Transformer - Technical Specification 10 To 1600KVA
Transformer - Technical Specification 10 To 1600KVA
CIN – U40102GJ2003SGC042906
Distribution Transformer
CONTENTS
1. Code and Standards
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2. System Description
3. Design Criteria
4. Specific Requirement
5. Tank
8. Oil
9. Drying Out
14. Losses
17. Tests
20. Inspection
22. Deviations
23. Schedules
1.0 SCOPE:
This specification covers, engineering, manufacture, assembly, stage testing, and
inspection and testing before supply and delivery at site of oil immersed,
naturally cooled 3 phase 11/0.433 -0.250 KV Distribution Transformers for
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outdoor use.
1.1 It is not the intent to specify completely herein all the details of the design and
construction of equipment. However the equipment shall conform in all
respects to high standards of engineering, design and workmanship and shall be
capable of performing in continuous commercial operation upto the Bidder’s
guarantee, in a manner acceptable to the purchaser, who will interpret the
meanings of drawings and specification and shall have the power to
reject/accept any work or material which, in his judgment is there or not in
accordance therewith. The offered equipment shall be complete with all
components necessary for their effective and trouble free operation. Such,
components shall be deemed to be within the scope of Bidder’s supply
irrespective of whether those are specifically brought out in this specification
and / or the commercial order or not.
1.2 Standard Ratings:
The Standard Ratings shall be 10 KVA, 25 KVA, 63 KVA, 100 KVA, 160 KVA, 200
KVA, 250 KVA, 315 KVA, 400 KVA, 500 KVA, 630 KVA, 750 KVA, 1000KVA,
1250KVA, 1600 KVA etc.
1.3 System Description :
The distribution transformers shall be installed at outdoor/indoor locations
along 11 kV distribution networks, which consist of both underground and
overhead networks. The HV winding shall be connected with HT
SFU/OCB/VCB/SF6 CB of the ring main unit through 11kV (E) XLPE/PILC cable or
with DO fuse through bare conductor. LV winding shall be connected to switch
type fuse section pillar through 1.1 kV I core 300 mm2 or suitable size Aluminum
conductor Cable.
2.0 STANDARDS:
2.1 The materials shall conform in all respects to the relevant Indian / International
Standard Specification, with latest amendments thereof, some of them are
listed below:
Indian Standard Title International &
Internationally recognized
standard
ISS -2026/1977 Specification for Power Transformer. IEC 76
ISS – 1180 Outdoor distribution Transformer up to
and including 100 KVA.
IS 12444 Specification for Copper wire rod ASTM B-49
ISS -3347/1967 Specification for porcelain Transformer DIN 42531,23,3
bushing.
ISS-335/1983 Specification for Transformer Oil. BS 148, D-1473, D-1533-
1934
Signature of Tenderer Company’s Round Seal Date Place
Technical specification for 10 KVA to 1600 KVA L-1, L-2 and L-3 rating Transformer Page 3 of 48
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301-500 56
501-750 57
751-1000 58
1001-1500 60
1501-2000 61
12. Permissible temperature rise over ambient
i. Of top oil measured by thermometer 35 Deg. C
ii. Of winding measured by resistance 40 Deg. C.
13. Minimum clearances in air of bushing
terminals with connectors fitted.
A. HV phase to phase/ phase to earth 255/205 Mm
B. LV phase to phase/ phase to earth 75/55 Mm
C. LV Phase to Neutral/ Neutral to Earth 75/55 Mm
5.1. CORE :
a. CRGO :
i Transformer core shall be stacked core type shell type or with wound core
construction using new and high quality CRGO core with heat resistant insulating
coating. The core shall be of NEW/Fresh high grade cold rolled grain oriented
annealed lamination core having low loss and good grain properties, coated with
hot oil proof insulation, bolted together and to the frames firmly to prevent
vibration or noise. The complete design of core must ensure permanency of the
core losses with continuous working of the transformers. The value of the
maximum flux density allowed in the design and grade of lamination used shall be
clearly stated in the offer.
ii Core Clamping :
1. MS channel shall be used on top and bottom
2. Core Channel on LV side to be reinforced at equidistance, if holes / cutting is done
for LT lead in order to avoid bending of channel.
3. MS Channels shall be painted with Hot oil-resistant paint.
4. The transformers core shall be suitable for over fluxing (due to combined effect of
voltage and frequency) up to 12.5% without injurious heating at full load
conditions and shall not get saturated. The Bidder shall furnish necessary design
data in support of this situation.
5. The nominal flux density in any part of the core shall not exceed 1.69 Tesla at
100% rated voltage and 1.9 Tesla at 110% of rated voltage. The vendor shall
furnish necessary design data in support of this stipulation.
6. No load current shall not exceed 3% of full load current and will be measured by
Signature of Tenderer Company’s Round Seal Date Place
Technical specification for 10 KVA to 1600 KVA L-1, L-2 and L-3 rating Transformer Page 6 of 48
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iv No load current shall not exceed 2% of full load current and will be measured by
energizing the transformer at rated voltage and frequency on the secondary.
Increase of voltage by 12.5% shall not increase the no load current by Max. 5% of
full load current. Test for magnetic balance by connecting the LV phase by phase
to rated phase voltage and measurement of an, bn, cn voltage will be carried out.
5.2 WINDINGS:
a. Materials: Double paper covered aluminum/Copper conductor or class H enamel
cover aluminum/Copper conductor shall be used for 11 KV class Transformers. A
mix of copper & aluminum conductors for HV & LV winding will not be permitted.
b. Current density(Maximum):
Copper conductor : Shall not be more than 2.3 A/sq.mm.
Aluminum Conductor: Shall not be more than 1.50 A/sq.mm.
(However, +5% tolerances for LV winding are permissible).
Note: LV winding shall be in form of even layers so that the neutral formation
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will be at top.
c. Internal Insulations and Clearances :
1. Insulating material: Electrical grade insulating craft paper of
Triveni/Ballarpur/Cauvery or equivalent make subject to approval of the
purchaser shall be used. Similarly Press Board of Senapathy, Whitelay or Raman
make or equivalent subject to the approval of the purchaser shall be used.
Perma wood or Haldi wood blocks shall be used for top and bottom yoke
insulation.
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5.2.1 Taps
a. No tapping shall be provided for transformers up to 100 KVA rating.
b. For ratings above 100 kVA and up to 1600 KVA, tapings shall be provided on the
higher voltage winding for variation of HV voltage within range of (+) 5.0 % to (-)
7.5% in steps of 2.5%. (However, in case of township, developer may select
tapings as per their requirement)
c. Tap changing shall be carried out by means of an externally operated self
Position rotary switch (to be mounted on top plate) and when the transformer is
in de-energized condition. Switch position No.1 shall correspond to the maximum
plus tapping. Each tap change shall result in variation of 2.5% in voltage. Provision
shall be made for locking the taping switch handle in position. Suitable aluminum
anodized plate shall be fixed for tap changing switch to know the position number
of tap.
5.2.2 OIL :
The insulating oil shall comply with the requirements of relevant standards IS 335
/ 1993 or BS 148 or REC 39/1993. Oil shall be filled under vacuum of 250 Tor +/- 5
%.
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Note: -
1. It is mandatory that transformers having rating 16 KVA to 200 KVA shall be L-2 as
per the BEE/IEC Guideline. Bidder has to submit BEE/IEC certificate with their offer
for respective star rating. Offer without BEE certificate will be out rightly rejected
without any correspondence.
Evaluation criteria:
1. The tender bids will be evaluated on the basis of TOC (Total owning Cost)
combined for CRGO & Amorphous Core Transformer.
2. Bidder can offer CRGO or Amorphous core material but they have to specify
clearly in their offer and price bid must be submitted for respective core
separately.
3. Bidder can also offer both CRGO as well as Amorphous core for same rating, but
they have to separately submit GTP for both core material Transformers and
they have to submit on line price bid separately for both core material. Bidder has
to clearly mention offer quantity with core material in ANNEXURE-4
4. Price evaluation will be calculated (i.e. L1, L2, L3, ___) on base of TOC (Total
owning Cost) and ranking will be given on the base of T.O.C. only.
5. Negotiation/Price matching will be carried out on the base of TOC Only.
6. Permissible band of minimum loss level of Distribution Transformer is as under.
*Total Load loss in watts at 100 % loading should not be lower than(Not equal to)
below mentioned losses.
Rating of Transformer in L-1 losses in Watts L-2 losses in Watts L-3 losses in Watts
KVA
16 480 440 400
25 695 635 595
63 1250 1140 1050
100 1800 1650 1500
160 2200 1950 1700
200 2700 2300 2100
Bids of parties offering losses less than lowest limit of loss band, difference in offered
losses and lowest limit of loss band shall be added to no load losses while calculating TOC
and accordingly offer will be evaluated.
5.3. Percentage Impedance:
1
Rating of Transformer in KVA Percentage Impedance.
10 KVA 3.75 %
16 to 100 KVA 4.5 %
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iii. iii. All joints of tank and fittings shall be oil tight and no bulging should occur
during service. The tank design shall be such that the core and windings can be
lifted freely. The tank plate shall be of such strength that the complete
transformers when filled with oil may be lifted bodily by means of lifting lugs.
Inside of tank shall be painted with Hot oil resistive paint.
iv. iv. Manufacturer should carry out all welding operations as per the relevant
ASME standards and submit a copy of the welding procedure qualifications and
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v. v. The four walls of the tank shall be made of Two “L” shaped sheets (without
joints) fully welded at the corners from inside and outside of the tank for
withstanding a pressure of 0.8 kg/cm2 for 10 minutes.
OR
One “U” shaped bend sheet with straight plate and welded outside the tank at 2
corners for withstanding pressure of 0.8 Kg/cm2 for 10 minutes.
vi. The tank shall be reinforced by welded angle on all the outside walls on the edge
of the tank to form two equal compartments. Permanent deflection when the
tank without oil is subject to a vacuum of 525 mm of mercury for rectangular
tank and 760 mm of mercury for round tank, shall not be more than 5 mm upto
750 mm length and 6 mm upto 1250 mm length. The tank shall further be
capable of withstanding a pressure of 0.8 kg/sq.cm (g) and a vacuum of 0.3
kg/sq.cm (g) without any deformation.
vii. The radiators can be tube type or fin type or pressed steel type to achieve the
desired cooling to limit the specified temperature rise. The transformer shall be
capable of giving continuous rated output without exceeding the specified
temperature rise. Bidder shall submit the calculation sheet. Detachable
radiators with shut off valves above 500 KVA as required shall be provided. All
removable covers shall be provided with weatherproof, hot oil resistant,
resilient gaskets. The design shall be such as to prevent any leakage of water
into or oil from the tank.
viii. Lifting lugs: 2 Nos.of lifting lugs are to be provided in Transformers below 100
KVA rating and 4 Nos. lifting lugs are to be provided in Transformers for 100 KVA
and above rating transformers. Lifting lugs of MS plate 8 mm thick (min) suitably
reinforced by vertical supporting flat welded edgewise below the lug on the side
wall.
ix. Pulling lugs: 4 Nos. of welded heavy duty pulling lugs of MS plate 8 mm thick
(min) shall be provided to pull the transformer horizontally.
x. Top cover fixing bolts of G.I adequately spaced and 6 mm Neoprene bonded
cork gaskets conforming to IS 4253 part-II shall be placed between tank and
cover.
xi. The bolts outside tank shall have 2 flat washers & one spring washer.
5.6.b For Corrugated Tank
i) The transformer tank shall be of robust construction corrugated in shape and
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manufacturer’s recommendation.
5.7.7.3 Particular attention must be paid to full film thickness at edges.
5.7.7.4 The requirements for the dry film thickness (DFT) of paint and the materials to
be used shall be as given below.
Sr. No Paint Type Area to be No. of Total Dry film
painted coats thickness (min.)
1. Thermo setting paint. inside 01 20 microns
outside 01 60 microns
2. Liquid paint
a) Zinc chromate outside 01 30 microns
(primer)
b) Synthetic Enamel / outside 02 25 microns each
Poly Urethene
(Finish coat) inside 01 35 / 10 microns
c) Hot oil paint / Varnish
5.7.8. Tests
5.7.8.1 The painted surface shall be tested for paint thickness.
5.7.8.2 The painted surface shall pass the Cross Hatch Adhesion test, Salt spray test and
Hardness test as per the relevant ASTM standards.
NOTE: Supplier shall guarantee the painting performance requirement for a
period of not less than 5 years.
5.8. BUSHINGS AND TERMINALS :
5.8.1.A Transformer with bare bushing outdoor mounting: For 11 KV
Transformers - 12 KV class bushings shall be used and further for LV side, viz
250/433 volts, 1.1KV terminal bushing shall be used. Bushing of the same
voltage class shall be interchangeable bushing with plain shed as per IS 3347.
Bushings shall be mounted on top plate only.
OR
HT bushing should be kept in such a way that minimum air clearances should be
maintained by tilting the same.
The HV bushings shall have to be installed on top plate on turret, flange and
gaskets to prevent eventual entry of water. The turret height for HV bushing
should be minimum 25 to 30mm. In LV side bushing ,turret of minimum 10 mm
should be provided.
Radiator shall be provided on both sides on HV and LV sides. Bushings of
following or other makes having type tested as per IS 2099 and approved by the
UGVCL shall only be used & are acceptable.
The cross section of the connecting rods on LV side shall be stated and shall be
adequate for carrying the rated currents. On the HV side the terminal rod shall
have a diameter of not less than 12 mm of brass up to 200 KVA and above shall
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be of Copper
5.8.1.B Transformer with cable termination box or PSS mounting: The
transformer shall be fitted with suitable end termination boxes on 11 kV side to
terminate one 11 kV/ 3 core Aluminum conductor XLPE/PILC cable up to 300
mm2 size as per drawing. The HT cable box shall be prevented from ingress of
moisture into the box due to rainwater directly falling on the box. The H.T.
cable box shall be of split type with plain faces and machined and fitted with
suitable gasket and complete with brass wiping gland to be mounted on
separate split type gland plate with nut bolt arrangement and M.S earthing
clamp. The bushings of the cable box shall be fitted with nuts and stem to take
the cable cores without bending them. The stem shall be of copper with copper
nuts. The cross section of the connecting rods shall be stated and shall be
adequate for carrying the rated currents. On the HV side the terminal rod shall
have a diameter of not less than 12 mm of brass up to 200 KVA and above shall
be of Copper. The material of connecting shall be copper H.T Cable support
clamp should be provided to avoid tension due to cable weight. Required
diameter of hole for cable entry shall be provided at side as per requirement.
Required size of glands shall be supplied as stated by the purchaser.
The transformer shall be fitted with suitable LV cable end box having non-
magnetic metal material gland plate with appropriate size single compression
brass glands as per the attached drawing on LV side to terminate 1.1 kV/ 1 core
XLPE armored cable as mentioned herein below. Required diameter of holes for
cable entry shall be done at site as per requirement or as stated by the
purchaser before dispatch.
Terminal:
Primary: 12 kV Epoxy bushings as per IS: 2099 or Porcelain Bushings as per IS:
3347 as required by the purchaser for heavily polluted atmosphere having
suitable diameter with nuts and check nuts for pad and platform mounted
transformer as per drawing.
Secondary: Terminals shall be provided with 1.1 kV Epoxy bushings as per
IS:3347 for heavily polluted atmosphere having fixed palm type connectors with
suitable locking arrangement to restrict the rotation of palm assembly. Palm
shall be of copper and stud of copper duly brazed at the joint.
Suitable clamps with nuts and bolts for 1 core 300 mm2 XLPE/PVC cables as per
details given for different size of transformers. Detachable clamps with nuts
and bolts for ease of removing LV cables shall be provided with Epoxy bushings
Clamp arrangement with copper terminal assembly.
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l. Radiators: No. & length may be mentioned (as per heat dissipation
calculations)
m. Arcing horns for HV bushings .
n. Prismatic Oil level guage indicating the position of oil marked
(with background of yellow colour ) as follows.
Min. ( -5 deg.C), 30 deg. C, Max. 90 deg.C
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are suitable for the expected temperature rise over and above the
ambient temperature 55˚C under various loading conditions. The supplier
shall furnish all the type and routine test certificate of the circuit breakers in
accordance with IS : 13947 pt. 2.
5.13 FASTENERS:
All bolts, studs, screw threads, pipe threads, bolt heads and nuts shall comply
with the appropriate Indian Standards for metric threads, or the technical
equivalent.
Bolts or studs shall not be less than 6 mm in diameter except when used for
small wiring terminals.
All nuts and pins shall be adequately locked.
Wherever possible bolts shall be fitted in such a manner that in the event of
failure of locking resulting in the nuts working loose and falling off, the bolt will
remain in position.
All ferrous bolts, nuts and washers placed in outdoor positions shall be treated
to prevent corrosion, by hot dip galvanizing, except high tensile steel bolts and
spring washers which shall be electro-galvanized/ plated. Appropriate
precautions shall be taken to prevent electrolytic action between dissimilar
metals.
Each bolt or stud shall project at least one thread but not more than three
threads through the nut, except when otherwise approved for terminal board
studs or relay stems. If bolts nuts are placed so that they are inaccessible by
means of ordinary spanners, special spanners shall be provided.
The length of the screwed portion of the bolts shall be such that no screw
thread may form part of a shear plane between members.
Taper washers shall be provided where necessary.
Protective washers of suitable material shall be provided front and back or the
securing screws.
5.14. MOUNTING ARRANGEMENT:
The under base of all transformers shall be provided as per cl. No. 5.9 with two
nos of base channels having length minimum 460 mm with minimum 150 mm
extended on both sides of tank with holes to make them suitable for fixing on
a platform or plinth.
The transformers shall be suitable for loading as per IS: 6600 / 1972with latest
amendment if any.
5.15 The Inspection and Testing :
5.15.1 Proto type :
5.15.1 Drawings:
a
The manufacturer has to submit the following details and drawings along with
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ensure losses as per GTP, Transformer found with higher losses than GTP will
not be accepted and cost thereof will be recovered. The new Transformers
supplied in this circumstances must as per GTP submitted with tender and
shall match the losses offered by the supplier as per Tender.
The testing of each G.P .failed transformers will be carried out for all
acceptance test as per the relevant standard where no load losses and load
losses are also required t be maintained identical as per GTP attached
4. The supplier situated outside Gujarat State shall have to establish suitable
and adequate arrangement for repairing and testing of failed transformer in
Gujarat State at his cost. This arrangement shall have to be continued up to
the completion date of guarantee period of supply of last lot.
6.0 TESTS:
a. All the equipment offered shall be fully type tested by the bidder or his
collaborator as per the relevant standards including the additional type tests
mentioned at clause 6.2. The type test must have been conducted on a
transformer of same design. The Bidder shall furnish four sets of type test
reports along with the offer. All the required Type test reports for the
tendered items should invariably furnish a Notarized Copy. Offers without
type test reports will be treated as Non-responsive.
All the necessary Type tests will have to be carried out in NABL accredited
laboratory of INDIA before submission of the tender and to be submitted
along with the Technical bid. The type tests which are more than 05(five)
years old will not be considered and such tender will be rejected. All the
required type tests should not be older than 5(five) years from the due date
of tender.
b. Special tests other than type and routine tests, as agreed between purchaser
and Bidder shall also be carried out as per the relevant standards.
c. The requirements of site tests are also given in this clause.
d. The test certificates for all routine and type tests for the transformers and
also for the bushings and transformer oil shall be submitted with the bid.
The successful bidder may submit the type test report of Temperature Rise
Test within commencement period only on receipt of LOI. If successful bidder
fails to submit the Temperature rise Test report within commencement
period only on receipt of LOI. UGVCL / Purchaser / order placement authority
/ LOI placement authority may initiate penal action against such successful
bidder.
6.1 ROUTINE TESTS:
Following tests shall have to be carried out by manufacturers at their works
before offering proto/lot acceptance tests and record of the same shall be
maintained and produced at the time of acceptance tests for inspector’s
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verification.
1. Ratio, polarity and phase sequence.
2.No Load current and losses at service voltage and formal
frequency
3. Load losses at rated current and normal frequency
4. Impedance Voltage test
Resistance of windings at each tap, cold (at or near the test bed temp.)
6. Insulation resistance
7. Induced over voltage withstand test.
8. Separate source voltage withstand test.
9. Neutral current measurement
10. Oil samples (one sample per lot) to comply with IS 1866.
11. Measurement of no load losses and magnetizing current at rated frequency
and 100% and 112.5% voltage.
12. CT parameter as per relevant IS ( if provided )
6.2 TYPE TESTS TO BE CONDUCTED ON ONE UNIT:
In addition to the Tests mentioned in para 6.1 following Tests shall be
conducted.
1. Temperature rise test for determining the maximum temperature rise after
continuous full load run.
The ambient temperature and time of test should be stated in the test
certificate.
2. Impulse voltage test: As per Clause No. 13 (With chopped wave) of IS - 2026
part-III Latest version. BIL for 11 kV shall be 95 kV Peak instead of 75 kV
3. Air Pressure Test: As per C1.22.5 of IS - 1180 / part-I/1989
4. Short Circuit withstand test: Thermal and dynamic ability.
5. Magnetic Balance Test
a. Noise-level measurement
b. Measurement of zero-phase sequence impedance.
c. Measurement of Harmonics of no-load current
d. Pressure relief device test ( if provided)
e. Transformer tank shall be subjected to specified vacuum. The tank
designed for vacuum shall be tested at an internal pressure of 0.35 kg. Per
sq. cm. absolute (250 mm of Hg) for one hour. The permanent deflection of
flat plates after the vacuum has been released shall not exceed the values
specified below:
Horizontal length of flat plate (in mm) Permanent deflection (in mm)
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f. Transformer tank together with its radiator and other fittings shall be
subjected to pressure corresponding to twice the normal pressure or 0.35 kg
/ sq.cm. whichever is lower, measured at the base of the tank and
maintained for an hour. The permanent deflection of the flat plates after the
excess pressure has been released, shall not exceed the figures for vacuum
test.
g. The pressure relief device shall be subject to increasing fluid pressure. It
shall operate before reaching the test pressure as specified in the above
class. The operating pressure shall be recorded. The device shall seal-off
after the excess pressure has been released.
Type test certificates for the tests carried out on prototype of same
specifications shall be submitted along with the bid.
The purchaser may select the transformer for type tests randomly.
6.3. TESTS AT SITE:
The purchaser reserves the right to conduct all tests on Transformer after
arrival at site and the manufacturer shall guarantee test certificate figures
under actual service conditions.
In order to ensure quality the acceptance test shall be carried out even after
installation of transformer within grantee period. If acceptance test
standards are not met during such field test, 5% penalty may be imposed on
all transformers supplied as per that proto type design.
6.4. ACCEPTANCE TESTS :
The transformers shall be subjected to the following routine/ acceptance test in
presence of purchaser’s representative at the place of manufacture before
dispatch without any extra charges. The testing shall be carried out in
accordance with IS: 1180 and IS:2026.
1. Checking of weights, dimensions, fitting and accessories, tank sheet
thickness, oil quality, material, finish and workmanship as per GTP / QA Plan
and contract drawings.
2. Physical verification of core coil assembly and measurement of flux density of
one unit of each rating, in every inspection with reference to short circuit
test report
3. All tests as specified here under.
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6.5 TOLERANCES:
Unless otherwise specified herein the test value of the transformers supplied
would be within the tolerance permitted in the relevant standards. No positive
tolerance is allowed on guaranteed No Load and Load losses.
7.0. INSPECTION:
All tests and inspection shall be made at the place of manufacturer and unless
other wise especially agreed upon the manufacturer and the purchaser at the
time of purchase to satisfy him that the material is being furnished in
accordance with specification.
The manufacturer shall afford the inspector representing the purchaser all
reasonable facilities, like local logistics, conveyance and well comfortable
accommodations.
Along with the bid the manufacturer shall prepare Quality Assurance Plan
identifying the various stages of manufacture, quality checks performed at each
stage and the Customer hold points. The document shall also furnish details of
method of checking, inspection and acceptance standards / values and get the
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ii. Type test certificates of the raw materials and bought out accessories.
8.3 The successful Bidder shall submit the routine test certificates of bought out
accessories and central excise passes for raw material at the time of routine
testing.
9.0. DOCUMENTATION:
The Bidder shall furnish along with the bid the dimensional drawings of the
items offered indicating all the fittings.
ii) Dimensional tolerances
ii) Wight of individual components and total weight
10.0 PACKING & FORWARDING:
10.1 The packing shall be done as per the manufacturer’s standard practice.
However, it should be ensured that the packing is such that, the
material would not get damaged during transit by Rail / Road / Sea.
10.2 The making on each package shall be as per the relevant IS.
11.0 MANADATORY SPARES:
Mandatory spares shall be supplied as per the purchaser’s requirement.
The other manufacturer can also request challenge testing for any test based
on specification and losses. The challenger would request for testing with
testing fee. The challenge test fees are proposed at least three time the cost of
testing .This is likely to deter un necessary challenges. The challenger would
have the opportunity to select the sample from the store and any such
challenge should be made within the guaranty period. The party challenged,
challenger and the utility could witness the challenged testing.
The challenged testing would cover the 1) Measurement of magnetizing
current. 2) No load losses test. 3) Load losses test (at 50% loading or as per
acceptance test). 4) Temperature rise test.
The challenge test could be conducted at NABL accredited laboratory, like ERDA
and CPRI. If the values are within limit the product gets confirmed else not
confirmed. No positive tolerance in losses be permitted. If the product is not
confirmed the manufacturer would pay the challenge fee and challenger would
get the fee refunded. However as a redressal system the challenger would be
allowed to ask for fresh testing of two more samples from the store and the
same be tested in NABL laboratory in presence of party challenged, challenger
and the utility. If any one or both sample does not confirm the test then the
product is said to have failed the test. In such cases the manufacturer will be
declared as un successful manufacturer for the said product with wide publicity
and would not be allowed to compete in tenders of the Board for the period of
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discretion), all Testing fees, expenses of the inspector & other expenses
incurred by the company will be to successful tenderer’s account. For
acceptance as above, the decision of the company shall be final & will be
binding to successful tenderer.
The test results will be binding on the suppliers. Company in general will not
allow re-sampling. If the material fails in any of the acceptance tests carried
out (except for no load and load losses), the materials supplied till date will be
considered as rejected and if replacement is not possible due to consumption
of the materials Company will deduct penalty @ 1% of the end cost prices of all
transformers supplied till date of receipt of failure report. If the same are not
utilized / consumed, Company at sole discretion may ask for replacement or
may accept the material with penalty as above. For failure in No Load and or
Load Losses, transformers supplied till date of receipt of failure report shall be
rejected or penalty @ Rs.395.00 per watt for No Load Losses and penalty @
Rs.79.00 per watt for Load Losses for the transformers supplied till date of
receipt of failure report shall be charged. The decision of the Company will be
binding on the successful tenderer.
In the event of transformer failing during any of the type tests (temperature
rise test is part of type test), following recovery shall be made.
Recovery, equivalent to 1% of end cost of particular rating transformers
supplied against the order till receipt of test reports.
Further in case, any transformer taken for type testing, fails either in
short circuit test or impulse test or temp. rise test, or other type tests (if
decided by the Company), supplier will be allowed for modification in
their design and other technical parameters. In that case, supplier will
have to obtain prior approval from UGVCL for such proposed changes /
modifications desired to be effected, by submitting revised drawings and
other technical details, clearly indicating the changes proposed to be
made, compared to previous design.
In case, if transformers shall fail in testing and same are rejected or accepted
with penalty, Company shall pick up another transformer for Acceptance Tests
/ Type Tests (as the case may be) of same rating from replaced and or
subsequently supplied lots for testing to have verification of the quality of
other transformers supplied.
In case of any dispute for testing, the Company’s decision will be final
and binding to the supplier. If supplier will not agree to accept the
Company’s decision, the order for balance quantity will be cancelled
without any clarification and material will be purchased by the Company
at risk and cost of the supplier.
CIN – U40102GJ2003SGC042906
SCHEDULE - A
ANNEXURE-I
CIN – U40102GJ2003SGC042906
6. a) Flux density
CIN – U40102GJ2003SGC042906
2) 100% load
3) 75% load
4) 50% load
5) 25% load
16. Regulation at
a) Unity P.F.
b) 0.8 P.F. at 75 deg.C.
17. % Impedance at 75 deg.C.
18. Flash Test
HV 28 kV / 50 HZ for 1 minute
LV 3 kV/50 Hz for 1 minute
19. Over potential Test Double Voltage &
Double frequency for 1 minute
20. Impulse test value in KVP
21. . Weight content of
a) Core lamination (min)
b) Windings (min) Aluminum./Copper
c) Tank & Fittings
d) Oil
e) Oil qty (min)
f) Total Weight
22. Oil Data
1. Qty for first filling (min)
2. Grade of oil used
3. Maker’s name
4. BDV at the time of filling
23. Transformer:
1) Overall length x breadth x height
2) Tank length x breadth x height
3) Thickness of plates for
a) Side plate (min)
b) Top & Bottom plate (min)
4) Conservator Dimensions
24. Radiation:
1) Heat dissipation by tank walls exclusive top & bottom
2) Heat dissipation by cooling tube
3) Dia & thickness of cooling tube
4) Whether calculation sheet for selecting cooling area to ensure that the
transformer is capable of giving continuous rated output without exceeding
temperature rise is enclosed.
CIN – U40102GJ2003SGC042906
CIN – U40102GJ2003SGC042906
SCHEDULE -A
ANNEXURE-II
ADDITIONAL DETAILS
Sr.No. Description
1. Core Grade
2. Core diameter mm
3. Gross Core area cm
4. Net Core area cm
5. Flux density Tesla
6. Wt. of Core kg.
7. Loss per kg. of Core at the specified Flux density
8. Core window height Watts
9. Center to center distance of the core mm
10. No. of L.V. Turns mm
11. No. of H V turns
12. Size of LV Conductor bare/ covered mm
13. Size of HV conductor bare/covered mm
14. No. of parallels
15. Current density of LV winding amps/sq.mm.
16. Current density of HV winding amps/sq.mm
17. Wt. of the LV winding for Transformer kg.
18. Wt. of the HV winding for Transformer kg.
19. No. of LV Coils/phase
20. No. of HV coils / phase
21. Height of LV Windings mm
22. Height of HV winding mm
23. ID/OD of LV winding mm
24. ID/OD of HV winding mm
25. Size of the duct in LV winding mm
26. Size of the duct in HV winding mm
27. Size of the duct between HV & LV mm
28. HV winding to LV winding clearance mm
29. HV winding to tank clearance mm
30. Calculated impedance %
31. HV to earth creep age distance mm
32. LV to earth creep age distance mm
CIN – U40102GJ2003SGC042906
ANNEXURE-III
1. Laminations
2. Copper Conductor/ Aluminum Conductor
3. Insulated winding wires
4. Oil
5. Press Boards
6. Kraft Paper
7. MS Plates / Angles / Channels
8. Gaskets
9. Bushing HV / LV
10. Paints
CIN – U40102GJ2003SGC042906
SCHEDULE-B
-----------------------------------------------------------------------------------------------------------
SR.NO. CLAUSE NO. DETAILS OF DEVIATION
-----------------------------------------------------------------------------------------------------------
NAME OF FIRM-----------------------------------------------
DESIGNATION -----------------------------------------------
DATE -----------------------------------------------------------
CIN – U40102GJ2003SGC042906
SCHEDULE - C
Sr. No Name of Client & Value of order Period of Name & address to
Description along with supply and whom reference
capacity of commissionin may be made
transformer g
1 2 3 4 5
DATE ___________________________________
SCHEDULE - D
CIN – U40102GJ2003SGC042906
-------------------------------------------------------------------------------------------------------
Sr. Particulars Stipulation of Stipulation of Remarks
No. specified stan- standard adopted
dards by tenderers
-------------------- -----------------------
Standard Stipul- Standard Stipula-
Ref. ations Ref. tions
-------------------------------------------------------------------------------------------------------
DESIGNATION __________________________________
DATE :-
CIN – U40102GJ2003SGC042906
SCHEDULE – E
-----------------------------------------------------------------------------------------------------------
Sr. Name of Test Standard Requirement Proposed Reason for
No. No. and of standards deviation deviation
clause no.
----------------------------------------------------------------------------------------------------------
1. TYPE TEST
2. ADDITIONAL TEST
3. ACCEPTANCE TEST
4. ROUTINE TEST
DESIGNATION ___________________________________
DATE __________________________________________
CIN – U40102GJ2003SGC042906
This document indicates the requirement expected by the Purchaser from the
manufacturer of Transformers. Manufacturer shall submit for purchaser’s approval a
quality assurance plan in line with this document incorporating specific document numbers
for “format of records”, “acceptance norms” and “ reference documents” for purchaser’s
approval.
Quality assurance plan is the document setting out the specific quality practices, resources,
and sequence of activities relevant to a particular product. Quality plan helps both the
purchaser and supplier as it defines each and every material used, every stage of
manufacturing process, characteristics to be checked, extent of check, reference
documents, acceptance norm and format of record specifically.
Abbreviations:
PS - Plant Standard / Process Specification
TR - Test Report
IS - Indian/ International Standard
CS - Customer Specification
AD - Approved Document such as Drawing, Purchase Order
V - Verified by
P - Performed by
W - Witnessed by
H - Hold by Purchaser
1 - Purchaser
2 - Manufacturer
3 - External laboratory
4 - Sub Vendor QC
Notes:
1. Minor: The characteristics of a component, process or operation
whose failure neither materially reduce the usability of the product in operation, nor does
it affect the aesthetic aspects.
CIN – U40102GJ2003SGC042906
If 100% “Witness” of tests is carried out by Prime supplier, Customer will witness on
sample basis or if 100% “Witness” of tests is carried out by Sub Vendor, Manufacturer will
witness on sample basis.