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2X382 MW CCPP at Vemagiri

L&T - S&L LIMITED


LARSEN & TOUBRO LIMITED SPECIFICATION FOR Rev : R0 Date : 16/9/2009
GENERATOR STEP-UP
TRANSFORMER FOR GTG AND
STG
E&C POWER BUSINESS UNIT Page: 53

LARSEN & TOUBRO LIMITED


E&C POWER BUSINESS UNIT

TECHNICAL SPECIFICATION FOR GENERATOR STEP UP


TRANSFORMER FOR GTG AND STG
PROJECT: 2X382 MW CCPP at Vemagiri (Phase 2)

L&T’s CONSULTANT:
L&T-SARGENT & LUNDY LIMITED, BARODA

PROJ. NO. Total No. of Pages: 54


No. of drawings:
REVISION CERTIFICATION
REVISION R0 R1 R2
NO.
NAME SIGN DATE NAME SIGN DATE NAME SIGN DATE
PREPARED
REVIEWED
APPROVED
2X382 MW CCPP at Vemagiri

L&T - S&L LIMITED


LARSEN & TOUBRO LIMITED SPECIFICATION FOR Rev : R0 Date : 16/9/2009
GENERATOR STEP-UP
TRANSFORMER FOR GTG AND
STG
E&C POWER BUSINESS UNIT Page: 53

REVISION SUMMARY SHEET

REV. DETAILS / DESCRIPTION DATE


R0 For Procurement 16/9/2009
2X382 MW CCPP at Vemagiri

L&T - S&L LIMITED


LARSEN & TOUBRO LIMITED SPECIFICATION FOR Rev : R0 Date : 16/9/2009
GENERATOR STEP-UP
TRANSFORMER FOR GTG AND
STG
E&C POWER BUSINESS UNIT Page: 53

INDEX

SL. CONTENT DESCRIPTION REVISION NO. OF


NO. PAGES
1. SECTION I TECHNICAL SPECIFICATION R0 41
2. SECTION II TECHNICAL DATASHEET R0 11
3. SECTION III TECHNICAL DATASHEET FOR R0 1
COOLING SYSTEM
2X382 MW CCPP at Vemagiri

L&T - S&L LIMITED


LARSEN & TOUBRO LIMITED SPECIFICATION FOR Rev : R0 Date : 16/9/2009
GENERATOR STEP-UP
TRANSFORMER FOR GTG AND
STG
E&C POWER BUSINESS UNIT Page: 53

SECTION-I

TECHNICAL SPECIFICATION
2X382 MW CCPP at Vemagiri

L&T - S&L LIMITED


LARSEN & TOUBRO LIMITED SPECIFICATION FOR Rev : R0 Date : 16/9/2009
GENERATOR STEP-UP
TRANSFORMER FOR GTG AND
STG
E&C POWER BUSINESS UNIT Page: 53

CONTENTS
1.0 INTENT OF SPECIFICATION...................................................................................................................6

2.0 PROJECT INFORMATION........................................................................................................................6

3.0 SYSTEM DESCRIPTION............................................................................................................................7

4.0 SCOPE OF WORK ......................................................................................................................................8

5.0 CODES AND STANDARDS ......................................................................................................................11

6.0 OPERATION AND CONTROL PHILOSOPHY ......................................................................................12

7.0 DESIGN AND CONSTRUCTION REQUIREMENTS.............................................................................13

8.0 INSPECTION AND TESTING..................................................................................................................32

9.0 DRAWINGS / DATA / DOCUMENTS TO BE SUBMITTED BY BIDDER ALONGWITH THE BID .34

10.0 TRANSPORTATION AND HANDLING OF MATERIAL AND EQUIPMENT ……...………………...37

11.0 FITTING AND ACCESSORIES.………………………………………………….. ……...………………...40


2X382 MW CCPP at Vemagiri

L&T - S&L LIMITED


LARSEN & TOUBRO LIMITED SPECIFICATION FOR Rev : R0 Date : 16/9/2009
GENERATOR STEP-UP
TRANSFORMER FOR GTG AND
STG
E&C POWER BUSINESS UNIT Page: 53

1.0 INTENT OF SPECIFICATION

1.1 This specification is intended to cover the design, engineering, manufacture,


inspection and testing at manufacturer’s works, packing, supply on FOR basis,
supervision of erection, testing and commissioning at site of two (2) nos. of
Generator step up transformers for GTG and two (2) Nos. of generator step up
transformers for STG, inclusive of all fittings, accessories and spares for efficient
and trouble-free operation.

1.2 It is not the intent to completely specify all details of design and construction
herein. Nevertheless, the equipment and installation shall conform to high standards
of engineering design and workmanship in all respects and shall be capable of
performing continuous operation in a manner acceptable to the Purchaser.

2.0 PROJECT INFORMATION

Owner GMR Energy Limited

Project 2X382 MW CCPP at Vemagiri

Owner’s Engineer / TCE Consulting Engineers Limited


Consultant
Purchaser Larsen and Toubro Ltd.

Purchaser’s Engineer L&T-Sargent & Lundy Ltd.

Max Site Temperature 50 Deg C

Min Site Temperature 13 Deg C

Elevation above Mean Sea FGL: 24.5 M


Level
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LARSEN & TOUBRO LIMITED SPECIFICATION FOR Rev : R0 Date : 16/9/2009
GENERATOR STEP-UP
TRANSFORMER FOR GTG AND
STG
E&C POWER BUSINESS UNIT Page: 53

3.0 SYSTEM DESCRIPTION

A 2X382 MW CCPP is being set up at Vemagiri, Andhra Pradesh. The CCPP will
have two (2) nos. Gas Turbine Generators, two (2) nos. Heat Recovery Steam
Generators and two (2) nos. Steam Turbine Generator as main equipments.

The Gas Turbine Generator (GTG) and Steam Turbine Generator (STG)
Transformers will be used for connecting the Gas Turbine and Steam turbine
Generators to the 400kV system.

The Gas Turbine Generator transformer LV terminals will be connected to the


15.75 kV generator terminals by isolated phase bus-duct via the generator circuit
breaker. The Steam Turbine Generator transformer LV terminals will be connected
to the 15.75 kV generator terminals by isolated phase bus-duct. GTG/STG
transformer HV terminals will be connected to the 400 kV switchyard by overhead
stringing connection.

3.1 POWER SUPPLY CONDITIONS

Supply Description Variation Application


Generation 15.75 kV, 3-, 3 wire, 15.75kV () 5% Generator, Isolated
System 50Hz, Non effectively 50Hz (+)4%, (-)5% phase busduct,
earthed, Fault level: 83 kA Combined volt. And Generator Circuit
for 1 sec at generator freq.: 10% abs. Breaker, etc.
terminal (subjected to
change)
Power 400 kV, 3-, 3 wire, 50Hz, 400kV () 10% Switchyard
Evacuation Effectively earthed, 1550kV 50Hz () 5% Equipment
BIL Combined volt. And
Fault level: 40kA (rms) for freq.: 10% abs.
1 sec
L.T. Supply 415 V, 3-, 4 wire, 50Hz Volt. : () 10% Motors rated below
solidly earthed Freq.: () 5% 200 KW
Fault level: 50 kA (rms) for Combined volt. And
1 sec freq.: 10% abs.
DC Supply 220V DC, 2 wire, Volt. : () 10% DC alarm, control,
Ungrounded system, indication and for DC
lighting, DC motors.
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LARSEN & TOUBRO LIMITED SPECIFICATION FOR Rev : R0 Date : 16/9/2009
GENERATOR STEP-UP
TRANSFORMER FOR GTG AND
STG
E&C POWER BUSINESS UNIT Page: 53

4.0 SCOPE OF WORK

The scope of work under this package will include design, engineering,
manufacturing, inspection and testing at manufacturer’s works, packing, supply on
FOR site basis, and supervision of erection, testing and commissioning at site of
GTG and STG Transformers as described hereunder. Items though not specifically
mentioned but are required to make the system complete will be treated as included
in the scope of Supplier unless otherwise specifically excluded. The total system
design and engineering will be sole responsibility of Supplier.

4.1 SCOPE OF SUPPLY

4.1.1 The scope of supply shall cover the following:

a) Gas Turbine Generator Transformer: - Two (2) number. 275 MVA

b) Steam Turbine Generator Transformer: - Two (2) number. 170 MVA

c) Remote Tap Changing Cabinet (RTCC) with communication interface

4.1.2 The scope of supply for each of the above transformers shall include but not limited
to the following:

a) Fittings and accessories such as sampling Valve, Conservator drain valve,


Roller, Dial Thermometer, Oil and Winding Temperature indicator with high
and very high indication contacts, Buchholz Relay, Top Oil Filter Valve,
Inspection cover, Bus duct flange, Magnetic oil level gauge, inspection
manholes / hand holes, lifting lugs, jacking pads, bi-directional flanged rollers,
haulage lugs, skids, earth ads, neutral earthing down comers (2 nos.) supported
on pin insulators, terminal marking, rating and diagram plates, marshalling
boxes, conservators with breathers (flexible oil resistant air bag), valves for
various purposes including draining, filtering, filling, magnetic (150 mm dia)
and prismatic oil level gauges, anti-earthquake clamping arrangement, tank
mounted radiators with accessories, and pressure relief valve etc. shall be
provided.

b) Air release plug and 2 nos. Plugged pipe outlets for vacuum pulling to be
provided.

c) Pipe to soak pit with valve for quick oil drainage in case of fire to be provided.
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LARSEN & TOUBRO LIMITED SPECIFICATION FOR Rev : R0 Date : 16/9/2009
GENERATOR STEP-UP
TRANSFORMER FOR GTG AND
STG
E&C POWER BUSINESS UNIT Page: 53

d) Cable, trays, supports and conduits between the Supplier’s devices and marshalling
box / cooler control cabinet except those specifically excluded.

e) Structure for supporting conservator, radiator, control cabinet and any other
structure if required for supporting any parts of transformer.

f) First fill of oil (as per IS 335) till the level generally required in the conservator
including with 10% extra quantity in non-returnable sealed containers.

g) Touch-up paint as required at site.

h) Aluminium paint for GSU.

i) All relevant drawings, data, routine & type test reports, erection & commissioning
instructions and operation & maintenance manuals.

j) Start-up and commissioning spares.

k) Bidder shall indicate the list of recommended spares.

l) Bidder shall supply special tools, tackles & materials as required for erection,
commissioning & maintenance and shall include in the bid separately.

4.2 SCOPE OF SERVICES


Bidder shall provide the following services under the scope of this specification:
a) Design and engineering in accordance with specification requirements,
manufacturing and arranging inspection.

b) Packing, loading, for transportation and delivery of all the materials by rail/road
to site.

c) Supervision of erection, testing and commissioning. Bidder shall arrange their


representatives/commissioning engineers for supervision of
erection/installation, testing, start-up/charging and commissioning of the
supplied equipment at site. The responsibility of commissioning engineers shall
be to commission the transformers & associated systems supplied by the bidder
to the satisfaction of owner/ owner’s engineer and hand over the unit to the
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LARSEN & TOUBRO LIMITED SPECIFICATION FOR Rev : R0 Date : 16/9/2009
GENERATOR STEP-UP
TRANSFORMER FOR GTG AND
STG
E&C POWER BUSINESS UNIT Page: 53

Owner. In addition to that, Commissioning Engineers shall be available at site


during grid synchronisation.

Purchaser reserves the right to call these engineers at a notice of 7 days.

d) Submission of all necessary data sheets, drawings, documents, and QAP for
Purchaser’s approval. Submission of test certificates and carry out all testing /
inspection, inline with approved QAP. Vendor will also provide facilities for
Purchaser’s / Owner’s representatives to witness various tests inline with
approved QAP.

e) Submission of detailed civil/structural designs, including all equipment


foundation loading data.

f) Submission of control schematics for cooler cabinet and marshalling box.

m) The bidder shall give an optional price for training of Owner's engineers at the
manufacturing works and plant site. Bidder to indicate in his bid, the duration of
training in man-days at each location and man-day rate considered. The same
shall however be finalised before award of contract.

n) Submission of all drawings/manuals and as built.

4.3 TERMINAL POINTS

a) HV bushings (Suitable for overhead stringing connection)

b) LV bushings (Suitable for Isolated phase bus connections)

c) Neutral grounding point

d) Ground pads for connection to purchasers earth Grid.

e) Marshalling box (All Purchaser’s external power (3Phse 415V AC and 220V
DC), control & instrument cables)

4.4 EXCLUSIONS

a) Civil foundations for transformer including rails. However, the foundation


details shall be submitted along with the offer.
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LARSEN & TOUBRO LIMITED SPECIFICATION FOR Rev : R0 Date : 16/9/2009
GENERATOR STEP-UP
TRANSFORMER FOR GTG AND
STG
E&C POWER BUSINESS UNIT Page: 53

b) Fire protection system.

c) Erection and installation and commissioning except supervision.

d) Oil filtration / treatment at site.

e) Cabling beyond transformer marshalling box.

f) 415 V, 3-phase, 3-wire, 50 Hz power supply and 220 V DC power supply (as
required). Bidder shall clearly indicate the auxiliary power supply requirements
(Number of supplies, voltage level, current ratings etc.) in his bid.

g) Connections to the owner’s station earthing grid and lightning protection.

h) Protective relays and control panel for transformer protection.

5.0 CODES AND STANDARDS

5.1 The equipment, systems and services furnished as per this specification will
conform to the codes and standards mentioned here which are furnished for
Supplier’s guidance.

5.2 In case of any conflict between this document and the Indian and Internationals
codes and standards, referred to herein, the stipulations of the more stringent
one will prevail.

5.3 Standards as applicable from the following list, or other internationally accepted
equivalent standards should be used in the design, manufacture and testing:

Power transformer IS : 2026

Fittings and accessories IS : 3639

Loading of oil immersed IS : 6600


transformers

Oil IS : 335

Bushings IS : 2099
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LARSEN & TOUBRO LIMITED SPECIFICATION FOR Rev : R0 Date : 16/9/2009
GENERATOR STEP-UP
TRANSFORMER FOR GTG AND
STG
E&C POWER BUSINESS UNIT Page: 53

Degree of protections IS : 2147

Tests IS : 2026

Tolerance on guaranteed IS : 2026


particulars

Buchholz relay IS : 3637

Electrical insulation classified by IS : 1271


thermal stability.

Application guide for power IS: 10561, 1983


transformer.

Current Transformers IS: 2705

Specifications for Three Phase IS: 325


Induction Motor

Fittings and accessories for Power IS: 3639


Transformers.

Specification for PVC insulated IS: 1554


(heavy duty) electric cable

Application Guide for OLTC IS-8478

Application Guide for CTs IS-4201

6.0 OPERATION AND CONTROL PHILOSOPHY

6.1 Generator transformers covered under this specification, shall be operated in


parallel with the 400 kV grid (paralleling will be at the power plant 400 kV bus).
The electrical power generated from the CCPP will be evacuated to the 400kV
2X382 MW CCPP at Vemagiri

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LARSEN & TOUBRO LIMITED SPECIFICATION FOR Rev : R0 Date : 16/9/2009
GENERATOR STEP-UP
TRANSFORMER FOR GTG AND
STG
E&C POWER BUSINESS UNIT Page: 53

power grid. For this purpose the CCPP shall have its own 400 kV switchyard with a
1½-breaker arrangement.

6.2 The Generator Transformer shall be so sized as to be able to evacuate power from
the GTG / STG to which it is connected under all conditions of ambient
temperature. Gas Turbine curve showing Power output w.r.t ambient temperature is
attached with this specification. GTG Transformer rating should be higher than the
Gas Turbine output throughout the ambient temperature range.

6.3 Cooler control: Two (2) 100% capacity separately mounted radiator banks shall be
provided. Each bank shall be provided with adequate number of fans and pumps
and one oil pump and one fan spare. 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 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 radiator shall have upper and lower shut-off valves with blanking at
either ends. The cooling fans for AF and cooling pumps for OF shall have provision
for local and remote operation. The controls shall also consist of an auto / manual
selection. Fan running indication from auxiliary contact of fan power contactor and
an oil flow indicator along with an electrical contact for alarm / interlock shall be
provided for the confirmation of the oil pump operating in a normal state.

Tap changer control: Generator transformers shall be equipped with On-Load tap
changer (OLTC) of range +7.5% to -15% in steps of 1.25% on the HV side and
suitable for bi-directional power flow. OLTC shall be operated from local OLTC
panel as well as from RTCC & remote. Tap position indication shall be provided in
local OLTC panel, RTCC and remote. Suitable interlocks shall be provided to
prevent inadvertent / mal operation of the tap changer.

7.0 DESIGN AND CONSTRUCTION REQUIREMENTS

7.1 GENERAL

a) The transformers shall be of the latest design, mineral oil immersed type.
Transformers shall be suitable for outdoor installation.
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LARSEN & TOUBRO LIMITED SPECIFICATION FOR Rev : R0 Date : 16/9/2009
GENERATOR STEP-UP
TRANSFORMER FOR GTG AND
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b) The transformer shall be capable of remaining in operation without injurious


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

c) 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 dynamic ability to withstand short circuit shall be demonstrated
by calculations.

d) The type of cooling shall be Oil Natural Air Natural, Oil Natural Air Forced and
Oil Forced Air Forced, as specified, and the corresponding ratings of
transformer shall be as indicated in the specific requirements.

e) The transformer shall be designed to deliver rated MVA continuously on all


tapings without exceeding the applicable temperature rise limits for the power
supply conditions.

f) The transformer shall be capable of withstanding shock loading / unloading


during parallel operation. There shall be no limitation imposed by bushings, CTs
and other accessories.

g) The transformer and all accessories including bushings, CTs, etc shall be
capable of withstanding the short circuit stresses due to terminal fault on one
winding with full voltage maintained on the other winding for minimum period
of one (1) seconds without damaging effect as well as any external short circuit
at bushing terminal.

h) The Transformers shall operate without injurious heating at the rated MVA
continuously at any voltage within + 10% of the rated voltage of the Tap.

i) The transformer shall be free from annoying hum or vibration. The design shall
be such as not to cause any undesirable interference with radio or
communication circuits.

j) The transformer and the associated accessories shall be suitable for bi-
directional flow of power. The transformer will be back-charged from the EHV
system to charge the unit auxiliary transformers.
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LARSEN & TOUBRO LIMITED SPECIFICATION FOR Rev : R0 Date : 16/9/2009
GENERATOR STEP-UP
TRANSFORMER FOR GTG AND
STG
E&C POWER BUSINESS UNIT Page: 53

k) Core clamping arrangement shall be equipped with core and coil lifting eyes.
Anti-earthquake clamping arrangement shall be provided.

l) Jacking, lifting, pulling, rolling, and skidding provisions must be provided to


allow for installer’s choice of installation methods. Transformer cover shall be
equipped with lifting eyes duly painted with zebra of the colour combination
based on the weight of the assembly to be lifted as per the relevant standard.

m) Transformers shall be so designed that the average sound level will not exceed
the value 85dB at the distance of 1 meter from the equipment, as measured at
factory and site.

n) The transformer shall be mounted on bi-directional flanged wheels and shall be


provided with boltable & lockable wheels. The locking arrangement shall be
furnished by the Bidder for review.

o) All hardware used in the transformer and accessories shall be zinc plated &
chrome passivated / stainless steel to suit the site environment.

7.2 TRANSFORMER TANK

a) The generator transformer shall be outdoor type, of welded mild steel plate
construction fabricated from good commercial grade low carbon steel of
adequate thickness and provided with gaskets steel cover plates. Base shall be
suitably reinforced to prevent any distortion during lifting. Base channels shall
be provided with skids and pulling eyes to facilitate handling. Bell type design
shall be adopted for transformer tank.

b) The tank of the transformer along with radiators, conservators, bushings and
other fittings shall withstand full vacuum of 760 mm of Hg while filling the oil
under vacuum and also an excess internal pressure of 0.35 kg/sq. cm.

c) All seams and those joints not required to be opened at site shall be welded and
wherever possible they shall be double welded in factory itself for absolute oil
tightness. After completion of tank and before painting, dye penetration test
shall be carried out on welded parts of jacking bosses, lifting lugs and all load
bearing members. Grinding shall clean all welds. Any tack welding deposits
shall be removed.
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LARSEN & TOUBRO LIMITED SPECIFICATION FOR Rev : R0 Date : 16/9/2009
GENERATOR STEP-UP
TRANSFORMER FOR GTG AND
STG
E&C POWER BUSINESS UNIT Page: 53

d) The tank covers shall be fitted with thermometer pockets (in locations expecting
maximum operating oil temperature) for bulbs of oil and winding temperature
indicators. The thermometer pockets shall be filled with a captive screwed top to
prevent ingress oil water. It shall be possible to remove these bulbs without
lowering the oil in tank.

e) Tank shields and two (2) inspection openings to be provided in transformer tank.
Tank shields shall be such that no magnetic field shall exist outside the tank.
They shall be of magnetically impermeable material. If required impermeable
shields shall be provided in the tank for positioning the core and coil assembly.
The inspection covers shall be suitably designed to prevent ingress of rainwater
and shall have suitable lifting arrangements. Bushings, turrets, inspection covers,
thermometer pockets etc. shall be designed to prevent ingress of water into, and
leakage of oil from the tank.

f) Tanks shall not resonate when excited at the natural frequency of the equipment.

g) The tank, radiator banks and marshalling box shall have at least two (2) distinct
stainless steel earth pads terminals, capable of carrying maximum system earth
fault current for a duration of one (1) sec, for connection to Purchaser’s earth
grid by 75 x 10 mm GI Flat.

h) Flanged bi-directional wheels are to be provided at the base with locking


arrangements. Jacking steps shall be provided. It shall be possible to change the
direction of the wheels through 90 Degrees, when Transformer is lifted on Jacks
to permit movement of the Transformers both in longitudinal and transverse
directions.

i) Tank, tank cover and other associated components on the transformers shall have
electrical continuity for earthing.

j) All the bolted connections shall be fitted with weatherproof hot oil resistant
SRBP gasket / nitrile rubber gasket in between for complete oil tightness. If
gasket is compressible, metallic stops shall be provided for avoiding over
compression. Necessary bridging with copper strips shall be provided for the
electrical continuity across a gasket joint.

k) Suitable guides shall be provided for positioning the various parts including core
and coil during assembly or dismantling. Adequate space shall be provided
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between the cores and windings and the bottom of the tank for collection of any
sediment

l) Each tank shall be equipped with the following valves with the standard flange
connection for external piping.

i) One drain and lower filter valve located on the low voltage side of the
transformer and so placed to completely drain the tank. The valve shall be
equipped with a small sampling cock.
ii) One filter valve located at the top of the tank on the high-voltage side. The
opening of this valve shall be baffled to prevent aeration of the oil.
iii) One filter valve, located diagonally opposite to (ii) slightly above the bottom
of the tank.
iv) Spring loaded pressure relief device, as required, to operate at a pressure
below the test pressure for the tank.
v) All valves excepting radiator valves shall be of gunmetal. Radiator valves
shall be of cast iron with stainless steel / gunmetal moving parts. All valves
shall be provided with stopper.
vi) Suitable pad locking arrangements should be provided for drain & bottom
sampling valves, to lock them in close / open position. All valves should be
provided with clear open/close position indications. Wherever rising spindle
type valves are provided the valves should be clockwise rotating for closing
operations.

m) In addition to the valves mentioned above, each transformer shall be provided


with a suitable nozzle along with the valve for oil spray during filtering for
degasification and other benefits like extraction of residual moisture from
winding. All points terminating in a flanged connection exposed to atmosphere
shall be supplied with blank flanges, bolts, nuts and gaskets.

7.3 TRANSFORMER CORE AND WINDINGS

7.3.1 CORE

a) Core shall be constructed of high grade, low loss, high permeable CRGO silicon
steel laminations. Maximum flux density in any part of the Core and Yoke at
rated MVA, voltage and frequency shall be such that under 10% continuous over
voltage condition it should not exceed 1.9 Wb/m2. Bidder shall submit the over
fluxing curve along with the offer.
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The transformer shall be suitable for following over fluxing duties:


110% - continuous
125% - 1 minute
140% - 5 seconds

b) The framework, clamping arrangement and general structure of the cores of


each transformer shall be of robust construction and shall be capable of
withstanding any shock to which they may be subjected during transport,
installation and service. Anti-earthquake clamping arrangement shall be
provided.

c) The Transformer shall be subjected to Load rejection conditions and shall be


able to withstand 1.4 times the rated voltage for 5 seconds.

d) The transformer shall be subjected to load rejection conditions and shall be able
to withstand 1.4 times the rated voltage for 5 seconds as per IS: 2026.

e) The framework and the core bolts shall be efficiently insulated from the core so
as to reduce the eddy-currents to a minimum.

f) The limbs and the yokes of the core shall have similar sections to minimise
heating and noise arising from transverse flux. The joints in the laminated
magnetic circuit shall be interleaved. Necessary cooling ducts shall be provided
for heat dissipation from the core so that the anticipated maximum hot spot
temperature in the core shall not be injurious to any material used in the core
assembly.

g) The frame, clamps and core-bolts shall be electrically insulated from the core.
Such insulation shall be capable of withstanding maximum temperature existing
in the core. For this purpose, Class-A or better insulation shall be used. Core
clamps shall be electrically connected to the tank.

h) Core shall be grounded with removable test connection accessible from


manhole. All metal parts of the transformer with the exception of the individual
core laminations, core bolts and associated individual clamping plats shall be
earthed. The magnetic circuit shall be earthed to the clamping structure at one
point only through a bushing brought out separately on the tank cover and then
grounded to the transformer tank.
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LARSEN & TOUBRO LIMITED SPECIFICATION FOR Rev : R0 Date : 16/9/2009
GENERATOR STEP-UP
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i) Earthing of Coil Clamping Rings – Where coil-clamping rings are of metal at


earth potential, each ring shall be connected to the adjacent core clamping
structure on the same side of the transformer as the main earth connection.

j) Size of Earthing Connections – Main-earthing connections shall be designed for


the maximum fault rating in magnitude and duration.

k) The insulation of core to bolts and core to clamp plates shall be able to
withstand a voltage of 2 kV RMS for one (1) minute.

l) The completed core shall be provided with the lifting eyes and lugs to facilitate
its removal from the transformer tank and shall be adequately braced &
supported to prevent movement during transit or service. All steel sections used
for supporting the core shall be thoroughly sand blasted after cutting, drilling
and welding.

7.3.2 WINDINGS

a) The windings shall be made of enamelled copper conductors of high


conductivity and 99.9% purity. Windings shall be designed to withstand the
thermal and dynamic short-circuit stresses to meet requirement of the Standards.

b) Insulation material shall be of proven design. Coils shall be so designed that


impulse and power frequency voltage stresses are minimum. Losses will be
considered during evaluation. The loss figures quoted by the bidder shall not
have any positive tolerance and shall be inclusive of power consumption of
associated auxiliaries like fans, coolers, marshalling box etc.

c) All windings shall be fully insulated for the highest system voltage of 420 kV
systems. The 420 kV star connected windings shall have graded insulation
while 15.75 kV winding shall be uniformly insulated, as defined in IS: 2026.
The insulation shall be as specified in Vol III, Section II, Annexure-1. Coils
shall be so insulated that impulse and power frequency voltage stresses are
minimum. All neutral points shall be insulated to withstand applied voltage test
as defined in the relevant standard.

d) The transformer winding shall be suitably clamped by mechanical means at the


top and bottom to prevent shifting which may occur through rough handling and
vibration during transport, switching & other transient conditions like short
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circuit. Anti-earthquake clamping arrangement shall be provided. End


connection of winding to be properly insulated. The winding structure and
major insulation shall be designed to permit unobstructed flow of cooling oil
through core cooling ducts to ensure efficient core cooling.

e) The windings shall be duly sectionalised. Accessible joints brazed or welded


and finished smooth shall connect similar sections. No corona discharge shall
result on the winding upon testing the transformer for induced voltage test as
specified in IS.

f) The windings also be thoroughly seasoned during manufacture by the


application of axial pressure at a high temperature for such length of time which
shall ensure that further shrinkage is unlikely to occur in service. Provision shall
however be made for taking up any further contraction by means of spring
loaded and adjustable clamps or other similar devices.

g) In the post-order stage, drawings shall be submitted showing type of winding,


methods of bracing and clamping details of electrical connection within
windings and details of oil cooling ducts and precautions taken to prevent
shrinkage of insulating material in service.

h) The end turns of the high voltage windings shall have reinforced insulation to
take care of the voltage surges likely to occur during any abnormal condition.

i) The transformer winding shall be connected in proper vector-groups. All


termination and tapping marked shall be in accordance with IS 2026.

j) The windings shall be located in a manner, which shall ensure that they remain
electrostatically balanced and that their magnetic centres remain coincident
under all conditions of operation.

k) The windings shall be so designed that all coil assemblies of identical voltage
ratings shall be interchangeable, and field repairs to the windings can be made
readily, without special equipment. Insulating spacers and the barriers/bracing
shall support the coils and other insulation used in the assembly of the windings
shall be arranged to ensure a free circulation of the oil and to reduce hot spots in
the windings. Windings shall be suitably designed so as to conduct tan delta test
for winding/bushings at site or at factory.
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l) All materials used in the insulation and assembly of the winding shall be
insoluble, non-catalytic, and chemically inactive in the hot transformer oil, and
shall not soften or otherwise be adversely affected under the operating
conditions.

m) All threaded connections shall be provided with locking facilities. All leads
from the winding to the terminal board and bushings shall be rigidly supported
to prevent injury from vibration. Guide tubes shall be used where practicable.

n) The winding shall be brought out through bushing and provided with suitable
terminal connectors.

o) The assembled core and windings shall be vacuum-dried and suitably


impregnated before removal from the treating tank. The copper conductors used
in the coil structure shall be best suited to the requirements and all permanent
current carrying joints in the windings and the leads shall be welded or brazed.

p) Sharp bends should be avoided in the windings as far as possible, where


unavoidable such bends should be reinforced with extra insulation tapes.

q) The tolerance for the winding resistance measurement for different phases but at
same taps shall be limited to 1%.

r) The design of the magnetic circuit shall be such as to avoid static discharges due
to development of short circuit paths within itself or to the earthed clamping.

s) Loss Capitalisation: For comparison of tenders, the losses will be capitalised by


adding to the transformer price as given below:

Copper Loss – Rs. 0.85 Lacs per kW


Iron Loss – Rs. 1.6 Lacs per kW

7.4 CONSERVATOR

a) The conservators shall have adequate capacity to accommodate oil preservation


system and volumetric expansion of the total cold oil volume in the transformer
and cooling equipment for a change in oil temperature from minimum to
maximum oil temperature with specified maximum temperature rise.
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b) The conservators shall be bolted into position so that it can be removed for
cleaning purposes.

c) The conservators shall be fitted with magnetic type oil level gauge (MOG) with
two independent low level electrically insulated potential free alarm contacts
wired up to the MOG’s terminal box, further wired up to the control cabinet
terminal strip. The oil level at 30C shall be marked on the gauge; however, the
range of the MOG shall be from minimum to maximum oil level. The dial size
shall be 150 mm. The conservator shall also have a prismatic oil level gauge.
Both the gauges shall be placed on the opposite sides of the conservator.

d) In the conservator, flexible oil resistant air cell nitrogen fill (rubber diaphragm)
breathing through silica gel breather shall be provided. The air cell shall be made up
of nitrile rubber reinforced with nylon rubber and with nylon cloth. As such air cell
used shall be suitable for operating continuously at the temperature rise limits. Air
cell of conservator should 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 later is under vacuum by providing a vacuum sealing
valve or other suitable means in the pipe connecting main tank with the conservator.
The connection of air cell to the top of the conservator shall be by air proof seal
preventing entrance of air into the conservator. The air cell material should not get
decomposed under the severe most operating conditions and should also not react
with oil / oil vapour. Necessary fittings (valves) with pressure gauge shall be
supplied for commissioning the air cell.

7.5 TRANSFORMER COOLING SYSTEM

7.5.1 GENERAL

a) The cooling of transformer shall be ONAN/ONAF/OFAF. The ONAN rating


shall be at least 60% of the OFAF rating and ONAF rating shall be at least 80 %
of the OFAF rating.

b) Total cooling system shall be so designed that the transformer be capable of


operating at full load for 10 minutes after failure of the oil circulating pumps
without injurious heating and calculated hot spot temperature not exceeding 150
Deg C.

c) The cooler units shall be so arranged such that the transformer tank, bus-ducts /
cabling chamber, etc do not fall in the direct path of hot air coming out of the
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unit coolers. Each cooler unit shall have its own cooling fan and pump, oil flow
indicator with shut-off valves, oil filtering valves at top and bottom, a drain
valve, air release plugs, etc. An oil flow indicator along with an electrical contact
for confirmation of each oil pump operating in a normal state will be included.

d) Cooler units shall be connected to the tank by machined steel flanged joints
provided with suitable quality gaskets for sealing purpose. The flanges shall be
welded to the both cooler units and the tank. At each cooler unit connection on
the tank an indicating shut off valve shall be provided which can be fastened in
either open or closed position. A separate oil tight blank flange shall be provided
for each tank connection for use when the cooler unit is detached. Each cooler
unit shall have a lifting eye, an oil drain at the bottom, and a vent at the top. The
vent and drain plugs of coolers should be provided with Teflon gaskets. Flexible
Expansion Joint, one each on top and bottom pipe connection for each radiator
bank shall be provided.
e) Radiators need to be properly and freely supported from the ground such that the
transformer can be taken out for maintenance without disturbing the radiators.
f) Each cooler unit shall be provided with the following:

i) A valve at each point of connection to the transformer tank.


ii) A valve in the main oil connection at the bottom of each cooler in addition
to those mounted on the transformer tank.
iii) Loose blanking plates to permit the blanking off of the main oil
connection to the top.
iv) A 50mm filter valve at the top of each cooler.
v) A 50mm-drain valve at lowest point of interconnecting oil pipes.
vi) A thermometer pocket fitted with captive screw cap, in the inlet and in the
outlet oil pipes.
vii) Flanged air release plugs.
viii) Lifting eye
ix) Flexible Expansion Joints

7.5.2 TRANSFORMER COOLER CONTROL


a) The cooler control shall be redundant with two independent power supplies.
Two 415V, 3 phases, 3-wire, 50 Hz. Power supplies will be provided by the
Purchaser for feeding to the auxiliaries of the transformer. The marshalling box
shall have provision to accept these power supplies and shall have provision of
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auto changeover. The cooler control shall be suitable for both remote and local
indication.
b) Control equipment for pump and fan motors shall be mounted in a marshalling
box to be installed adjacent to the transformer and shall include the necessary
connections with automatic control and annunciation equipment with provision
for auto / manual control for each group of fans and oil pumps.
c) 240V, 1 ph, AC supply shall be derived by the Bidder from the 415V supplies
provided by the Purchaser to facilitate 240V AC supply to lights and heaters in
marshalling box.
d) The auto-changeover scheme shall be designed based on under-voltage relay
logic, to take care voltage dips on 415V supplies.
e) The main and starter control circuit for each fan and pumps feeder shall be
provided with fuses at both ends so that in case of fault on any contactor coil
only that particular fan shall be cut out and other fans can remain in service.
Each feeder shall also be provided with double pole switches to enable isolation
of the corresponding contactor in case replacement of the same is necessitated.
f) A single metal-enclosed main isolating switch, with HRC fuses, shall be
provided for the cooling plant contactor group.
g) The contactors, starters and relays provided in the marshalling box shall be of
reputed make. Bidder shall furnish the list of sub-vendors for purchaser’s
approval.
h) The switching in or out of the cooling equipment shall be controlled by winding
and oil temperature and there shall be provision for automatic switching in or
out at predetermined temperature levels which should be capable of adjustment
and setting at will.
i) A local mechanical indication scheme for all annunciations shall be provided in
the marshalling box with mechanical target relays/contactors.
j) Anodised aluminium plate showing details of all terminal nos. shall be provided
along with marshalling box.

7.6 BUSHINGS

a) All bushings shall conform to the requirements of IS:2099 - 1973 for the
respective application voltage. Bushings of identical ratings shall be
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interchangeable. The high voltage bushings shall be of oil impregnated paper


(OIP) type condenser bushings and without arcing horns. LV bushings shall be
porcelain type and without arcing horns. All current carrying parts of the power
transformer shall be copper or copper alloy material and surfaces shall be plated
to inhibit deterioration. HV bushings shall be provided with terminal connectors
suitable for termination of ACSR conductor. Where current transformers are
specified, the bushings shall be removable without disturbing the current
transformer. Bushing rated for 400A and above shall have non-ferrous flanges
and hardware.

b) The neutral of the star-connected winding shall be brought out to a separate


bushing terminal. The neutral bushing shall be provided on the tank side and the
lead of the two (2) earthing conductors from the neutral bushing shall be
brought-down to the ground level for Purchaser’s grounding connection. Tank
mounted pin type support insulators shall be provided for supporting the neutral
earthing bar along its run from the neutral bushing to ground level.

c) The colour of the bushings shall be manufacturer’s standard. Bushings are


subject to tan delta test at site and shall meet the respective standard.

d) WTI CT shall be provided on the transformer as per the design requirement.

e) All CT secondary terminals shall be wired up to the transformer-marshalling box


and terminated in terminal blocks. The terminals shall be stud type and dropping
type CT shorting arrangement shall be provided. CT terminals shall be spring-
loaded type and shall short the CT terminals on removing the connection. Knee
point voltage, magnetising current and Rct for Class PS CTs shall be intimated to
the bidder during detailed engineering.

7.6.1 BUSDUCT INTERFACE

The LV bushings shall be cover mounted and have a flanged enclosure suitable for
connection to an isolated phase busduct. Ample space and access shall be provided
for the installation of the isolated phase bus duct. The busduct interface chamber will
be air filled and all current carrying parts in it will be properly insulated, supported
and braced. The low point of flanged enclosure will be provided with a screened
drain.
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7.7 ON LOAD TAP CHANGER

a) On Load Tap Changer shall be provided on the HV winding of the transformer.


The OLTC gear shall be designed to complete successfully tap changes at 150% of
rated current. Devices shall be incorporated to prevent tap change when the
through current is in excess of the safe current that the tap changer can handle.
The OLTC gear shall withstand through fault current without injury.

b) The OLTC’s tap changing gear shall comply with IEC: 60214, IS:8478 and CBIP
manual on transformer - 1987. The tap changer shall be mounted in a separate tank
or compartment in accessible position on the transformer tank. The operation of
the transformer at any of the taps shall not produce phase displacement. All the tap
changing switches shall be rated for full bi-directional power flow.

c) The OLTC gear shall have diverter resistance or reactance and current diverting
contacts. The contacts shall be accessible for inspection and their tips shall be
replaceable. OLTC oil chamber shall have oil filling, drain and sampling facility. It
shall be provided with oil level indicator and alarm contacts. On load oil filter
connection orifices, valves and silica gel breather shall be provided.

d) OLTC shall be provided with separate conservator and oil temperature indicator
with contacts and oil surge relay.

e) OLTC devise shall be such that the oil in the compartment containing making and
breaking contacts does not mix with oil in other compartment of OLTC or
transformer tank.

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

g) OLTC shall be provided with the following modes of operation.


- Local - manual
- Local - electrical
- Remote – electrical

h) Mechanical Control

The cranking device for operation of the OLTC gear shall be removable and
located at a height not exceeding 1500mm above ground level for easy operation.
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The mechanism shall be complete with normal accessories including at least the
following

- Tap position indicator


- Mechanical operation counter
- Mechanical stops to prevent over cranking the mechanism beyond extreme
tap positions
- Cut off of power supply when manual handle is inserted

i) Electrical Control

Control circuit shall incorporate the following:

- Local-electrical operation
- Remote-electrical operation from RTCC/DCS
- Device to ensure a positive and full completion of tap change once it is
Initiated even if the control supply or any relay fails
- Protective devices to put the transformer out of service in case of abnormal
Tap changer performance and to initiate an alarm.
- Each operation of either the raise or lower control switch shall cause one tap
Movement only. The control switch shall be returned to the off position for
each successive operation.
- All electrical control switches and local operation gear shall be clearly
labelled to indicate the direction of the tap changing.
- Provision shall be made to cut out electrical control to prevent OLTC
operation during over-loaded operation of the drive mechanism motor.

j) Local Tap Changing Cubicle:

A local tap changer cubicle shall be provided for housing motor drive mechanism
for on load tap changing at transformer. The tap changing cubicle shall be
fabricated with 2.5 mm CRCA sheet steel complete with all wiring, fuses, links,
cubicle illumination lamps, anti-condensation heater with thermostatic control
switch, gland plate, etc. The cubicle shall be suitable for outdoor installation. The
tap changer shall contain the following:

- Inside tag with control scheme indelibly marked.


- Motor drive mechanism
- Thermostatically controlled space heater
- Tap position indicator
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- MCB with magnetic and thermal overload devices for controlling incoming
supply to OLTC.
- Limiting devices
- Padlocking arrangement for hinged cabinet door
- Operation counter
- Cubicle lighting
- Oil Temp. Indicator
- Removable cable gland plate

k) The driving motor and electrical control of the motor drive mechanism shall be
designed to operate satisfactorily within the limits of 80% to 110% of the rated AC
voltage of 415V  10%, 3 phase, 50Hz  5%.

l) Remote Tap Changing Cubicle (RTCC)

The RTCC shall be indoor simplex type, free standing, totally enclosed, floor
mounting type with rear access door. The panel shall be fabricated from structural
steel framework enclosed on all sides and top by CRCA sheet steel of minimum
2.5mm thickness. The panel shall be complete with all wiring fuses, links,
illumination lamps with door switch, anti-condensation heater with thermostatic
control switch, gland plate, etc.

The RTCC shall comprise of the following.

- Local Remote selector switch individual/parallel selector switches.


- Raise /lower control switch
- Tap position indicator - Digital type
- Tap changer in local position lamp
- AC supply failure lamp and Bell
- Timer to control OLTC hunting
- Indicating lamp for tap changer in progress
- Alarm, accept, reset, lamp test push buttons

m) Indicating lamp for Tap position maximum reached, Tap position minimum reached
and Tap changer stuck to be provided in local panel and also contacts for remote
indication to be provided.

OLTC devise shall be suitable for remote electrical parallel control with Master-Follower scheme.
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n) Automatic and manual operation facility including hardware, AVR as required shall
be provided for the OLTC system.

o) Provision shall be kept for complete remote operation of OLTC.

p) Cut off of power supply when manual handle is inserted.

7.8 CONTROL CABINET AND WIRING

a) A sheet steel, weather proof, vermin and dust proof marshalling box suitable for
out door application shall be furnished with each transformer to accommodate :

i) Temperature indicators.
ii) Transducers for WTI/OTI
iii) Terminal blocks for incoming and outgoing cables.
iv) Interposing Relays / Amplifiers for the Proximity switches

b) The sheet steel used shall be at least 2.5 mm thick. The box shall be free standing
floor-mounted type and having a sloping roof canopy. The degree of protection
shall be IP 55 for outdoor application

c) The temperature indicators shall be so mounted that the dials are not more than
1600 mm from ground level. The marshalling box door shall have a glazed
window of suitable size for convenience of temperature indicators reading.

d) The marshalling box shall contain all control circuits, auxiliary relays, terminal
boards, etc., as required to provide a single interface location

e) Following signals will be hooked up to the purchaser’s relay panel located at


Central Control Room. The transformer marshalling box shall have necessary
dedicated potential-free contacts and 4-20mA signals for hooking up with
Purchaser’s panels:

Equipment Signal
Generator Buchholz relay alarm
transformer control Buchholz relay trip
cabinet Winding temperature alarm
(Marshalling box) Winding temperature trip
Oil temperature alarm
Oil temperature trip
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Equipment Signal
Oil level low alarm
Pressure relief device trip
4-20mA signal from WTI/OTI
Oil flow indicator for each cooler bank
Cooler bank failure
Cooler bank in service
AC control supply failure
DC control supply failure

f) Wiring from the current transformers and other control and alarm equipment
shall be carried out in conduits or alternatively in concealed trays and terminated
in the marshalling box.

g) All incoming cables shall enter the marshalling box from the bottom. The cable
glands shall be of brass and double compression type. A removable undrilled
gland plate shall be provided at the bottom of the box for accommodating glands
for Purchaser’s incoming and outgoing cables, which shall not be less than 450
mm from finished floor level. The gland plate shall be minimum 3.0 mm thick
and shall be made into detachable halves, for facilitating the termination of
incoming and outgoing cables separately. The gland plate and the associated
compartment shall be sealed in a suitable manner to prevent the ingress of
moisture, rodents, insect etc.

h) Terminal blocks shall be furnished in the marshalling box. All terminal blocks
shall be of disconnecting type. Terminal blocks for short circuiting the current
transformer shall be provided separate from the terminal blocks accommodating
the control and indicating circuits. The direct and alternating current terminals
shall be isolated from each other.

i) All tapping of CTs shall be brought to terminals in the marshalling box and 10%
spare links shall be provided. The terminals for the current transformer leads
shall be suitable for accommodating 6 sq.mm. cable leads while the terminals for
the control and other circuits shall be suitable for accommodation 2.5 sq.mm.
cable leads. Atleast 20% spare terminals for control wiring shall be provided.

j) CT terminal blocks shall be provided with test links and isolation facilities.
Neutral CT terminals shall be brought out to the terminal box for the connection.
Terminal blocks for 415 V power cables shall be suitably sized to terminate the
required size of cable.
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k) Suitably rated switches shall be provided to enable the control supply to the
transformer to be cut off from the marshalling box.

l) Enough space shall be provided at the bottom of the operating marshalling box to
mount the Purchaser's control cables glands. The number and size of the cable
glands shall be intimated later. All terminal blocks for control shall be rated for
minimum 10 Amps.

m) Complete control cabling between the transformer and the marshalling box shall
be in the scope of the Bidder and it shall be supplied loose along with the
marshalling box.

n) All wiring in the housing shall be stranded copper and the insulation shall be
1100V grade PVC and shall be of reputed make. Size of wires shall be not less
than 4 sq.mm. for CT leads and not less than 2.5 sq mm for other connections.
CT circuit wiring shall be done using colour coded wires for better identification.

o) Not more than two (2) wires shall be connected to one terminal.

p) Wire and cable bunching saddles PVC channels shall be provided on all terminal
blocks on either side. The wire terminals shall be engraved or otherwise indelibly
marked ferrules and the wires shall be colour coded. All control wires shall have
cross ferruling at both ends for identification.

q) All devices and terminal blocks inside the marshalling box shall be clearly
identified by symbols corresponding to those used on applicable schematic or
wiring diagram. The terminal block shall be stud type. All terminal blocks should
have terminal nos. on either side of terminals.

r) All major equipment, devices, panels, and cubicles shall be provided with
stainless steel nameplates fastened with self-tapping screws. Nameplates shall be
provided on doors of cooler control cabinet, CT junction box and thermo
junction box. They shall be located so that a person standing on the ground can
read them without visual aids. Each current transformer shall be provided with a
diagrammatic type nameplate located near the CT terminal blocks. Self-adhesive
labels shall not be used.

s) Stud type fuse mounts shall be provided with an insulating cover as protection
against accidental contact with live terminals.
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t) Drawing pouch with cooler control scheme drawings covered in the polythene
paper shall be provided inside marshalling box on the door.

u) All alarm and control devices shall be ungrounded.

v) The marshalling box shall be supplied with space heater, cubicle lighting
(Compact fluorescent lamp) and 240 V receptacle with ON-OFF switches and
associated fuses. It shall be located in such a way that the same shall not face
towards the transformer. Heaters shall be provided with suitable protective cover
to avoid accidental contact with the element (i.e. wire mesh enclosure with
asbestos sheet cover at the front).

w) Bidder shall furnish a list of the relays, control switches, timers, etc. indicating
the make, type, auxiliary supply requirements, contact rating etc. along with the
quotation.

8.0 INSPECTION AND TESTING

a) Bidder shall furnish his standard Quality Assurance Plan along with the bids.
Inspection and testing shall be as per approved QAP. Transformer oil (both test
purpose as well as fresh oil) shall be as per relevant IS.

b) The bidder shall use his own transformer oil for testing purpose and the fresh oil
shall be supplied to site. In case of transformer are supplied oil filled than fresh
oil shall be filled in presence of Purchaser. The insulating oil shall conform to
the latest revision of IS-335.

c) The necessary topping up oil shall be supplied for the Transformer in non-
returnable container. 10% excess oil shall also be provided, in non-returnable
containers suitable for outdoor storing for one GTG Transformer.

d) As a minimum, the following tests shall be carried out:

i. Type tests

Following type tests and special tests (excluding short circuit test) as per IS
2026 shall be conducted on one transformer of each rating.
 Temperature rise test.
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 Measurement of zero sequence impedance.


 Measurement of acoustic noise level.

 Measurement of the harmonics of the no-load current.

 Measurement of the power taken by the fans and oil pumps

ii. Additional Type Tests

Additionally, the following tests shall be conducted as type tests on one


transformer of each rating.

 Impulse on all three legs of HV and LV windings including chopped wave


tests.

 Heat run test with dissolved gas analysis before and after.

 Vacuum withstand and deflection measurement on tank.

 Pressure test on tank with deflection measurement.

 Determination of cooler losses.

 Partial discharge test.

 Radio interference voltage with 400 kV bushing.

iii. Routine Tests

The following routine tests as per IS : 2026 shall be conducted on each of the
transformer.

 Measurement of winding resistance.

 Measurement of voltage ratio and checking of voltage vector relationship .

 Measurement of impedance voltage/ short circuit impedance (principal


tapping) and load loss.

 Measurement of no-load loss and current.


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 Measurement of insulation resistance.

 Dielectric tests.

 Tests on OLTC as per IS: 2026.

 Operation test after the tap changer is fully assembled on the transformer.

 Auxiliary circuits insulation test – after the tap changer is assembled on the
transformer, a power frequency test shall be conducted on the auxiliary
circuits.

iv. Additional Routine Tests

The following additional routine tests on each of the transformer shall be conducted.

 No load loss and excitation current at 415V from LV side and at 90% and
110% rated voltage.

 Oil leakage test – 12 hours.

 Magnetic balance test

 Measurement of tan delta and capacitance of each winding.

 Measurement of zero sequence impedance.

All Tests as mentioned above and any other tests as required by the relevant codes and
standards and as deemed necessary is to be conducted by the bidder.
Bidder shall furnish his proposed QAP along with his bid for Purchaser’s review.

9.0 DRAWINGS / DATA / DOCUMENTS TO BE SUBMITTED BY BIDDER


ALONGWITH THE BID

a) As a minimum, the bidder shall furnish the following relevant drawings,


documents and catalogues of the transformers offered in requisite sets failing
which the bids shall be rejected.
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i) Typical general arrangement drawing of the transformer showing disposition


of radiator banks, marshalling boxes, HV & LV terminal arrangements and
overall dimensions.

ii) Overall dimensional physical layout drawing of the transformer.

iii) Equipment weight

iv) Foundation plan and mounting information with loading and transformer
anchoring details.

v) Total tank and cooling equipment oil volume

vi) Shipping weight and dimensions

vii) Transformer cooling arrangement along with Control scheme for cooler
control unit.

viii) Compensating CT / Bushing CT wiring diagram

ix) Quality assurance plan

x) Type test reports of identical transformers

xi) Catalogues for transformer and fittings & accessories (preferably in


electronic form)

xii) Experience certificates of supply of identical types of transformers.

xiii) Curve for Maximum Continuous Output vs. Ambient Temperature (13 oC to
50 oC)

xiv) Performance curves for auxiliary consumption (cooler consumption) with


respect to ambient temperature and MVA loading.

xv) Performance curves for total losses vs. ambient temperature and MVA
loading at 0.85 pf.

xvi) GA drawing of the transformer indicating the scope of supplies and


dimensions.
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xvii) Terminal arrangement LV and HV side including termination arrangement


for Isolated Phase Bus Duct / segregated phase bus duct including flange
details.

xviii) List of sub-vendors for purchaser’s approval.

xix) Confirmed transformer technical particulars data sheet

9.1 DRAWINGS / DATA / DOCUMENTS TO BE SUBMITTED BY


SUCCESSFUL BIDDER FOR APPROVAL AFTER AWARD OF CONTRACT

Following drawings / documents are required to be submitted after placement of LOI


for Purchaser and Owner’s approval and distribution in requisite sets as stated in
General Conditions of Contract:

Sl. Drawings / Documents


No.
1 GA drawing showing weight centres of gravity both empty and full of oil,
physical dimensions, plan and elevation views, disposition of cooler
banks, HV & LV terminal arrangements, marshalling boxes and various
fittings.
Foundation plan with loading and transformer anchoring details
2 Transformer Cooling arrangement along with control scheme for cooler
control unit.
3 Bushing CT wiring diagram
4 Type Test reports of identical transformers
5 Catalogues for transformers accessories (preferably in electronic form)
6 Curve for Maximum Continuous Output v/s Ambient Temperature (13
Deg C to 50 Deg C)
7 Performance curves for auxiliary consumption (cooler consumption) with
respect to ambient temperature and MVA loading.
8 Confirmed performance curves for total losses V/s Ambient temperature
and MVA loading at 0.85 pf.
9 Terminal arrangement LV and HV side including termination
arrangement for isolated phase bus duct including flange details
10 Confirmed transformer technical particulars data sheet
11 Rating and terminal diagram plate drawing
12 Dimension drawings of HV & LV terminations
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Sl. Drawings / Documents


No.
13 Drawings of major components like bushings, CTs, radiator banks,
Buchholz relay etc.
14 Drawings of HV bushings, LV bushings and Neutral bushings
15 Marshalling box connection diagram and layout of instruments
16 Control schematics and wiring diagrams for cooler control panel along with
Write-up on Controls and Interlocks provided
17 Valve location plate for the oil forced cooling circuit indicating clearly all
the details required for each components used for the purpose
18 Electronic copy of all the final drawings submitted, in a floppy disc / CD
19 Operation and Maintenance Manual
20 Erection and commissioning manual
23 Start-up and shutdown procedure
24 Instruction for pre-commissioning check up, operation, abnormal
conditions, maintenance, repair and protection
26 Recommended inspection points and period of inspection
27 Schedule of preventive maintenance
28 Replaceable parts list with ordering information
29 Recommendation for type of lubricants, lubrication points, frequency of
lubrication and lubrication changing schedule

In addition, the supplier shall supply comprehensive part list, spares & tools list,
supplemented by all drawings and catalogues of transformer and its fittings &
accessories.

10.0 TRANSPORTATION AND HANDLING OF MATERIAL AND EQUIPMENT

The major components shall be delivered to site as a single piece and minor
components removed for shipping. Where this is not possible, individual modules
shall be delivered as to require only a minimum amount of site assembly. In the last
case the Bidder shall include with his proposal detail of how unit will be broken
down and estimates of the man-hours and equipment required at site. Project
information shall be legibly punched on the components.

Normally transformers will be delivered without oil, filled with inert gas and without
bushings and externally mounted accessories as applicable.
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Care shall be taken during handling of insulation oil to prevent ingress of moisture or
foreign matter. In the testing, circulating, filtering or otherwise handling of oil, rubber
hoses shall not be used. Circulation and filtering of oil, heating of oil by regulated short
circuit current during drying runs and sampling and testing of oil shall be in accordance
with the Manufacturer’s instructions and Code of Practice as per IS 10028

(i) Packing

Bidder shall adequately prepare all the equipment for shipment. Where required by
the nature of the equipment, Bidder shall furnish and install necessary covers to
protect the equipment from rain, hail, wind, dust, etc. Equipment shall be adequately
sealed and protected during shipment to prevent corrosion, entrance of foreign
matter, and possible damage from rough handling during transit. Any articles or
materials that might otherwise be lost in shipping shall be boxed or wired in bundles.

Suitable weather protection (like PVC sheets) shall be provided to prevent wetting of
components during transportation and outdoor storage at site.

(ii) Protective Coatings and Preservatives

Preservative coatings used on components shall be suitable for the conditions


normally expected during transportation, storage and throughout the erection period.

Each type of preservative used shall be identified as to quality, life expectancy and
type. Toxic and hazardous - type preservatives will not be allowed. Complete
information shall be submitted to the Purchaser (L&T)/Consultant covering step - by
- step procedures, including Indian governing laws for handling and removal of each
type of preservative. This information shall be submitted one (1) month prior to
delivery.

(iii) Marking

All loose components shall be identified with company material code, part no.,
weight and name for easy site identification. Bill of loading / shipping list shall be
provided prior to equipment dispatch. Each truck / separately despatched items shall
have a packing list giving details of the items supplied incloding number of
containers.
A comprehensive list of all items shipped shall also be submitted before despatch to
purchaser. A shipping list should be sent along with each consignment with the
despatch documents.
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10.1 Transportation

a) All equipment shall be adequately prepared for transportation and for a


maximum period of outdoor storage of six months. At time of shipment,
transformer shall be clean and properly protected against transit damages.

b) The equipment shall be prepared for transportation after testing has been
completed. Lifting points shall be clearly marked and all openings shall be
tightly and effectively closed. Covers, screwed openings closed with steel
plugs, shall protect flanges and weld ends shall have plastic covers.

c) Before the equipment is shipped, the original shipping stops, bolts, ties, etc.,
shall be reinstalled in all devices.

d) Electrical and control panels shall be protected against corrosion, weather, and
mechanical damage during transit. Temporary structural bracing shall be
installed as required to allow for normal field handling, skidding, and hoisting.

e) In addition to the foregoing, the Supplier shall provide internal and external
protection from the effects of corrosion for all parts not otherwise coated or
painted. Where closure is incomplete, plastic material adequately supported,
protected, and sealed shall be used to fabricate an effective barrier.

f) Equipment that is liquid leak tested in the shop by the Supplier shall be
completely drained prior to shipment. When such drainage requires the removal
of plugs, drain valves, or other parts, supplier shall reinsert or reassemble these
parts prior to shipment. The supplier shall despatch the transformer nitrogen
filled with Automatic gas filling device & pressure monitoring device.
Necessary arrangement shall be ensured by the supplier to take care of pressure
drop of nitrogen during transit and storage till completion of oil filling during
erection. A gas pressure-testing valve with necessary pressure gauge and
adopter valve shall be provided.

g) The Bidder shall furnish all instructions for proper care and handling after
delivery, including outdoor storage procedures, before the equipment is shipped
to the job site.
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11.0 FITTINGS AND ACCESSORIES


Each transformer shall be equipped with fittings and accessories as listed below. The
accessories that are necessary for successful operation but not listed below shall also
be included in the scope of supply.
1. Oil conservator for the oil tank with filler cap, drain valve, magnetic oil gauge
and plain oil level gauge, conservator for oil tank with filler cap, drain valve;
magnetic oil gauge and plain oil level gauge (rubber bellows filled with air and
installed within the conservator).
2. Air release plugs for radiator banks and main tank.
3. Pressure relief devices as required - spring loaded with alarm & trip contacts
4. Double float Buchholz relay (with testing facility) with gas release cock, shut-off
valve on both sides and separate set of contacts for alarm and trip. The Buchholz
relay shall be provided with rain hood (canopy) to prevent ingress of rainwater in
its terminal box. The gas collection box and gas release cock shall be brought
down to around 1.2 m from ground level by providing copper tubing of suitable
diameter.
5. Neutral bushing for earthing with post insulator mounted on tank.
6. Bushing CTs.
7. Dial type winding temperature indicator with maximum reading pointer and four
sets of electrically separate contacts for alarm and trip.
8. Dial type oil temperature indicator with maximum reading pointer and two sets of
electrically separate contacts for alarm and trip.
9. Transducers for remote signalling of WTI/OTI (4-20mA output)
10. For oil tank conservator diaphragm type oil preservation and Silica gel breather
with oil seal.
11. Valves:
i) Drain valve with plug & pad locking arrangement
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ii) Sampling valves at top and bottom of main tank


iii) Radiator isolation valves
iv) Filter valve with threaded adopter at the top and bottom.
12. Weatherproof marshalling box for housing control equipment and terminal
connection.
13. Off circuit, hand-operated tap changer mechanism with proximity switches and
associated accessories for each tap position.
14. Cooling accessories: Requisite no. of radiators, cooling fans oil pump and oil
flow indicator with alarm contacts, shut-off valves, oil filtering valves at top and
bottom, drain valve, air release plugs etc.
15. Rating and terminal marking plate
16. Jacking pads (minimum 4 nos.), haulage & lifting lugs and lifting eyebolts.
17. Foundation bolts and nuts.
18. Inspection covers for various items e.g. bushings, current transformers, windings,
earth connections etc.
19. Rollers - Flanged bi-directional type with locking and bolting device.
20. Two (2) grounding pads each for main tank in opposite sides, transformer
marshalling box, cooler banks, etc.
21. Ladder for accessing the top of the transformer with a lockable hinged plate at the
bottom about 1.5 m from ground.
22. Danger board written in Hindi, Telugu & English.
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SECTION-II

TECHNICAL DATASHEET

Ratings and requirements for GTG and STG Transformer

Sr. Item GTG transformer STG transformer


No

1. MVA Rating
a) With OFAF cooling 275 170
b) With ONAF cooling 220 136

c) With ONAN cooling 165 102

2. GTG Transformer OFAF


At 15 Deg C By Bidder
At 29 Deg C By Bidder
At 43 Deg C By Bidder
3. Qty. Two (2) Two (2)
4. Applicable Standards IS 2026 IS 2026
5. Frequency 50 Hz 50 Hz
6. Voltage Ratio 15.75/420 kV 15.75/420 kV
7. System earthing
(I) HV side Solidly earthed Solidly earthed
(ii) LV side Non-effectively earthed Non-effectively earthed
8. System fault level
(i ) HV side 40 kA (rms) / 1 sec 40 kA (rms) / 1 sec
9. (ii) LV side Later Later

10. Normal operating voltage (+) 10 % to (-) 10 % (+) 10 % to (-) 10 %


range on 400 kV side
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Sr. Item GTG transformer STG transformer


No

11. Rated Current


a) HV Windings (A) By bidder By bidder
b) LV Windings (A) By bidder By bidder
12. Service / Duty/ Type/Oil Outdoor / continuous / bi- Outdoor / continuous /
directional/ Mineral Oil bi-directional/ Mineral
Oil
13. Type of cooling ONAN/ONAF/OFAF ONAN/ONAF/OFAF
14. No. of cooler banks x 2 x 100 % 2 x 100 %
capacity
15. Each Cooling Unit is
provided with
a) Make of Motor By bidder By bidder
b) No x kW rating of By bidder By bidder
Fan Motor
c) No x kW rating of By bidder By bidder
Oil Pump
d) d) Automatic Yes Yes
operation of
Cooling Fan /
Pumps provided
(Yes / No)

16. Winding connection


(i) HV Side Star Star
(ii) LV Side Delta Delta
17. Vector Group YNd1 YNd1
18. Termination
(i) HV side Aluminium ACSR Aluminium ACSR

(ii) LV side Isolated phase busduct Isolated phase busduct


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Sr. Item GTG transformer STG transformer


No

(iii) HV Neutral Two (2) nos. tinned copper Two (2) nos. tinned
flats shall be provided upto copper flats shall be
the base of main tank provided up to the base
supported on pin of main tank supported
insulators. on pin insulators.
19. Type of Insulation of Cellulose Based /Class A Cellulose Based /Class A
winding
20. Tap changer
(i) Type On Load Tap Changer On Load Tap Changer
(ii) Voltage range +7.5% to -15% in steps of +7.5% to -15% in steps
1.25% of 1.25%
21. Category of voltage CFVV CFVV
variation
22. Guaranteed positive 12.5% 12.5%

sequence Impedance at 75
Deg C with 100% loading
a) principal tap
b) Maximum Tap By Bidder By Bidder
c) Minimum Tap By Bidder By Bidder
23. Zero Sequence Impedance By Bidder By Bidder
at 75 Deg C
24. X/R ratio of Generator By Bidder By Bidder
Transformer
25. Winding Resistance

a) HV Winding By Bidder By Bidder


b) LV Winding By Bidder By Bidder
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Sr. Item GTG transformer STG transformer


No

26. Maximum Flux Density at


any part of Core / Yoke at
rated MVA and 10% over
voltage condition Wb/m2
26. No Load HV Current as By bidder By Bidder
%age of FLC
At 90% rated voltage By Bidder By Bidder
At 100% rated voltage By Bidder By Bidder
At 110% rated voltage By Bidder By Bidder
27. Maximum temperature rise 50C 50C
of top oil at 100% of full
load (measured by
thermometer)
28. Maximum temperature rise 55C 55C
of winding at 100% of full
load for 24 hours
(measured as per IS-2026)
29. Winding hot spot By Bidder By Bidder
temperature
30. Rated power frequency
withstand voltage for
bushing
( i ) HV side 630 kV (rms) 630 kV (rms)
( ii ) LV side 50 kV (rms) 50 kV (rms)
(iii) HV Neutral 38 kV (rms) 38 kV (rms)
31. Rated lightning withstand
voltage for bushing (1.2 /
50 microsecond) Impulse
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Sr. Item GTG transformer STG transformer


No

( i ) HV side 1425 kV (Peak) 1425 kV (Peak)


( ii ) LV side 125 kV (Peak) 125 kV (Peak)
(iii) LV Neutral 95 kV (rms) 95 kV (rms)
32. Rated power frequency
withstand voltage for
winding
( i ) HV side 630 kV (rms) 630 kV (rms)
( ii ) LV side 50 kV (rms) 50 kV (rms)
(iii) HV Neutral 38 kV (Peak) 38 kV (Peak)
33. Rated lightning withstand
voltage for winding
( i ) HV side 1425 kV (Peak) 1425 kV (Peak)
( ii ) LV side 125 kV (Peak) 125 kV (Peak)
(iii) LV Neutral 95 kV (rms) 95 kV (rms)
34. Over fluxing withstand time

a) For over fluxing factor 1.10 Continuous Continuous

b) Over fluxing factor 1.25 60 s 60 s

c) For over fluxing factor 1.40 5s 5s

35. Minimum creepage 20 mm / kV for HV and 20 mm / kV for HV and


distance LV bushings LV bushings
36. Minimum clearances in air
Phase to Phase to Phase to Phase to
phase (mm) earth (mm) phase earth (mm)
(mm)
(i) HV Side / HV (n) 4000 3500/320 4000 3500/320
(ii) LV Side As per CBIP/IS
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Sr. Item GTG transformer STG transformer


No

37. Short circuit withstand time


without injury due to
terminal fault with rated
voltage maintained on the
other side.
(i) With 3 phase dead short 3 sec 3 sec
circuit
(ii) With single phase short 3 sec 3 sec
circuit
38. Noise level Average sound level Average sound level
value 85db at the distance value 85db at the
of 1.0 meter distance of 1.0 meter

39. Finishing paint type Epoxy paint Epoxy paint


40. Paint shade RAL 7032
41. a) Rated voltage of HV LV Neutral
Bushings (kV)
420 24 36
b) Manufacturer By Bidder By Bidder
c) Bushing Type HV - OIP Condenser HV - OIP Condenser
LV - Porcelain, Oil filled LV - Porcelain, Oil filled
HVN - Porcelain, Oil HVN - Porcelain, Oil
communicating communicating
Reference standard IS: 2099 IS: 2099

42. HV Neutral Bushing CT 5P20 5P20


a) Core-1 : For Restricted
earth fault protection
(64GT)
b) HV Neutral Bushing CT 5P20 5P20
Core-2 : Standby earth fault
protection (51NGT)
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Sr. Item GTG transformer STG transformer


No

43. HV bushing CT

a) Core-1: Restricted earth Class PS, Class PS


fault protection (64GT)
b) Core-2: For other
transformer protections

44. LV side CT for Differential Class PS Class PS


protection (87)
45. Guaranteed losses at rated
voltage and frequency on
principal tap at full load at 75
deg.C
Copper Losses (kW) By Bidder By Bidder

Iron Losses (kW) By Bidder By Bidder

Cooler Losses (kW) By Bidder By Bidder

Sub-Total (kW max) By Bidder By Bidder

46. Efficiency at 75 deg.C and 0.8 By Bidder By Bidder


p.f. Lag
a) At 100% load By Bidder By Bidder

b) At 75% load By Bidder By Bidder

c) Maximum efficiency By Bidder By Bidder

d) Load and p.f. at which it By Bidder By Bidder


occurs
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Sr. Item GTG transformer STG transformer


No

47. Voltage regulation at full load,


at 75 deg. C
a) At 0.90 p.f. Lag By Bidder By Bidder

b) At 0.85 p.f. Lag By Bidder By Bidder

48. a) No load current at rated By Bidder By Bidder


voltage and rated frequency
(A)
b) Magnetizing inrush current By Bidder By Bidder
as percentage of full load
current (A)
49. Transformer oil preservation
system
a) Main conservator Conservator with aircell and Conservator with aircell
silica gel breather and silica gel breather
b) Oil drain valve

Type By Bidder By Bidder

Size By Bidder By Bidder

c) Size of oil sampling valve By Bidder By Bidder

d) Size of gas sampling valve By Bidder By Bidder

e) Total volume of conservator By Bidder By Bidder

50. Gas Detection Device


(Buchholz)
a) Manufacturer By Bidder By Bidder
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Sr. Item GTG transformer STG transformer


No
b) Type By Bidder By Bidder

51. Fault Pressure Device

a) Manufacturer By Bidder By Bidder

b) Type By Bidder By Bidder

c) Numbers provided By Bidder By Bidder

d) Operating pressure By Bidder By Bidder

52. Winding

a) Type of winding By Bidder By Bidder

b) Current density at rated By Bidder By Bidder


load for HV winding
c) Current density at rated load By Bidder By Bidder
for LV winding

53. Winding Temperature


Indicator
a) Manufacturer By Bidder By Bidder
b) Model Number By Bidder By Bidder
c) Accuracy By Bidder By Bidder
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Sr. Item GTG transformer STG transformer


No

54. Oil Temperature Indicator

a) Manufacturer By Bidder By Bidder


b) Model Number By Bidder By Bidder
c) Accuracy By Bidder By Bidder

55. Approximate weights: With


oil filled up to transport level
a) Core and windings By Bidder By Bidder

b) Tank and fittings By Bidder By Bidder

c) Oil By Bidder By Bidder

d) Total weight By Bidder By Bidder

56. Transformer core details

a) Net core area By Bidder By Bidder


b) Core material and grade By Bidder By Bidder
used
c) Thickness of stamping By Bidder By Bidder
57. Approximate weights: Without
oil and filled with nitrogen gas
a) Core and windings By Bidder By Bidder
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Sr. Item GTG transformer STG transformer


No
b) Tank and fittings By Bidder By Bidder

c) Total weight (with nitrogen By Bidder By Bidder


filled)
58. Shipping Data

a) Weight of the heaviest By Bidder By Bidder


package
b) Dimension of the largest By Bidder By Bidder
package (LxBxH)

59. Curve showing variation of Yes Yes


Transformer MVA output vs.
ambient temperature
superimposed on GT curve
furnished (Yes/No)
Type test certificates furnished Yes Yes
(Yes/No)
GA drawing furnished Yes Yes
(Yes/No)
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SECTION-III

TECHNICAL DATASHEET FOR COOLING PUMP/FAN MOTORS

Sl. Description Units Particulars


No.
1. a) Degree of protection (service IP55
outdoor)
2. Method of Cooling TEFC
3. Method of starting DOL
4. Duty Cycle
5. Supply Voltage 415 V AC
6. Phase 3Ph
7. Frequency 50 Hz
8. Class of insulation Class F
9. Temperature rise Class B
10. % Voltage variation & % Frequency +/-10% & +/-5%
variation
11. Combined voltage and Frequency 10% (abs)
variation
12. System earthing Effectively earthed
13. Starting current at rated voltage <600%
including IS tolerance
14. Fault withstand capacity of terminal 50 kA for 0.25 Sec
box
15. Number of Grounding pads By bidder
i) Motor body
ii) Terminal boxes
16. Paint type and shade RAL 7032