Transformers (Level-1 & 2)
Transformers (Level-1 & 2)
Transformers (Level-1 & 2)
PGVCL/RJT/Proc/CPP/10KVA
PGVCL/RJT/Proc/CPP/10KVA Level-1
Level DTR/717
1.0 SCOPE:
As per the Electrical Transformer (Quality Control) Order, 2014, it is
mandatory that No Electrical Transformers shall be manufacture or store for
sale, sell or distribute which do not confirm to the specified standard and do
not bear standard Mark of the bureau, on obtaining certification mark
license. Accordingly,
Accordingly, the bidder shall have valid BIS license of the quoted
item or higher as per approved scheme of BIS.
This specification covers, engineering, manufacture, assembly, stage testing,
and inspection and testing before supply and delivery at site of mineral oil-
oi
immersed,
sed, natural air-cooled,
air outdoor type, double-wound
wound 3 phase
11/0.433 -0.250
0.250 KV Distribution Transformers for outdoor use in power
distribution systems with nominal system voltagesof following types and
ratings:
• Three Phase ratings lower than 63 KVA both non-sealed
non sealed type and sealed
type. (REF: IS 1180 PART-1
PART 2014, 3.2&3.3).
• Three phase ratings higher than and including63 KVA,non-sealed
KVA,non type.
(REF: IS 1180 PART-1
PART 2014, 3.2&16).
• Single phase ratings 5 KVA sealed type.
typ
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
performing in continuous commercial operation up to
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
whether those are specifically brought out in this
specification and / or the commercial order or not.
1.2 The transformer and accessories shall be designed to facilitate operation,
inspection, maintenance and repairs. The design shall incorporate every
precaution n and provision for the safety of equipment as well as staff
engaged in operation
operatio and maintenance of equipment.
1.3 All outdoor apparatus, including bushing insulators with their mountings,
shall be designed so as to avoid any accumulation of water.
Signature of Tenderer Company’s Round Seal Date Place
Page 1 of 45
TENDER No. PGVCL/RJT/Proc/CPP/10KVA Level-1 DTR/717
1.4 STANDARD RATINGS:
The Standard Ratings shall be 5 KVA, 10 KVA,16KVA, 25 KVA, 63 KVA, 100
KVA, 200 KVA and 500 KVA.
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 – 1180 / Part-I/ Outdoor/Indoor type Oil immersed
2014&Amendmentno.1 distribution Transformer upto and including
August 2016 to IS : 2500 kVA, 33KV Specifications Mineral Oil
1180-Part-1/2014 Immersed
5484 Specifications for Aluminum wire rods ASTM B-233
649 Testing of Steel sheet and strips for magnetic
circuits
191: 2007 Copper
335 : 1993 New insulating oils BS 148, D-1473,
D-1533- 1934
IEC Pub 296-
1969
554 : 1999 Pipe threads where pressure-tight joints are
made on the threads — Dimensions,
tolerances and designation
1576 : 1992 Solid pressboard for electrical purpose IEC 641
1608 : 2005 Mechanical testing of metals — Tensile
testing
1747 : 1972 Nitrogen
1885 (Part 38) :1993 Electro technical vocabulary: Part 38 Power
transformers and reactors
1897 : 2008 Copper strip for electrical purpose
2026 Power transformers : IEC 76
(Part 1) : 2011 General
(Part 2) : 2010 Temperature rise
(Part 3) : 2009 Insulation levels, dielectric tests and external
clearances in air
(Part 5) : 2011 Ability to withstand short circuit
(Part 8) : 2009 Application guide
(Part 10) : 2009 Determination of sound levels
2099 : 1986 Bushings for alternative voltages above
1000 volts
6. Line current LV 20.0 A 13.3 A 21.33 A 33.33 A 84.0 A 133.0 A 266.0 A 665.0 A
7. Frequency 50 c/s +/- 50 c/s +/- 50 c/s +/- 50 c/s +/- 50 c/s +/- 50 c/s +/- 50 c/s +/- 50 c/s +/-
5% 5% 5% 5% 5% 5% 5% 5%
8. No. of Phases Single Three Three Three Three Three Three Three
10. Connection LV Individual Star Star Star Star Star Star Star
(Neutral (Neutral (Neutral (Neutral (Neutral (Neutral (Neutral
brought brought brought brought brought brought brought
out) out) out) out) out) out) out)
11. Vector group -- Dyn-11 Dyn-11 Dyn-11 Dyn-11 Dyn-11 Dyn-11 Dyn-11
12. Type of cooling ONAN ONAN ONAN ONAN ONAN ONAN ONAN ONAN
B. AMORPHOUS :
i. The core shall be high quality Amorphous ribbons having very low loss
formed into wound cores of rectangular shape, bolted together to the
frames firmly to prevent vibration or noise. The complete design of core
must ensure permanency of the core loss with continuous working of the
transformers. The value of the flux density allowed in the design shall be
clearly stated in the offer. Curve showing the properties of the metal shall
be attached with the offer.
5.2.1 TAPS:
5.2.2 OIL :
The insulating oil shall comply with the requirements of IS 335. Use of recycled
oil is not acceptable. The specific resistance of the oil shall not be less than 35
X1012 ohm-cm at 27⁰C when tested as per IS 6103.
Oil shall be filtered and tested for break down voltage (BDV) and moisture
content before filling.
The oil shall be filled under vacuum of 250 Tor +/- 5 %.
The design and all materials and processes used in the manufacture of the
transformer, shall be such as to reduce to a minimum the risk of the
development of acidity in the oil.
*Total Losses in watt at 100 % loading = No Load losses in watt + Full Load
losses in watt at 75 Deg. C
NOTE: -
It is mandatory that transformers having rating 5 to 500 KVA shall be of Level-
1/Level-2as per the Electrical Transformer (Quality Control) Order-2014 of
Ministry of Heavy Industries and Public Enterprises.
The bidder having BIS certificate with higher Energy Efficiency Level and
capacity shall also cover transformer with lower Energy Efficiency Level and
capacity as specified in the IS within the group
Bidder has to submit copy of certification marks license with their offer for
respective rating and as per tender requirement of Energy Efficiency level.
Details of Factor A& Factor B for different rating distribution transformers are
as under.
Signature of Tenderer Company’s Round Seal Date Place
Page 13 of 45
TENDER No. PGVCL/RJT/Proc/CPP/10KVA Level-1 DTR/717
A. EVALUATION CRITERIA
1. The tender price bids will be evaluated on the basis of TOC (Total owning
Cost) for CRGO/ Amorphous Core Transformer.
2. Bidder can offer CRGO/ 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 materials
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 basis of TOC only.
5. 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.
Bids not meeting the above limits of temperature rise will be treated as non-
responsive.
5.6 PENALTY FOR NON PERFORMANCE:
A. During testing, if it is found that the actual measured losses are more than
the values quoted by the bidder, the purchaser will have right to exercise
one of the following options
Reject the complete lot OR Penalty shall be recovered from the bidder for
the excess losses per watt as under
a. No load loss @ twice the value of Factor A in Rs.
b. Load loss @ twice the value of Factor B in Rs.
C. 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.
5.7 TANK :
Transformer tank construction shall conform in all respect to clause 15 of IS
1180(Part-1):2014.The transformer tank can be with radiator fins/ rounded
or elliptical cooling tubes or made of corrugated panels.
A. FOR RECTANGULAR PLAIN TANK:
i. The transformer tank shall be of robust construction rectangular in shape
and shall be built up of tested MS sheets.
The tank shall be made of prime quality MS sheet of thickness stated below
with necessary stiffener to withstand the pressure built in during the
expansion of oil due to temperature rise.
The exterior of the transformer tank and other ferrous fitting shall be
thoroughly cleaned , scraped /sand blasted and given a priming coat and
two finishing coats of durable oil and weather resistant paint of dark
admiral grey conforming to color code No. 632 of IS-5/1961.
The internal clearance of tank shall be such that, it shall facilitate easy lifting
of core with coils from the tank without dismantling LV bushings.
ii. 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.
iii. Manufacturer should carry out all welding operations as per the relevant
ASME standards and submit a copy of the welding procedure qualifications
and welder performance qualification certificates to the customer.
The Bidder may offer Elliptical tanks for 10 &16 KVA transformers, robust in
construction with adequate strength to withstand the pressure built in
during the expansion of oil due to temperature rise. The tank sheet shall be
electrically welded to impart proper mechanical strength and to plug
leakage of oil. All joints of tank and fittings shall be oil tight and no bulging
shall occur during service. The tank sheets shall be of such strength that the
complete transformer when filled with oil may be lifted by means of lifting
lugs provided. All the welding shall be continuous.
The elliptical tank constructed by two welding joints only, one is at bottom
cover and another is at the tank shell so that the leakages due to joints can
be reduced. The tank shall withstand a pressure of 80 kPa for 30 minutes and
vacuum of 250 mm of mercury for 30 Min and the permanent deflection
after pressure/ vacuum has been released, shall not exceed 5 mm.
E. PAINTING PROCEDURE:
i. All painting shall be carried out in conformity with both Specification and
with the paint manufacturer’s recommendation. All paints in any one
particular system, whether shop or site applied, shall originate from one
paint manufacturer.
ii. Particular attention shall be paid to the manufacturer’s instructions on
storage, mixing, thinning and pot life. The paint shall only be applied in the
manner detailed by the manufacturer e.g. brush, roller, conventional or
airless spray and shall be applied under the manufacturer’s recommended
condition.
F. DAMAGED PAINTWORK:
i. Any damage occurring to painting of any part shall be made good to the
same standard of corrosion protection and appearance as that originally
employed, within guarantee/ warrantee period at free of cost.
ii. Any damaged paint work shall be made good as follows:
a) The damaged area, together with an area extending 25 mm around its
boundary, shall be cleaned down to bare metal.
b) A priming coat shall be immediately applied, followed by a full paint
finish equal to that originally applied and extending 50 mm around the
perimeter of the original damage.
c) The repainted surface shall present a smooth surface. This shall be
obtained by carefully chamfering the paint edges before and after
priming.
G. TESTSFOR PAINTED SURFACE:
i. The painted surface shall be tested for paint thickness.
ii. The painted surface shall pass the cross hatch adhesion test and impact test
as acceptance tests and Salt spray test and Hardness test as type test as per
the relevant ASTM standards.
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
Dimensions of the bushings of the voltage class shall conform to the Standards
specified and dimension of clamping arrangement shall be as per IS 4257.
Bushing can be of porcelain material.
The cross section of the connecting rods on LV side shall be as per IS 3347
Part1/Sec 2 1979and 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 as per IS 3347 Part3/Sec 2 1982and above200 KVA shall be of
Copper.
Note : For 5 KVA Single Phase & 10 KVA, 16 KVA and 25 KVA, Three Phase
transformer having provision of MCCB, hence LV Bimetallic clamps are not
required.
HV AND LV TERMINALS:
The LV and HV bushing stems shall be provided with suitable terminal
connectors as per IS 5082 so as to connect the jumper without disturbing the
bushing stem. Terminal connectors shall be type tested as per IS 5561.
Current density in HV and LV Terminals shall not exceed 1 Amp/sq.mm in case
of Brass terminals and 2 Amp/sq.mm in case of copper terminals.
B. INTERNAL CONNECTION:
1. HV WINDING:
i. In case of HV winding all jumpers from winding to bushing shall have cross
section double the winding conductor.
ii. Inter coil connection shall be done by brazing as per ASME, section-IX.
iii. In case of AL/CU winding Delta joint shall be with brazing only.
iv. Lead from Delta joint shall be connected to bushing rod by brazing only.
The transformers shall be suitable for loading as per IS: 6600 / 1972with
latest amendment if any.
The under base of all transformers shall be provided with holes to make them
suitable for fixing on a platform or plinth.
NOTES:
1. Minimum and maximum positions correspond to the operating
temperature of–5°C and 90°C respectively (for non-sealed type
transformer).
2. Only Minimum position corresponds to the operating temperature
of 30°C (for sealed type transformers).
5.13 OVER LOAD PROTECTION:
5.13.1 The transformer shall have external mounted LT circuit breaker on the
secondary side up to 25 KVA capacity of transformer. The breaker shall be
housed in an enclosure confirming to IP44 as per IS: 13947 forming integral
part of the transformer. Suitable louvers fitted with wire gauze shall be
provided to ensure circulation of air but not to allow ingress of rain water. An
operating handle shall be provided outside the enclosure in such a way that
ON & OFF operation of the breaker can be conveniently performed from the
ground level by means of an operating rod. The ON & OFF position of the
handle shall be clearly and bodily mark on the enclosure.
5.13.2 The breaker box shall be mounted on side wall (short side) of the tank
opposite side of the name plate for comfortable wiring at site.
5.13.3 The manufacturer will provide 1.1KV; Stranded PVC insulated armored
Aluminum cable from Transformer terminal to Incoming of MCCB having
below mentioned cable size and the purchaser will connect LT cable to the
outgoing terminals of MCCB after installation of the transformer at site.
Detachable gland plate with bellow mentioned sized cable shrinkable PVC
gland to be provided at the bottom of the enclosure.
5.13.4 The circuit breaker shall generally confirm to the requirement of IS: 13947.
The electrical characteristics of the breaker shall be mentioned by bidder as
follows.
Transformer Full load LV current of Transformer terminal to Breaker cable
rating (KVA) the transformer (Amp) size (minimum)-Alum.
5 16.2 2.5 mm²
10 13.33 4 mm²
16 21.33 6 mm²
25 33.33 10 mm²
The above drawings/ details are illustrative. However, the bidder may
submit their own drawing/ details if they so desires. Offer without
drawings/ details shall not be considered.
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 as under should invariably furnish a Notarized Copy. Offers
without type test reports will be treated as Non-responsive.
1. Temperature rise test for determining the maximum
temperature rise after continuous full load run.
2. Lightening Impulse voltage test: As per Clause No. 13 (With
chopped wave) of IS – 2026- part-III latest version. BIL for 11
kV shall be minimum 95 KV Peak.
3. Vacuum Test: As per IS - 1180 / part-I/2014
4. Air Pressure Test: As per IS - 1180 / part-
I/2014ORTransformer 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.
5. Short Circuit withstand test: Thermal and dynamic ability.
6. Magnetic Balance Test.
7. Noise-level measurement.
8. Measurement of zero-phase sequence impedance.
9. Measurement of Harmonics of no-load current.
10. Pressure relief device test (if provided).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.
11. Type tests for MCCB as per relevant IS (Upto 25KVA)
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.
The testing shall be carried out in accordance with IS: 1180Part-1 2014 and
IS:2026 latest amendment& CEA Guideline as applicable.
6.4 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 losses.
7.0 INSPECTION:
All tests and inspection shall be made at supplier works mentioned in A/T. The
manufacturer shall afford the inspector representing the purchaser all
reasonable facilities, without charge to satisfy him that the material is being
furnished in accordance with specification.
The manufacturer shall provide all services to establish and maintain quality of
workman ship in his works and that of his sub-contractors(for bought out
material/equipments)to ensure the mechanical / electrical performance of
components, compliance with drawings, identification and acceptability of all
materials, parts and equipment as per latest quality standards of ISO 9000.
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.
However, purchaser or his representative shall have the right to review the
inspection reports, quality checks and results of manufacturer’s in house
inspection department which are not customer hold points and the
manufacturer shall comply with the remarks made by purchaser or his
representative on such reviews with regards to further testing, rectification or
rejection etc. Manufacturer should submit the list of equipment for testing
along with valid calibration certificates from NABL accredited laboratory to
the purchaser along with the bid.
Purchaser shall have every right to appoint a third party inspection to carryout
the inspection process. The purchaser has reserved the rights to have the test
The tenderer shall submit the list of orders for similar type of equipments,
executed or under execution during last three years, with full details to enable
the purchaser to evaluate the tender.
The test results will be binding on the suppliers. DISCOM in general will not allow re-
sampling. If the material fails in any of the acceptance tests/type tests carried out
(except for no load and load losses), the full lot of materials will be considered as
rejected, and if replacement is not possible due to consumption of the materials, in
that case for whole of the rejected lot, DISCOM will deduct penalty as per below
mentioned details. If the same are not utilized / consumed, Company at sole
discretion may ask for replacement or may accept with penalty having details as
under and all these will be binding on the supplier.
To reject the complete lot OR recovery of penalty up to 30% in line with commercial
condition clause of audit testing.
1.Up to 30% penalty in line with commercial condition clause of audit testing.
Schedule A
H.V. BUSHINGS
1) JAYASHREE
2) BEPCO.
3) W.S. INSULATORS
4) ASSOCIATED PORCELAIN (11KV ONLY)
5) JAIPUR GLASS
6) SESHASAYEE
7) LUSTER CERAMICS
8) AGRAWAL SALT CO., BIKANER.
9) B.P.P.L., BIKANER.
10) VENKATESHWARA CERAMICS P.
11) CJI PORCELAIN INDIA LTD.
12) MAXWELL CERAMIC, WADHWAN, (ONLY 11KV)
13) RAVIKIRAN (ONLY 11KV)
14) VISHAL MALLEABLE LTD.
15) AS INSULATOR
16) REAL INSULATOR
17) REDIANT CERAMIC
18) SUN INSULATOR
19) PRIME INSULATOR
20) GENESIS ENTERPRISES PRIVATE LIMITED
L.V. BUSHINGS:
1) J.S.I. (RISHRA)
2) LUSTER CERAMICS
3) JAIPUR GLASS
4) AGRAWAL SALT CO., BIKANER.
5) B.P.P.L., BIKANER.
6) VENKATESHWARA CERAMICS, PVT. LTD.
7) CJI PORCELAIN
8) MAXWELL CERAMIC, WADHWAN.
9) RAVIKIRAN
10) VISHAL MALLEABLE LTD.
11) AS INSULATOR
12) REAL INSULATOR
13) REDIANT CERAMIC
14) SUN INSULATOR
15) PRIME INSULATOR
16) GENESIS ENTERPRISES PRIVATE LIMITED
1) Siemens
2) L&T
3) ABB
4) GE POWER
5) Schneider
6) Crompton Greaves
7) Havells
8) HPL
11 Losses
i Core loss Watts
a) at Normal Voltage Watts
b) at Maximum Voltage Watts
ii Full Load losses at 75 deg.C. Watts
iii Total losses at 50 % loading at 75 deg.C. Watts
iv Total losses at 100 % loading at 75 deg.C. Watts
12 Percentage Impedance at 75 deg.C. %
13 Maximum temperature rise of
a) Windings by resistance method 40 deg C
(35 deg C for 5KVA)
b) Oil by Thermometer 35 deg C
(30 deg C for 5KVA)
14 Clearances
a) Core & LV mm
b) LV & HV mm
c) HV Phase to Phase mm
d) End insulation clearance to Earth mm
e) Any point of winding to tank mm
f) HV to earth creepage distance mm
g) LV to earth creepage distance mm
Signature of Tenderer Company’s Round Seal Date Place
Page 40 of 45
TENDER No. PGVCL/RJT/Proc/CPP/10KVA Level-1 DTR/717
Sr. Particulars Unit / Type As per Firm's
No. Offer
15 Efficiency at 75 deg.C.
a) Unity P.F.
1) 125% load %
2) 100% load %
3) 75% load %
4) 50% load %
5) 25% load %
b) 0.8 P.F.
1) 125% load %
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 CORE CRGO/ Amorphous
i Core Grade
ii Core diameter mm
iii Gross Core area Mtr²
iv Net Core area Mtr²
v Flux density Wb/Mtr²
vii Wt. of Core Kg
viii Loss per kg. of Core at the specified Flux Watts
density
ix Core window height mm
x Centre to centre distance of the core mm
xi The nominal flux density at
a) 100% rated voltage ≤ 1.69 Wb/Mtr²
b) 110% of rated voltage ≤1.9 Wb/Mtr²
xii % No load current of full load current at rated
voltage and frequency on the secondary and
Increase of voltage by 112.5%
(i) CRGO Core: at 100% and 112.5% of rated
Voltage
a) Up to 200 KVA Transformer ≤ 3% and ≤ 6 %
Type of Core
3 1 CRGO-1,Amorphous-2
Material
Core
4 1 Stack-1, Wound-2
construction
7 0
Month of 2 digits for Month of
manufacturing manufacturing
8 2
9 1
Year of 2 digits for Year of
manufacturing manufacturing
10 7
11 9
12 0
CPP Tender
4 digits for CPP tender no.
No.
13 3
14 2
15 0
5 digits for transformer sr. no.
16 0 given by supplier
Sr. No. of
(e.g. M/s XYZ will give
transformer
17 0 transformer sr. no. from 00001
given by
to 00260 for P.O. of 260 no.
Supplier
transformers issued to them vide
18 0
CPP tender no.9032 )
19 1