEC: 60144
for low voltage switchgear & control
IS : 5 Colours for ready mix paints
IS: 1866 Code of practice for maintenance &
Supervision of mineral insulating oil in
equipment
IS: 6272 Industrial cooling fans
IS: 6600 Guide for Loading of oil immersed IEC: 60354
transformers
IS: 320 Code of practice for climatic proofing of
Electrical equipment
IS: 3347 Specification for dimensions of porcelain
bushing
IS: 8468 On load tap changers IEC:60214
High voltage test technique IEC: 60060
Insulation co-ordination IEC: 60071
NEMA standard publication for Power NEMA-TR-1
transformers
IS: 10597 Code of practice for selection, Installation
operation & maintenance of pumps for
industrial applications
IS: 9434 Guide for sampling & analysis of free & IEC: 60567
dissolved gas & oil from oil filled electrical
equipment
IS: 12676 Dimensions for OIP insulated condenser
bushings
IEEE: 32 IEEE standard requirement terminology&
test procedure for neutral grounding device

3.00.00 DESIGN CRITERIA & PERFORMANCE

3.01.00 Generator Transformer (GT) shall be of step up type having unidirectional

power flow. Generated voltage of Turbo generator shall be stepped up to 800kV
which is the power evacuation voltage through 800kV grid switchyard.

3.02.00 Generator Transformer should be sized to deliver the gross unit output of the
generator with turbine operation in VWO (Valve Wide Open) condition and Unit

Obra “C” 2x660 MW Thermal Power Extension

Project

Bidding Doc. No. : 14A22-SPC-G-0001

HeadOffice Uploading Date And Time::::: Wednesday, September 30, 2015 5:48:24 PM

DCPL Volume IV: Ch 07: Generator Transformer

Sheet l 3 of 32
Electrical Works

Transformers out of service. The loads of Unit Transformers will be supplied

from the station bus for an extended period.

3.03.00 GT shall be suitable to meet the Generator power rating of 660MW at 0.85
power factor lag without deducting the unit auxiliary power, excitation power or
any other power. GT shall be sized with 5% design margin.

3.04.00 The primary voltage of GT should be equal to the nominal voltage of

generator. For deciding the nominal voltage of GT following shall be
considered:

3.05.00 The variation of nominal voltage due to excitation control of generator is to be

taken in to account. This is to be taken as ±5%.

3.06.00 The secondary voltage of transformer at full output load at 0.85 pf (lag)
should be 800kV. For this GT percentage impedance and required no load
secondary voltage range chosen shall be chosen such that after allowing for
voltage drop, the required 800kV is available at full load .

3.07.00 Based on above considerations, voltage ratio is to be decided.

3.08.00 GT shall have Off Circuit Tap Changer (OCTC). The tap range shall be such
that after considering the voltage control by excitation system, the balance
compensation, as necessary during system disturbances, shall be by OCTC.

3.09.00 Bidder shall submit the calculation (ETAP study considering above minimum
criteria) for sizing the GT rating, voltage ratio and tap Selection considered.

3.10.00 The transformer will be installed in hot, humid and tropical atmosphere. All
equipment, accessories and wiring shall be provided with tropical finish to
prevent fungus growth.

3.11.00 The transformer shall be capable of continuous operation at rated output

under the following condition:

(a) Voltage variation : ± 10%

(b) Frequency variation : ± 5%
(c) Combined voltage and frequency : 10% (absolute sum)

Suitable for continuous operation at any tap at rated MVA; and capable of
delivering rated current at a voltage equal to 105% of rated voltage without
exceeding specified temperature rise.

3.12.00 The air core reactance of HV winding of transformers shall not be less than
20%.

3.13.00 The transformer shall be so designed that it is capable of operation at 125%

rated voltage for a period of one minute and 140% rated voltage for a period
of five seconds due to sudden load throw off.

3.14.00 The noise level shall be as per NEMA TR-1

3.15.00 Over fluxing Capability

Obra “C” 2x660 MW Thermal Power Extension

Project

Bidding Doc. No. : 14A22-SPC-G-0001

HeadOffice Uploading Date And Time::::: Wednesday, September 30, 2015 5:48:24 PM

DCPL Volume IV: Ch 07: Generator Transformer

Sheet l 4 of 32
Electrical Works

Maximum flux density in core & yoke at 110% rated voltage will be 1.9 Tesla.
Over fluxing withstand capability will be better than indicated below:

V/f Duration
1.1 pu Continuous
1.25 pu 1 Minutes

1.40 pu 5 Seconds

3.16.00 Operation during Failure of Forced-Cooling

Capable of full load operation in hot condition for at least 10 minutes after
complete failure of all forced-cooling without calculated winding hot spot
temperature exceeding 140 deg C; and capable of full load operation in hot
condition for at least 20 minutes after failure of one bank (50%) of
forced-cooling.

3.17.00 Basic Insulation Level

Rated lightning impulse withstand voltage of the transformer HV winding will

be 1425 kV (peak) and LV winding will have an impulse voltage withstand
according to relevant standard. All winding terminals will be brought out to
outdoor, weather-proof oil-filled condenser type bushings, designed for
heavily polluted atmosphere & complying with IEC60137/IS:2099.

The transformer & all its accessories including CTs etc, shall be designed to
withstand without injury the thermal & mechanical effects of any external
short circuit to earth & of short circuits at the terminal of any winding for a
period of 3 secs. Contractor shall submit the short circuit withstands
calculations assuming maximum operating voltage.

4.00.00 SPECIFIC REQUIREMENTS

4.01.00 HV Phase Bushings

i. Bushing rated 52 kV class and above shall be oil impregnated paper

condenser bushings. Bushing rated below 52 kV voltage class shall be
solid porcelain or oil communicating type.

ii. Condenser type bushing shall be provided with oil level gauge, bottom
drain plug and test terminal for measurement of loss factor (tan- delta)
and capacitance.

iii. Bushings shall be provided with terminal connectors of approved type

and size.

iv. Bushing location shall provide adequate phase and ground clearances.

v. Creepage distance of HV bushings will not be lower than 31 mm per kV.

4.02.00 HV Neutral Bushing

HV neutral terminal will be brought out to 36 kV class bushing with a terminal

connector suitable for two runs of GS flats of size 100 x 12 mm supported
along the transformer tank on insulators for connection with Owner's earth

Obra “C” 2x660 MW Thermal Power Extension

Project

Bidding Doc. No. : 14A22-SPC-G-0001

HeadOffice Uploading Date And Time::::: Wednesday, September 30, 2015 5:48:24 PM

DCPL Volume IV: Ch 07: Generator Transformer

Sheet l 5 of 32
Electrical Works

grid through tinned copper flexible. The GS flats will be terminated 300 mm
above grade level. All insulators, flexible and connecting hardware for this
earth connection will be furnished.

4.03.00 LV Bushings

LV bushings will be of 36 kV class type coming out vertically. LV connections

will be throat type with separate matching flanges and copper flexible leads
for connection to rubber expansion joints of isolated phase busducts. Design
of LV bushing hood will be co-ordinated with isolated phase busducts supplied
as part of this contract.

4.04.00 HV Bushing CTs

HV phase and neutral bushings of transformer will be fitted with ring type
current transformers, having 1000/1-amp ratio and output/accuracy class for
protection as indicated below:

Phase CT Neutral CT (+)

Application BCT BCT BCT BCT BCT
Restricted Differential Differential Restricted Stand By
Earth Fault Earth Fault Earth Fault

Quantity 3 3 3 1 each 1
phase
Current -/1* -/1* -/1* -/1* 150/1*
Ratio
Class PS PS PS PS 5P20
Burden - - - - 30*
Knee point To be decided by Bidder
voltage
Excitation To be decided by Bidder
current at
Vk/2
Secondary To be decided by Bidder
resistance at
75°C

Rated 50 50 50 50 50
frequency
Voltage 800kV 800kV 36 36 36
class +10% to - +10% to -
5% 5%

(*) Tentative to be decided by the Bidder

(+) – These CT’s shall be located after formation of Neutral. Also bushing CT shall be provided
for each single phase transformer.

Note: Contractor shall decide CT details. CT calculation shall be submitted for

approval. All necessary ICT’s are included in Bidder’s scope.

Obra “C” 2x660 MW Thermal Power Extension

Project

Bidding Doc. No. : 14A22-SPC-G-0001

HeadOffice Uploading Date And Time::::: Wednesday, September 30, 2015 5:48:24 PM

DCPL Volume IV: Ch 07: Generator Transformer

Sheet l 6 of 32
Electrical Works

These current transformers will be provided apart from the WTI CTs.

4.05.00 Core & Coils

i. Core will be made of laminations of high-grade non-ageing, cold-rolled

super grain-oriented (CRGO), silicon steel of high permeability without
burrs. Each lamination will be insulated with high quality insulation
coating, which will not deteriorate due to pressure and hot oil.

ii. The magnetic circuit will be earthed to core-clamping structure at one

place through a removable link placed in accessible position beneath an
inspection opening in tank cover.

iii. The core clamping structure will be earthed by connection to top structure
by vertical clamping plates. The operating flux density in any part of the
core & yoke at rated MVA, Voltage & Frequency at any tap shall not
exceed 1.71 Tesla at 100 % rated voltage.

iv. Transformer should be boltless type. The core cutting facility should be
available in house at works to avoid mixing of sub standard cores.

v. The coils shall be manufactured from electrolytic copper conductor and

fully insulated for rated voltage. However, HV winding shall be non-
uniformly graded for voltage class above about 33kV. Insulation shall be
of Class A.

vi. Insulating material shall be of proven design. Coils shall be so insulated

that impulse and power frequency voltage stresses are minimum.

vii. Coil assembly shall be suitably supported between adjacent sections by

insulating spacers and barriers. Bracing and other insulation used in
assembly of the winding shall be arranged to ensure a free circulation of
the oil and to reduce the hot spot of the winding.

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

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

x. The insulation of core to tank, clamp to tank & core to clamp plates shall
be able to withstand a voltage of 10 kV (rms.) for 1 minute in air.

xi. In order to ensure prevention of multiple core earthing, core isolation

test at 1 kV for 1 minute shall be done duringpre commissioning stage.
To facilitate above, the core earthing ahs to be done outside the tank
with suitable bushing.

xii. Adequate liftings lugs will be provided to enable the core & windings to
be lifted.

4.06.00 Tank

Obra “C” 2x660 MW Thermal Power Extension

Project

Bidding Doc. No. : 14A22-SPC-G-0001

HeadOffice Uploading Date And Time::::: Wednesday, September 30, 2015 5:48:24 PM

DCPL Volume IV: Ch 07: Generator Transformer

Sheet l 7 of 32
Electrical Works

i. Tank will be of bell-shaped design and welded construction, made out of

tested quality low-carbon mild steel of sheet thickness to be indicated with
joint at about 500 mm above the bottom of the tank. In case the joint is
welded, it shall be provided with flanges suitable for repeated welding.

ii. Proper tank shielding shall be done to prevent excessive temperature rise
of the joint and all seams and those joints not required to be opened at
site shall be factory welded both inside and outside.

iii. After construction of tank and before painting, Dye penetration test shall
be carried out on welded parts, of jacking basses, lifting lugs and all loads
bearing members. The requirement of post heat treatment for tank/stress
relieving parts shall be based on recommendation of BS-5500.

iv. The complete assembly will be oil/gas/vacuum tight and capable of

withstanding internal gas pressure of 0.35 kg/cm2 (5 psi) with oil at
operating level.

v. The tank will be fitted with an access ladder, suitable man-holes with
covers, lifting lugs, hauling eyes, skids and earthing pads. Manholes with
bolted covers shall be provided in the top or sides of transformers of easy
access to the power ends of bushings, tap changers and to permit
replacement of auxiliaries without removing tank cover. The inspection
covers shall not weight more than 25 kG. Handles shall be provided on the
inspection cover to facilitaite lifting.

vi. Tank stiffeners shall be provided for general rigidity and these shall be
designed to prevent retention of water.
vii. The tank shall be designed to withstand:
Mechanical shock during transportation
Vacuum filling of oil.
Continuous internal pressure of 35 kN/m2 over normal hydrostatic
pressure of oil.
Short circuit forces.

viii. Wherever possible the transformer tank and its accessories shall be
designed without pockets where in gas may collect. Where pockets can
not be avoided, pipes shall be provided to vent the gas into the main
expansion pipe.
ix. The shields of the tank shall be such that no magnetic field shall exist
outside the tank. They shall be of magnetically permeable material. If
required, impermeable shield shall be provided at the coil ends. Tank
shield shall not resonate when excited at the natural frequency of the
equipment. Bidder may confirm use of tank shields in the schedule of
additional information.
x. Suitable guides shall be provided in the tank for positioning the core and
coil assembly.
xi. Each tank shall be provided with:-
Lifting lugs suitable for lifting the equipment’s complete with oil
A Minimum of four jacking pads in accessible position at 500 mm height
to enable the transformer complete with oil to be raised or lowered using
hydraulic or screw jacks.
Haulage holes shall be provided to facilitate movement of the
transformer in all four directions. All heavy removal parts shall be
provided with eyebolt for ease of handling

Obra “C” 2x660 MW Thermal Power Extension

Project

Bidding Doc. No. : 14A22-SPC-G-0001

HeadOffice Uploading Date And Time::::: Wednesday, September 30, 2015 5:48:24 PM

DCPL Volume IV: Ch 07: Generator Transformer

Sheet l 8 of 32
Electrical Works

xii. All removable covers shall be provided with weatherproof, hot oil
resistant, resilient gaskets. The design shall be such as to prevent any
ingress of water into or oil from the tank.

xiii. The transformers are to be provided with flanged bi-directional wheels

& axles & shall be mounted on wheels on foundation. Suitable locking
arrangement shall be provided for the wheels to prevent accidental
movement of transformer. The rail track gauge shall be 1676 mm
along longer axis as well as along shorter axis. Wheels shall have
suitable rust-resistant bearings. Anti earthquake clamping devices for
seismic design of GT foundation is envisaged.

xiv. Metal parts surrounding the conductor of individual phase for LV shall
be nomagnetic.

xv. All bolted connections shall be fitted with weather proof & hot oil
resistant of ‘O’ ring of nitrile rubber in between for complete oil
tightness. If gasket is compressible, metallic stops shall be provided to
prevent over compression.

4.07.00 Pressure Relief Devices

Minimum two spring-loaded relief valves of proven make, having 100% discharge
capacity, operating below test pressure for tank & radiators will be provided with
an operation device visible from ground level and contacts for remote alarm/trip.
Suitable trough will be provided for collection of splashed oil. Air vents will also
be provided.

4.08.00 Oil Preservaiton Equipment

Bidder shall offer air cell type sealing in conservator to prevent oxidation and
contamination of ol due to contact with water .The Bidder shall furnish his
experience list for the system offered .The requirements of air cell type oil sealing
system are given below.

a) Contract of the oil with atmosphere is prohibited by using a flexible

urethane or nitrile rubber reinforced with nylon cloth air cell.

b) The temperature of oil is likely tto rise up to 1100C. As such air cell used
shal leb suitable for operating continuously at 1100C.

c) Air cell of conservator shall be able to withstand the vacuum during

installation/ maintenance periods. Otherwise provision shall be kept to
isolate the conservator from the main tank when the latter is under
vacuum by providing a vacuum sealing valve or other suitable means in
the pipe connecting main tnak with the conservator.

d) The connection ofair cell to the top of the reservoir is by air proof seal
preventing entrance of air into the conservator.

4.09.00 Conservator Tank

a) The conservator tank shall have adequate capacity between highest and
lowest visible levels to meet the requirement of expansion of the total cold

Obra “C” 2x660 MW Thermal Power Extension

Project

Bidding Doc. No. : 14A22-SPC-G-0001

HeadOffice Uploading Date And Time::::: Wednesday, September 30, 2015 5:48:24 PM

DCPL Volume IV: Ch 07: Generator Transformer

Sheet l 9 of 32
Electrical Works

oil volume in vthe transformer and cooling equipment from minimum

ambient temperature to 1100C.

b) The conservator shall be bolted I nsuch a position so that it can be

removed for cleaning purposes and suitable provision shall be kept to
replace air cell in it.

c) Buchholz type gas detecitn relay with alarm contacts, on top of the
conservator to detect any gas bubbles from a ruptured conservator bag.
Contacts to be wiered down to the CMB

d) Conservator shall be provided in such a position so as not to obstruct the

electrical connections.

e) The conservator shall be fitted with magnetic oil level gauge with low level
electrically insulated alarm contact.

4.10.00 Cooling System

Cooling equipment for Generator Transformer shall be OFAF type.

a) The cooling system shall comprise of 6 (5 Running + 1 Stand-by) x 20%

units. Each unit shall be complete with its pumps,fans and other
accessories. Each cooling unit shall be detachable type.

b) Each unit cooler shall be provided with the following:

i) Two (2) nos. oil pumps (1 no. running + 1 no. standby)
ii) A number of fans such that in the event of outage of one fan per
bank, rated output can be maintained with the specified temperature.

c) Total capacity of unit coolers furnished for each transformer shall be

minimum 120% of actual requirements.

d) Cooler fans & oil pumps of all unit coolers (except standby cooler) shall
operate continuous. Unit coolers shall automatically start by generator
field breaker contract. Provision shall be kept to start the coolers by WTI
contact. Standby cooler shall automatically come in to service in case
failure of any running cooler.

e) Cooling fans shall not be directly mounted on radiator bank, which may
cause undue vibration.

f) The exhaust air flow from cooling fan shall not be directed towards the
main tank in any case.

g) Cooling fans for each radiator bank shall be located so as to prevent

ingress of rain water. Each fan shall be suitably protected by galvanized
wire guard.

h) Suitable manual control facility for cooler fans & oil pumps shall be
provided.

Obra “C” 2x660 MW Thermal Power Extension

Project

Bidding Doc. No. : 14A22-SPC-G-0001

HeadOffice Uploading Date And Time::::: Wednesday, September 30, 2015 5:48:24 PM

DCPL Volume IV: Ch 07: Generator Transformer

Sheet l 10 of 32
Electrical Works

i) Centrifugal or axial in line oil pumps shall be so designed that upon

failure of power supply to the pump motor, the pump impeller shall not
limit the natural circulation of oil.

j) An oil flow indicator shall be provided for the confirmation of normal

pump operation. An indicator shall be provided in the flow indicator to
indicate reverse flow through the pump.

k) Cooling fan & oil pump motor shall be suitable for opration on 415 +
10%V, three phase, 50 Hz + 3%, -5% power supply & shall conform to
IS:325. Each cooling fan & oil pump motors shall be provided with
starter with thermal overload & short circuit protection. The motor
winding insulation shall be conventional class B type. Motor shall have
enclosure with degree of protection equivalent to IP 55 as per IS: 4691.
The temperature rise of the motor shall be limited to 70 deg. C above
ambient of 50 deg. By winding resistance method & shall comply with
IS:3258

l) The oil pump and motor assembly shall be completely oil immersed
gland less type. It shall be removable for maintenance without the need
for lowering oil in the transformer or coolers. It shall be feasible to
operate the transformer at its ON rating after removing oil pump and
fitting suitable pipe extensions. Bleeding device shall be provided to
ensure that air is not returned to the transformer when the oil pump is
put back into service.

m) Complete control for pumps and fans inclusive of all switches, fuses,
starters, relays and wiring shall be furnished. Each motor circuit shall
have over load and short-circuit protection.

n) Fault indicating device – for each transformer, an alarm contact shall be

furnished to indicate the unintended stoppage of a fan, pump or oil flow.
The contractor shall also indicate if any additional lamp is required to be
provided in Employer’s control room.

o) Following lamp indications shall be provided in CMB/CCC.

1) Cooler supply failure (Main)

2) Cooler supply changeover
3) Cooler supply failure (Standby)
4) Control supply failure
5) Cooling unit failure for each unit cooler for GTs.
6) More than two cooler bank failure for GT.
7) No oil/reverse oil flow for pumps
8) Common thermal overload trip

One potential free initating contact for all the above conditions including
alarm for “supply fail to transfer” shall be wired independently to the
terminal blocks of CMB exclusively for DDCMIS.

p) 4-20mA signal to be provided for OTI & WTI for remote display and

q) Remote control shall be from DDCMIS.

4.11.00 Radiators

Obra “C” 2x660 MW Thermal Power Extension

Project

Bidding Doc. No. : 14A22-SPC-G-0001

HeadOffice Uploading Date And Time::::: Wednesday, September 30, 2015 5:48:24 PM

DCPL Volume IV: Ch 07: Generator Transformer

Sheet l 11 of 32
Electrical Works

Radiators will be of detachable type with bolted and gasketted, flanged

connections complete with lifting lugs, top & bottom shut-off valves, oil filtering
valves, top oil filling plug, air release plug at top, oil drain plug, oil flow indicator
with alarm/trip contacts etc. As per CEA Regulation, total capacity of cooler for
each transformer shall be minimum 120% of actual requirement. Necessary
expansion bellows, supporting steel structure etc. will be included. Cooling fans,
oil pumps, thermometer pocket fitted with captive screw cap on inlet & outlet
shall be provided.

4.12.00 Valves

a) All valves up to and including 50 mm shall be of gunmetal or of cast steel.

Larger valves may be of gunmetal or may have cast iron bodies with
gunmetal fittings. They shall be of full way type with internal screw and
shall open when turned counter clockwise when facing the hand wheel.

b) Suitable means shall be provided for locking the valves in the open and
close positions. Provision is not required for locking individual radiator
valves.

c) Each valve shall be provided with the indicator to show clearly the position
of the valve

d) Gland packing/gasket material shall be of “O” ring of nitrile rubber for all
the valve’s flanges. All the flanges hsall be machined.

e) Oil sampling shall have provision to fix rubber hose of 100mm size to
facilitate oil sampling.

f) After testing, inside surface of all cast iron valves coming in contact with
oil shall be applied with one coat of oil resisting paint/varnish with two
coats of red oxide zinc chromate primer followed by two coats of fully
glossy finishing paint conforming to IS: 2932 and of a shade (Preferably
red or yellow) distinct and different from that of main tank surface.
Outside surface except gasket setting surface of butterfly valves shall be
painted with two coats of red oxide zinc chromate conforming to IS:2074
followed by two coats of fully glossy finishing paint.

g) Sampling & drain plug/valves should have zero leakage rate.

h) All hardware used shall be cadmium plated / electrogalvanised.

i) The minimum number of valves to be provided are as mentioned below:-

i) 100 mm drain valve
ii) 2 - 50 mm filter valves
iii) Oil sampling valves on top & bottom
iv) Air release plugs
v) Valves between radiators and coolers
vi) Two (2) plugged pipe outlets for vacuum application
vii) Isolating valves for pipe connections from headers
viii) Three-way valve in each cooler bank for auto start of standby
cooler pump.

4.13.00 Cooler Control Cabinet

Obra “C” 2x660 MW Thermal Power Extension

Project

Bidding Doc. No. : 14A22-SPC-G-0001

HeadOffice Uploading Date And Time::::: Wednesday, September 30, 2015 5:48:24 PM

DCPL Volume IV: Ch 07: Generator Transformer

Sheet l 12 of 32
Electrical Works

An outdoor, weather proof cooler control cabinet will be furnished having the
cabinet terminals, power circuits & busbars designed for connection to 415V, 3
phase, 3 wire, 50 Hz ac supply with a fault level of 50kA (rms). The cooler
scheme will have following features:

a) The cooler control capacity will be minimum 120% of actual requirement.

b) Provision for auto start of standby oil pump in each cooler group when the
running pump trips or the main pump fails to start within a pre-set time of
closing of WTI contact.

c) Facility to select any pump for 'Normal' or 'Standby' service.

d) Auto/Manual selection of each pump for maintenance.

e) Auto start of standby fans on failure of normal running fans in the group.

f) Auto/Manual/Off selection and normal/standby selection for each fan.

g) Potential-free contacts for annunciating failure of auto start of standby

fan/pump.

h) Each fan/pump power circuit will have a switch-fuse/MCCB, overload relay

(with single phasing preventer) and power contactor.

i) The control voltage will be 110V AC derived through step-down

transformer(s). Owner will make two (2) separate 3 ph. 415 V supply
feeders available for this purpose. The contractor will provide a suitable
scheme for auto changeover of supplies. Contacts to annunciate failure of
individual supplies as well as total power failure will be provided.

j) Potential free contacts required from relay for SCADA purpose.

· WTI alarm
· WTI trip
· OTI alarm
· Buchholz alarm
· Buchholz trip
· MOG alarm
· OSR trip
· Main PRV trip
· Tap change stuck up
· DC supply fail
· Over voltage relay operated
· Under voltage relay operated
· Tap changer on SCADA/ LOCAL
· Tap changer on AUTO / MANUAL
· Intertrip to breaker from Relay
· Fan Control

k) Cooler control circuitry will switch off all pumps and fans in case of
transformer lockout relay operation or fire protection system operation.

l) Contacts for remote indication of running of each fan/pump.

Obra “C” 2x660 MW Thermal Power Extension

Project

Bidding Doc. No. : 14A22-SPC-G-0001

HeadOffice Uploading Date And Time::::: Wednesday, September 30, 2015 5:48:24 PM

DCPL Volume IV: Ch 07: Generator Transformer

Sheet l 13 of 32
Electrical Works

m) Local indication shall be provided for running and overload trip of any
pump or fan, failure of auto start of standby fan/pump and changeover of
supply when main supply fails.

4.14.00 Construction of CCC

i. Control panels shall be of CRCA sheet steel construction with protection

class of IPW-55 for outdoor installation.

ii. The frames and load bearing panels shall be fabricated of not less than 2
mm thick sheet steel. The doors and covers shall not be less than 1.6mm
thick. All access doors shall be provided with channel rubber/ neoprene
gaskets all round.

iii. The operating height shall be limited from 750mm to 1800mm.The total
height of the panel and its depth shall be matched with adjacent panel.

iv. The operating handle shall have locking arrangement. The panels shall be
complete with floor channel sills, vibration damping pads and stainless
steel kick plates.

v. All instrument, relays, switches, etc. mounted on the front face of the
panel shall be flush or semis flush type. Switch contacts shall be silver
faced and rated at least 10 Amp at operating voltage. Push buttons shall
have required number of contacts.

vi. Panel shall be provided with internal illumination lamp with door switch,
space heater with thermostat one 5A, 3 pin receptacles with plug.

vii. The annunciation system shall be solid-state type with optical isolation for
input signals. It shall be complete with its own power supply, audible
alarms, acknowledge, reset, and test buttons and other necessary
accessories.

viii. The control panels shall be fully wired up at factory. All spare contacts of
relays and switches shall be wires up to the terminal blocks.

ix. The panel shall have provision of cable entry from bottom. Bottom gland
plate shall be 3mm thick.

x. 50 x 6 mm copper ground bus shall be provided on the panel extending

along the entire length of the assembly. The ground bus shall have two-
bolt drilling with GS bolts and nuts at each end to receive plant grid’s
ground connection of 75x10 mm. GS flat.

xi. Sufficient space shall be provided to avoid sharp bending and for easy
connection of cables. A minimum space of 200mm and 150mm shall be
provided from the gland plate to the nearest terminal block and two rows
of terminal blocks respectively.

4.15.00 Protective & Monitoring Devices/Instrumentation

Following minimum devices will be supplied:

a) Magnetic oil level gauge with alarm & trip contacts.

Obra “C” 2x660 MW Thermal Power Extension

Project

Bidding Doc. No. : 14A22-SPC-G-0001

HeadOffice Uploading Date And Time::::: Wednesday, September 30, 2015 5:48:24 PM

DCPL Volume IV: Ch 07: Generator Transformer

Sheet l 14 of 32
Electrical Works

b) Buchholz or gas pressure relay with alarm/trip contacts separately for

main transformer.

c) Winding temperature transducer, local & remote winding temp. indicators

with alarm/trip/cooler control contacts.

d) Top oil temperature transducer, local & remote oil temp. indicators with
alarm/trip contacts.

e) Four (4) oil flow indicators, each with 2 N/O or 2 N/C contacts.

f) Two (2) pressure relief valves/devices each with 2 N/O or 2 N/C contacts.

Remote tap position indicator.

All the above devices in addition to alarm / trip contacts shall also be
provided with transducers for 4 to 20 mA signals to DAS / DCS in the
bidders scope as per Volume II for Control & Instrumentation

4.16.00 Tapping

i. OFF circuits taps shall be provided on high voltage winding.

ii. Off load Tap changer should be from reputed manufacturers like
BHEL/MR.

iii. The transformer shall be capable of operation at its rated KVA on any tap
provided the voltage does not vary by more than +/- 10% of the rated
voltage corresponding to the tap.

iv. The winding including the tapping arrangement shall be designed to

maintain electromagnetic balance between HV and LV windings at all
voltage ratios.

v. OFF-Circuit Tap Changer

a) The off-circuit tap changing of 3nos. single phase transformer bank of

a 3- phase system shall be effected by individual tap change switch of
each transformer. Interlocks shall be provided for each tap position
with limit switches or a suitable arrangement such that transformers
cannot be energized unless the taps of all the transformers of the
same bank are in the same position. Contacts shall also be provided to
give alarm and de-energize the transformer in case any tap of any
transformer of the same bank is in different position.

b) Arrangement shall be such that switch can be operated at standing

height from ground level.

c) The operating handle can be pad locked at any tap position. The
design shall be such that the lock cannot be inserted unless the
contacts are correctly engaged. Warning plate indicating “Tap change
should be operated only when transformer is de-energised” shall be
fitted. The safety limit switch shall be actuated to give trip impulse for
transformer trip when tap change is initiated.

Obra “C” 2x660 MW Thermal Power Extension

Project

Bidding Doc. No. : 14A22-SPC-G-0001

HeadOffice Uploading Date And Time::::: Wednesday, September 30, 2015 5:48:24 PM

DCPL Volume IV: Ch 07: Generator Transformer

Sheet l 15 of 32
Electrical Works

d) The operating handle shall be located at a maximum operating height

of 1250mm from the top of rail level.

e) The mechanism shall be provided with a mechanical tap position

indicator and an operation counter.

f) All contacts shall be silver plated & held in position under strong
contact pressure to ensure low contact drop and avoid pitting.

4.17.00 Insulating Oil

i. No inhibitors shall be used in the transformer oil. The oil supplied with
transformers shall be new and previously unused.

ii. First filling of oil, along with 10% excess with non-returnable drum to
containers suitable for outdoor storage shall be provided.

iii. Oil preservation shall be by means of bellows/diaphragm sealed

conservator tank with silica gel breather to avoid direct connection
between atmosphere and transformer oil. It shall be complete with level
gauges, pipes, drain valve, buchholz relay with shut-off valves at both
sides etc. The level gauges shall be so placed that same can be readable
standing from ground. Necessary device shall be kept to provide
annunciation in the event of rupturing of bellow.

iv. The acceptable characteristics of transformer oil [EHV Grade-I] will be as

below:

a) Appearance : As per IS:335/BS 148/IEC 296

b) Density (Max.)at 27 deg.C : 0.89 g/cm3

c) Kinematics viscosity (Max.) : 27 cst at 27 deg. C

d) Interfacial tension at 27 deg.C: 0.04 N/mt 27 deg. C

(Min.)

e) Flash point (Min.) : 140 deg.C

(Pen key-Marten -closed)

f) Pour point (Max.) : -10 deg. C

g) Neutralization value : < 0.01 mg KOH/g

acidity (Max.)

h) Corrosive sulphur : Non-corrosive

i) Electric strength breakdown

voltage (min) :
i) New untreated oil as : 40 kV (rms)
received

ii) After treatment : > 70 kV (rms)

j) Dielectric dissipation factor : 0.002

(tan-delta) at 90 deg.C (max.)

Obra “C” 2x660 MW Thermal Power Extension

Project

Bidding Doc. No. : 14A22-SPC-G-0001

HeadOffice Uploading Date And Time::::: Wednesday, September 30, 2015 5:48:24 PM

DCPL Volume IV: Ch 07: Generator Transformer

Sheet l 16 of 32
Electrical Works

k) SK value (max.) : 6 % (Max)

l) Water content (max.) : 30 ppm (as received)

m) Specific resistance (min.) :

i) At 90 deg.C : 35 x 1012 Ohm-cm

ii) At 27 deg.C : 1500 x 1012 Ohm-cm

n) Oxidation stability

i) Neutralization valve : < 1.2

mg/KOH/g

ii) Sludge, % by mass : < 0.8

o) Anti Oxydants additives : Not detectable

p) PCA content : <1%

q) Impulse withstand Level, : >145

kVp

r) Gassing tendency at 50 Hz : <5

after 120 min, mm3/min

Subsequently oil samples shall be drawn at

1. Before fillign in main tank at site & tested for

i) BDV 60 kV (min)
ii) Moisture content 10 ppm (max.)
iii) Tan delta at 90 deg. C 0.005 (max.)
iv) Interfacial tension 0.04 N/m (min.)

2. Prior to energization at site for following properties & acceptance norms:

i) BDV 60 kV (min)
ii) Moisture content 10 ppm (max.)
iii) Tan delta at 90 deg. C 0.05 (max.)
iv) Interfacial tension 0.03 N/m (min.)

4.18.00 Terminal Arrangements

4.18.01 Bushings

A) The electrical & mechanical characteristics of bushings shall be in

accroodance with IS:2099, IS: 3347 & IS: 12676

Obra “C” 2x660 MW Thermal Power Extension

Project

Bidding Doc. No. : 14A22-SPC-G-0001

HeadOffice Uploading Date And Time::::: Wednesday, September 30, 2015 5:48:24 PM

DCPL Volume IV: Ch 07: Generator Transformer

Sheet l 17 of 32
Electrical Works

b) Bushings for 52 kV & above shall be of the oil filled condenser type `&
shall be of draw lead / rod type to facilitate removal. Busings of rating
below 52 kV shall be solid porcelain or oil communicating type.

c) Condenser type busings shall be provided with:

1) Oil level gauge

2) Oil filling plug & drain valve (if not hermetically sealed)
3) Tap for capacitance & tan delta test.

d) Clamps & fittings shall be of hot dip galvanized steel.

e) Bushing & fittings shall be provided with vent pipes that shall be
connected to route any gas collection through the Buchholz relay.

f) No arcing horns shall be provided o n the busings.

g) LV Bushing palm shall be Silver / Tin plated.

4.18.02 Bus Duct Terminations

A) Two (2) nos low voltage terminals for each single phase transformers shall
be brought out thru' separate top cover mounted bushings with matching
flanges around each bushing for necessary delta connection by isolated
phase busduct .

B) For termination of busduct a flanged throat or equivalent connection shall

be provided for termination of busduct enclosure. The LV winding
termination shall be on outdoor type of bushings. The Busduct supplier
would provide necessary flexible connection between the bushing terminal
and the busduct conductor. The material of the busduct termination shall
be non-magnetic. A drain with stopcock arrangement shall be provided at
flange to drain leakage of oil/water at termination. As bus duct will be
pressurized stopcocks shall be airtight.

C) Tolerance permissible for the height of the terminal connected to busduct

over rail top level is ± 10 mm. Contractor has to ensure that radiator &
conservator does not obstruct the path of the bus ducts in position &
during movement of transformer. The contractor shall co-ordinate final
design of terminal arrangement to suit bus duct arrangement during
detailed engineering.

D) The transformer bushing enclosed in bus duct enclosure shall be designed

for satisfactory operation in the high ambient temperature existing inside
the bus duct enclosure. The temperature inside the bus duct enclosure
may be of the order of 90 – 100 deg. C. The bus duct conductor
temperature may be as high as 105 deg. C & temperature in the bus duct
enclosure will be of the order of 80 deg. C.

4.18.03 Terminal Connector

i) High voltage line side terminals shall be brought out thru' top cover
mounted bushings for connection to overhead ACSR conductors.
ii) Bushing terminal shall be provided with terminal connectors of approved
type & size for connection to external part. Terminal connectors must have
been successfully type tested as per IS: 5561.

Obra “C” 2x660 MW Thermal Power Extension

Project

Bidding Doc. No. : 14A22-SPC-G-0001

HeadOffice Uploading Date And Time::::: Wednesday, September 30, 2015 5:48:24 PM

DCPL Volume IV: Ch 07: Generator Transformer

Sheet l 18 of 32
Electrical Works

iii) These shall be suitable for either horizontal or vertical take off.
iv) Aluminum alloy if used shall conform to designation 4600 M of IS: 617 or
of better quality.
v) No part of a clamp shall be less than 10 mm thick.
vi) All ferrous parts shall be hot dip galvanized conforming to IS: 2633.
vii) For bi-metallic clamp, copper alloy liner of minimum 2-mm thickness shall
be cast integral with aluminum body. Alternatively Contractor may offer
bimetallic connector with loose bimetallic sleeve.
viii) Flexible connectors shall be made from tinned copper sheets.
ix) Size of terminal/conductor for which the clamp is suitable & rated current
under the conditions shall be embossed/ punched on each component of
the clamp, except hardware.
x) Rated current of the terminal connectors shall be same as that of
corresponding bushing. However the short circuit current for 800 kV
connectors shall be 40 kA for 1sec.

In general, the arrangement shall be such as to permit removal of transformer

without dismantling the bus duct/cable connection.

High voltage winding neutral for each single-phase transformer shall be brought
out through top cover mounted bushing for neutral formation. All necessary
insulators, 10x125 mm hard copper flat, mounting hardware will be supplied
along with one of three single phase transformer. However provision for neutral
grounding shall be provided in all transformers.

4.18.04 MARSHALLING BOX

A sheet steel, weatherproof, IPW55, marshalling box shall be provided for the
transformer. The box shall contain all auxiliary devices except those, which
must be located directly on the transformer. All terminal blocks required for
cable connection shall be located in this box.

The marshalling box shall be provided with cubicle lamp with door switch,
space heater with thermostat and removable cable gland plate.

4.18.05 WIRING

i. All control, alarm and indication devices provided with the transformer
shall be wired upto the terminal blocks.

ii. Wiring shall be done with copper, flexible, 1100V grade PVC wires in
conduit or PVC armoured cable. Minimum wire size shall be 4 sq. mm
for CT leads and not less than 2.5 Sq.mm for other connections. 10%
spare terminals shall be provided on each terminal block.

iii. Multi-way terminal block complete with mounting channel, binding

screws and washers for wire connections and marking strip for circuit
identification shall be provided for terminating the panel wiring.
Terminals shall be stud type, suitable for terminating 2 nos. 2.5 mm2
stranded copper conductor and provided with acrylic insulating cover.
Terminals for C.T. secondary leads shall have provision for shorting
and grounding.

iv. All devices and terminal blocks shall be identified by symbols

corresponding to those used in applicable schematic or wiring diagram.
Each wire shall be identified, at both ends, with interlocking type

Obra “C” 2x660 MW Thermal Power Extension

Project

Bidding Doc. No. : 14A22-SPC-G-0001

HeadOffice Uploading Date And Time::::: Wednesday, September 30, 2015 5:48:24 PM

DCPL Volume IV: Ch 07: Generator Transformer

Sheet l 19 of 32
Electrical Works

permanent markers bearing wire numbers as per Contractor’s Wiring

Diagrams. AC/DC wiring shall have separate colour coding.

v. Wire termination shall be made with crimping type connectors with

insulating sleeves. Wires shall not be spliced between terminals.

4.19.00 GROUNDING

The grounding pads, located on the opposite sides of the tank, shall be provided
for connection to station ground mat. Grounding pad shall have clean buffed
surface with two tapped holes, M10 GS bolts and spring washers for connection
to 75 x 10 mm GS flat.

Ground terminals shall be also provided on marshalling box to ensure its

effective earthing.

For continuity of earth connection, all gasketted joints shall be provided with
braided copper wire jumpers.

4.20.00 AUXILIARY SUPPLY

A.C. supply will be made available to transformer by two separate feeders one
normal and the other standby.

Isolating switch fuse unit shall be provided for each of the incoming supply
along with automatic changeover scheme to switch on to the standby source in
case of failure of the normal supply.

4.21.00 AUXILIARY EQUIPMENT

Neutral bushing current transformers and phase bushing current transformers

shall be furnished when specified in the annexure.

The arrangement shall be such that the C.T. can be removed from the
transformer without removing the tank cover.

CT secondary leads shall be wired upto the terminal blocks.

4.22.00 PAINTING

i. All steel surfaces shall be thoroughly cleaned by sand blasting or chemical

agents as required, to produce a smooth surface free of scales, grease and
rust.

ii. The interior of all transformer tanks and other oil filled chambers and internal
structural steel work shall be cleaned of all scale and dust by sandblasting
unless otherwise approved.

iii. The paints shall be carefully selected to withstand tropical heat, rain etc. The
paint shall not scale off or crinkle or be removed by abrasion due to normal
handling.

iv. Sufficient quantity of touch up paint shall be furnished for application after
installation at site.

v. All supporting structures and hardware shall be hot dip galvanized.

Obra “C” 2x660 MW Thermal Power Extension

Project

Bidding Doc. No. : 14A22-SPC-G-0001

HeadOffice Uploading Date And Time::::: Wednesday, September 30, 2015 5:48:24 PM

DCPL Volume IV: Ch 07: Generator Transformer

Sheet l 20 of 32
Electrical Works

vi. Painting of transformer and its accessories shall be in accordance with the
following chart:

PARTS NAME TYPE OF PAINT NO. OF COATS TOTAL DFT

Inside Of tank and Oil & heat One coat Atleast 30 micron
accessoreis resistant fully
(Except CM Box glossy white
and CCC)
External surface Chemical resistant One coate each Atleast 100
of transformer epoxy zinc micron
and accessories phosphate primer,
including CM MIO (Micaceious
Box/CCC (except iron oxide) as
cooler) intermediate paint
followed by
polyurethane
finish paint (RAL
5012 Blue)
External Cooler Anticorrosive Two coats each Atleast 100
surface primary paint micron
followed by high
quality full glossy
outer finish paint
(RAL 5012 Blue)
Internal surface of Chemical resistant Two coats each Atleast 100
Cm Box / CCC epoxy zinc micron
phosphate primer
followed by
chemical and heat
resistant epoxy
enamel white
paint

Obra “C” 2x660 MW Thermal Power Extension

Project

Bidding Doc. No. : 14A22-SPC-G-0001

HeadOffice Uploading Date And Time::::: Wednesday, September 30, 2015 5:48:24 PM

DCPL Volume IV: Ch 07: Generator Transformer

Sheet l 21 of 32
Electrical Works

5.00.00 TRANSPORTATION

Transformer tank shall be dispatched filled with oil or pure dry inert Nitrogen
gas depending upon the transport weight limitations. A positive pressure of 2 to
2.5 PSI at temperature of 36°C approximate shall be kept. In case the tank is
filled with oil, sufficient space is left above the oil to take care of the expansion
of the oil. The space is filled with pure dry air or inert gas under atmospheric
pressure.

The temperature and pressure at the time of gas filling shall be marked on a
tag. A graph showing pressure vs. temperature shall be attached for reading
pressures at different temperatures. Necessary valves, two-stage pressure
regulators, filled up Nitrogen cylinder etc. along with other accessories required
shall be provided with the tank for intermittent replenishment during
transportation.

Impact Recorder

Impact recorder/indicator shall be provided to monitor the impact experienced by

the transformer during transport. The recorder will be taken back only after
obtaining written permission from Purchaser’s Site Incharge

6.00.00 ONLINE MONITORING SYSTEM:

Temperature Measurement S ystem:

Temperature measurement of oil and w indings shall be done using

A) Fiber optic sensors, meeting following criteri a:

SY ST EM SHAL L BE OF PROVEN T ECHNOL OGY. THE T EMPER AT UR E

SENSI NG T IP OF THE F I BR E OPT I C CABL E SHAL L BE “ DI P-T I P
R UGGED PR OBES” . THE PROBES SHAL L BE DI R ECT L Y I NST AL L ED
IN EACH PHASE/ W I NDI NG OF POWER TRANSFORMER TO
MEASURE THE W I NDI NG HOT SPOT AND AT THE TOP (I NSI DE) OF
THE TRANSFORMER TO MEASURE TOP OIL TEMPERATURE. THERE
SHAL L BE MINIM UM EI GHT PROBES I NSI D E THE TRANSFORMER,
OUT OF WHICH FOUR ARE TO BE CONNECTED TO THE
MONITORING SYSTEM AND R EMAI NI NG FOUR ARE TO BE KEPT AS
STAND BY PROBES, TO BE CONNECTED TO THE MONITORIN G UNIT
IN CASE OF F AI L UR E OF COR R ESPONDI NG PR OBE FEATURES

i. Provides visual and audio alarm in case of any abnormality.

ii. Bidder to indicate detector parameters of the system including power

consumption, sensor life and performance feed back of field trials in
their bid.

Six (6) probes shall be installed in each phase / winding at the hottest
spots of each of the phase windings. The locations of the probe shall be
proposed by the manufacturer and location finalized by agreement of
the purchaser. Remaining two (2) probes shall be in the top inside of
the transformer for measuring top oil temperature.

iii. Probes shall be able to completely immersed in hot transformer oil,

they shall withstand exposure to hot kerosene vapor during the

Obra “C” 2x660 MW Thermal Power Extension

Project

Bidding Doc. No. : 14A22-SPC-G-0001