TITLE : Technical Specification For

4000KVA, 33/0.433 kV Transformer(Oil Filled)

TECHNICAL SPECIFICATION
FOR
AUXILIARY SERVICE TRANSFORMERS
(OIL FILLED)

2x4000 KVA, 33/0.433 kV

BHARAT HEAVY ELECTRICALS LIMITED

FABRICATION UNIT
Third Floor, Room No.305, Corporate office,
New Delhi- 110049

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 TITLE : Technical Specification For
4000KVA, 33/0.433 kV Transformer(Oil Filled)

CONTENTS

S. NO DESCRIPTION NO. OF SHEETS

1 SECTION ‘A’

SCOPE OF ENQUIRY 01

2. SECTION ‘B’

SPECIFIC TECHNICAL REQUIREMENTS 12

ANNEXURE - I (LIST OF O & M SPARES) 01

ANNEXURE – II (TYPE TESTS FOR LT TRANSFORMER) 01

ANNEXURE – III (TRANSFORMER LOSSES) 01

ANNEXURE – IV (DOCUMENTS / DRAWINGS SCHEDULE) 01

ANNEXURE - V (STANDARD QUALITY PLAN) 06

ANNEXURE- VI (SPECIAL TOOLS & TACKLES) 01

ANNEXURE- VII (COMMISSIONING SPARES) 01

ANNEXURE- VIII (APPLICABLE STANDARDS & CODES FOR 01

TRANSFORMER)

DATA SHEET -A FOR LT TRANSFORMER 03

DATA SHEET -B FOR LT TRANSFORMER 01

SCHEDULE OF DEVIATIONS 01

ANNEXURE- IX (QUALIFYING CONDITIONS) 01

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 TITLE : Technical Specification For
4000KVA, 33/0.433 kV Transformer(Oil Filled)

Section-A

SCOPE OF ENQUIRY

1.0 This specification covers the design, manufacture, inspection & testing
at manufacturer's works, proper packing, delivery to site and
supervision of (installation & commissioning) and testing at BHEL ’s
works of Two (02) Numbers 4000 KVA, 33/0.433 kV Power
Transformers (Oil filled) suitable for out door installation.

2.0 It is not the intent to specify herein all the details of design &
manufacture. However, the equipment shall conform in all respect to
high standards of design engineering and workmanship and shall be
capable of performing in continuous commercial operation.

3.0 The general terms and conditions, instructions to bidders and other
attachment referred to elsewhere are hereby made part of the tender
specification.

4.0 The bidders shall be responsible for and governed by all requirements
stipulated hereinafter.

5.0 Bidders shall confirm total compliance to the specification without any
deviation from the technical/ quality assurance requirements
stipulated.

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 TITLE : Technical Specification For
4000KVA, 33/0.433 kV Transformer(Oil Filled)

Section-B

SPECIFIC TECHNICAL REQUIREMENTS

1.00 INTENT OF SPECIFICATION

1.01 This specification covers the design, manufacture, inspection &

testing, packing at manufacturer’s works, delivery to site and
supervision of (installation & commissioning) and testing at BHEL’s
works of mineral oil filled LT Transformers complete with all fittings
& accessories for satisfactory operation at site.

1.02 The intent of specification is not to specify all details of design &
construction of equipment. The equipment shall, however, conform
in all aspects to high standard of design, engineering and
workmanship and be capable of performing in continuous operation
upto & after bidder’s guarantee period in manner acceptable to
purchaser who will interpret the drawings & specification and shall
have power to reject any work or material which in his judgment is
not in full accordance with this specification.

2.00 CODES AND STANDARDS

2.01 The equipment shall comply with all currently applicable safety
codes and statutory regulations of India as well as of the locality
where the equipment is to be installed including Indian Electricity
Act, Indian Electricity Rules and Bureau of Indian Standards.

2.02 The design, material, construction, manufacture, inspection, testing

and performance of LT Service Transformers shall conform to the
currently applicable standards and codes of practices as per
Annexure-VIII. General design, electrical & constructional features
and various fittings & accessories shall be as per CBIP manual on
Transformers Publication No. 275 (1999 edition or latest).

2.03 In case of conflict between the applicable reference standard and

this specification, this specification shall govern.

3.00 SCOPE OF ENQUIRY

3.01 Bidder shall quote for mineral oil filled LT Service Transformers
including 10% spare oil in accordance with various sections of this
specification. The transformer shall be provided with all fittings &
accessories (including foundation hardware) & shall be complete in
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 TITLE : Technical Specification For
4000KVA, 33/0.433 kV Transformer(Oil Filled)

all aspects, for satisfactory operation, in accordance with this

specification & technical particulars. Design ambient temperature
shall be 50 deg. C.

3.02. Bidder shall quote for following equipment & services:

3.02.01. Transformers- (Rating & quantity of transformers shall be as

per Data sheet-A).

3.02.02. Special Tools & Tackles required for installation &

commissioning and proper maintenance of equipment- One Lot
(Bidder to furnish list along with offer)

3.02.03. Commissioning spares for each transformer- One Lot (Bidder

to furnish list along with offer)

3.02.04. O & M spares as specified in Annexure-I

3.02.05 Supervision of Installation & commissioning at site.

3.02.06 Testing of Transformer at site

Note: Extra 10% of total oil quantity for each transformer shall be supplied along
with the transformers in sealed non returnable drums.

4.00 SERVICES & EQUIPMENT TO BE EXCLUDED

4.01 Installation of transformer at site.

4.02 Civil work such as transformer foundation, cable trenches etc.

4.03 External power connection for HV & LV side of transformer by

means of bus duct.

4.04 HV termination kits.

4.05 Connection to Station Earth.

4.06 Cable lugs and cable glands for external connections to purchaser’s
equipment.

5.00 TERMINAL POINTS

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 TITLE : Technical Specification For
4000KVA, 33/0.433 kV Transformer(Oil Filled)

I. HV bushings with terminal connector-Out door Aluminium

conductor.

II. LV bushings with terminal connector (3 Phase + 1 Neutral)

III. LV neutral earth busbar brought near the base of transformer.

IV. Transformer earthing pads.

V. Terminals of marshalling box for external connection to equipment

supplied by the purchaser.

6.00 TECHNICAL REQUIREMENTS:

6.01 Technical particulars of transformers are specified in Data Sheet–A.

6.02 Equipment shall give continuous service under specified site conditions.

6.03 All windings shall be fully insulated. Material of the windings shall be
electrolytic grade copper, free from scales and burrs. Winding shall be
uniformly insulated.

6.04 The core shall be constructed from high grade, non-ageing, cold rolled, grain
oriented silicon steel laminations.

6.05 Internal design of transformer shall ensure that air is not trapped in any
location.

6.06 Under base of tank shall be fixed type.

6.07 Nuts, bolts and pins used inside the transformer shall be provided with lock
washers& locknuts.

6.08 Specific technical requirements are as follows:

6.08.01 Tank: Fabricated from tested quality steel and designed to withstand
continuous internal pressure of 35 k N per sq. m. over normal
pressure as well as short circuit forces. The main tank body including
tap-changer compartment, radiators and coolers shall be capable of
withstanding full vacuum. All steel surfaces in contact with insulating
oil shall be painted with two coats of heat resistant oil in soluble
insulating varnish. Tank shields, if provided, shall not resonate at
natural frequency of equipment.

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 TITLE : Technical Specification For
4000KVA, 33/0.433 kV Transformer(Oil Filled)

6.08.02 Tank mounting: Transformer tank shall be mounted on bi-directional

rollers. Suitable locking arrangement shall be provided to prevent
accidental movement of transformer. Tank shall also be provided with
lifting lugs and minimum four jacking pads. Rollers shall be provided
with holding clamp plates (04 nos), required hardware and foundation
bolts etc. for each transformer.

6.08.03 Tank openings: At least two adequately sized inspection openings,

one at each end of the tank for easy access to bushings and earth
connections.

6.08.04 Oil preservation: Conservator tank of adequate capacity for expansion

of oil from minimum ambient to 100 deg. C shall be provided. The
transformers shall be provided with conventional conservator with dry air
filling of the space above oil and connected to silica gel breather.

6.08.05 Radiators: Tank mounted with shut off valves.

6.08.06 Insulating Oil: As per IS: 335.No external inhibitors are permitted.

6.08.07 Transformer shall be suitable for cable/ busduct termination as

indicated in data sheet-A.

6.08.09 Bushings/ Insulators:

a) The bushings shall conform to the requirements of IS: 2099 and IS:
3347 and shall be of porcelain.
b) For 33 KV windings, 36kV bushing shall be provided and for 433 V
windings, 1.1 KV bushing shall be provided

c) The porcelain shall not engage directly with hard metal and,
wherever necessary, gaskets shall be interposed between the
porcelain and the fitting.

d) Clamps and fittings of steel or malleable cast iron shall be

galvanised.
e) Where bushing current transformer is provided, the bushing shall be
mounted so that it can be removed and replaced without disturbing
the current transformers. CT s shall be cast resin type & suitable for
operation at ambient temperature existing at its location on the
transformer.
f) Creep age distance shall be minimum 25 mm/kV per unit of system
phase to phase voltage.
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 TITLE : Technical Specification For
4000KVA, 33/0.433 kV Transformer(Oil Filled)

f) Minimum rated current for bushings shall be as under:

1.) HV Bushing for 33KV, 4.0 MVA = Vendor to Conform
2.) Bus duct termination on LV = Vendor to Conform

6.08.10 Cable Box:

a) A dust tight air insulated type cable box with D.O.P. of IP: 55 shall
be provided for terminating the cables directly of size and type
specified in Data sheet-A.

b) Dimensions of cable box shall be subject to purchaser’s approval.

c) Inspection cover for fixed portion of cable box shall be provided.

Handles for lifting cable box shall be provided.

d) Creepage distance and clearances in air shall be as per CBIP

manual.

e) Provision shall be made for earthing the body of each cable box.
Separate earthing pads shall be provided for this purpose, suitable
for bolted connection to galvanised mild steel flat of size to be
specified during contract engineering stage.

f) Gland plate for single core cable termination shall be of Aluminum.

g) Cable box(es) shall be provided with suitable air-insulated

disconnecting chamber so that if required, transformer can be
removed from its position without disconnecting the cables in the
cable box(es). Independent supporting arrangement shall be
provided for cable box(es) for this purpose. Supporting arrangement
shall be supplied along with required hardware & foundation bolts
etc.

6.08.11 Bus duct Termination:

LV terminals are specified to be connected by means of a bus duct

for this purpose a flanged throat or equivalent connection shall be
provided to suit purchaser’s busduct. The winding termination shall
be on outdoor type of bushing. Necessary flexibles shall be provided
by purchaser to connect the bushing terminals to the busbar of the
busduct. Details of busduct shall be furnished during detail
engineering stage.
6.08.12 Neutral Terminals:
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 TITLE : Technical Specification For
4000KVA, 33/0.433 kV Transformer(Oil Filled)

Two (2) nos. neutral terminals shall be provided on LV side. One

neutral terminal shall be part of phase connection arrangement
busduct throat/ LV cable-box (as applicable). Other neutral terminal
shall be in a separate box and brought to tank bottom by means of
earthing bar of 50x6mm of copper, supported on porcelain
insulators mounted on transformer tank. The neutral earthing bar
brought to the tank bottom for connection to station earth shall be
provided with holes and suitable connecting hardware. This earthing
bar shall have fork type arrangement at the end.
6.09 Neutral CT

Bidder to provide neutral bushing CT as per details given in data

sheet - A for restricted earth fault protection or standby earth fault
protection. In case neutral CT is tank mounted, CT box shall be
weather proof having D.O.P. IP: 55. CTs shall be cast resin type. CT
mounted inside the tank shall not be acceptable.

6.10 Voltage control

On Load Tap Changer –On load Tap Changer to achieve voltage
regulation upto 5% should be provided. The OLTC should be
motorized with suitable controls. Options of providing the OLTC on
HV or LV side with details of the location & operating arrangement
should be given along with the offer.

6.11 Marshalling box:

a) Tank mounted vermin and dust proof marshalling box shall be

provided.

b) The marshalling box shall be fabricated using sheet steel of at least

2.5mm thickness. The marshalling box shall have domed or sloping
roof.

c) Marshalling box shall be complete with all internal wiring and

identification ferrules, cables, conduits required for wiring between
marshalling box and instruments on transformer. Wiring shall be by
2
650 V grade, copper cable of size 2.5 mm .
d) The terminal blocks shall be complete with insulating barriers and
2
clip-on type terminals suitable for 2.5mm stranded copper wires. At
least 20% spare terminals shall be provided.

e) The marshalling box shall be provided with thermostatically

controlled space heaters and shall have IP: 55 degree of protection.
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 TITLE : Technical Specification For
4000KVA, 33/0.433 kV Transformer(Oil Filled)

f) CT terminals shall be with shorting and disconnecting facility.

6.12 Flux density:

Flux density in any part of the core & yoke on any tap position with
±10% voltage variation from voltage corresponding to the tap shall
2
not exceed 1.9 Wb/m .
Transformer shall also withstand following conditions due to
combined voltage and frequency variations:
a. Continuous operation for 110% flux density
b. At least 1 minute operation for 125% flux density
c. At least 5 sec. operation for 140% flux density

6.13 Noise & Vibration:

The design and manufacture of transformer, fittings and accessories

shall be such as to reduce noise & vibration. Noise level shall not be
more than as specified in NEMA Standard Publication TR-1, when
measured with transformer energized at normal voltage and
frequency.

6.14 All transformers and their accessories shall be capable of

withstanding without damage any external short circuit at the
terminals for duration of two seconds.
Calculation shall be furnished by the bidder during contract
engineering stage to substantiate the adequacy of support system
to withstand short circuit forces.

6.15 Maximum Transformer losses including tolerances shall be as per

annexure – III.

6.16 LOADING CAPABILITY:

Transformer shall be suitable for continuous operation at rated kVA

on any tap with voltage variation of + 10 % corresponding to voltage
of the tap. Short duration overloading shall be in accordance with IEC
354/IS: 6600.

7.00 Fittings & accessories:

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 TITLE : Technical Specification For
4000KVA, 33/0.433 kV Transformer(Oil Filled)

7.01 Transformer shall be provided with, but not restricted to following

minimum fittings and accessories for satisfactory operation:

a) Conventional type conservator with drain plug and oil filling hole.
b) Magnetic oil level gauge with low-level alarm contact.
c) Prismatic & toughened glass oil level gauge.
d) Silica gel breather with oil seal.
e) Double float type Buchholz relay with alarm and trip contacts with
suitable gas collecting device with one shut-off valve on conservator
side.
f) Diaphragm type explosion vent for transformers.
g) Pocket on tank cover for thermometer.
h) Protected type mercury in glass thermometer.
i) Dial type (150 mm) Oil temperature indicator (OTI) with two sets of
electrical potential- free contact rated for 2A, 220V DC, for alarm and
trip purpose. The OTI shall be provided with anti-vibration mounting.
OTI shall have maximum reading pointer along with resetting device.
j) Dial type (150 mm) Winding temperature indicator (WTI) with two
sets of electrical potential- free contact rated for 2A, 220V DC, for
alarm and trip purpose. The WTI shall be provided with anti-vibration
mounting. WTI shall have maximum reading position along with
resetting devices.
k) Drain Valves.
l) Sampling devices.
m) Filter valves.
n) Earthing terminals – 2 Nos.
o) Rating & Diagram plates.
p) Valve schedule plate.
q) Two sets of lifting lugs (one for transformer with oil and other for tank
cover).
r) Jacking pads.
s) Skids and pulling eyes on both sides.
t) Air release devices.
u) Inspection covers.
v) Oil filling hole and cap.
w) Tank mounted marshalling box.
x) Detachable, flat, bidirectional rollers with 90 deg. swivel mechanism.
y) Clamping arrangement for rollers.
z) Ground support for cable box.
aa) Neutral CT secondary box.
bb) Haulage facilities.
cc) Two nos. spring operated pressure relief devices with extension pipe
to bring oil to plinth level along with electrically insulated contact for
alarm and tripping for transformer rating 4 MVA and above.
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 TITLE : Technical Specification For
4000KVA, 33/0.433 kV Transformer(Oil Filled)

7.02 Breather may be fitted at a height not exceeding 1.5 M.

7.03 Rating and diagram plate will be fitted at a height of about 1.75M above the
ground level.

7.04 The WTI and OTI shall have accuracy class of + 2 deg. C or better.

7.05 Rating/ Name/ Valve schedule plates shall be of white non-hygroscopic

material with engraved black lettering. Such plates shall be bi- lingual with
Hindi inscription first, followed by English. Alternatively, two separate
plates with Hindi & English inscription shall be provided.

8.00 PAINTING:

Paint shade shall be informed to successful bidder during detail engineering.

Successful bidder shall furnish painting specification/ procedure to be used
for BHEL approval during detailed engineering. Adequate quantity of touch
up paint shall also be supplied. There shall be no commercial or delivery
implication to BHEL on account of paint shade, paint specification/
procedure.

9.00 COMMISSIONING, O&M SPARES AND SPECIAL TOOLS & TACKLES:

9.01 Commissioning spares are those, which may be required during

commissioning of the equipment. Bidder to furnish list of commissioning
spares along with technical offer.

9.02 O & M spares are those which are required for satisfactory & trouble free
operation of equipment. List of O&M spares is enclosed as per Annexure-I.

9.03 The bidder shall supply with the equipment, one unused complete set of all
special tools & tackles required for the installation, assembly, disassembly
and proper maintenance of the equipment. A list of such tools & tackles
(price deemed to be included in the total bid price) shall be submitted by
the bidder along with the offer.

10.00 QUALITY ASSURANCE, TESTING & INSPECTION

10.01 BHEL’s Standard QP (QP NO. PED-302-00-Q-001/01) is enclosed as per

Annexure-V for reference. However, at contract stage, the successful
bidder shall submit the QP for BHEL approval. There shall be no
commercial implication to BHEL on account of QP approval.

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 TITLE : Technical Specification For
4000KVA, 33/0.433 kV Transformer(Oil Filled)

10.02 All materials, components and accessories of the transformers shall be

procured, manufactured, inspected and tested by vendor/ sub-vendor as
per approved quality plan.

10.03 Tests shall be performed in presence of BHEL’s representative. The bidder

shall give at least fifteen (15) days advance notice of date when the tests
are to be carried out.

10.04 All routine and acceptance tests as per relevant standards and
specification shall be carried out by the vendor/ sub-vendor on all
transformers. Charges for all these routine and acceptance tests for all the
equipments & components shall be deemed to be included in the bid price.

10.05 Additionally, the bidder shall include in his equipment price the cost of
carrying out the following special tests as routine tests on all the
transformers:
a) Oil Leakage test for 24 hours
b) Jacking test on transformer’s load bearing members.
c) Repeat no load loss tests after electrical tests.

10.06 Bidder shall furnish Type Test certificates already carried out on similar
transformers from a reputed institute (other than bidder) along with Part-I
bid. This Test certificates shall not be older than 3 years. In absence of this
certificate the offer is liable to be rejected.

10.07 Bidder shall furnish List of sub-vendors/ makes of items along with part-I
bid for BHEL approval.

11.00 DRAWINGS, DATA & DOCUMENTS TO BE SUBMITTED:

11.01 Following shall be submitted along with the offer:

a) The enclosed Data Sheet-B filled up completely
b) Clause – wise deviation, if any
c) Out line General Arrangement Drawings
d) Foundation plan Drawings
e) List of sub-vendors/ makes of items
f) Type Test certificates

11.02 Following documents shall be submitted after placement of order for

BHEL approval:

a) The Data Sheet – C duly filled up.( Data Sheet – C shall be given to
successful bidder)
b) Vendor drawing submission schedule.
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 TITLE : Technical Specification For
4000KVA, 33/0.433 kV Transformer(Oil Filled)

c) Design calculation for short circuit withstands capability (refer cl. 6.14).
d) Overall General Arrangement Drawing clearly showing all fittings,
accessories, termination details, foundation details with roller locking
arrangement.
e) General Arrangement of Marshalling Box.
f) Rating & Diagram Plate Drawing.
g) Valve Schedule Plate Drawing.
h) Cable Box Arrangement Drawing.
i) Bushing/ Insulator Drawings.
j) Bus duct Trunking Drawings.
k) Quality Plan.
l) Type test procedure
m) Wiring Diagrams.
n) Painting procedure of vendor for approval of customer.
o) Recommended Field Quality Plan
q) Routine test reports
r) O & M Manuals

The documents listed at sl. no. a), b) & c) shall be submitted by successful bidder
within 2 weeks from L.O.I. while documents sl. no. d) through o) shall be
submitted by successful bidder within 4 weeks from L.O.I.

No. of documents/ drawings required shall be as per “Documents/ Drawings

Distribution Schedule” enclosed as per Annexure-IV.

12.00 O & M MANUALS

12.01 O & M manuals for the installation, operation and maintenance of

transformers shall be furnished at least three months before
dispatch of equipment.

12.02 Draft manual should first be submitted for BHEL’s approval. The
manual should contain minimum following details:
a) General description of equipment.
b) Approved Technical Data Sheet
c) Salient constructional features.
d) Technical leaflets of fittings/ important parts.
e) All drawings.
f) Type and routine test certificates.
g) Instructions to be followed on receipt of equipment at site &
for storage.
h) Instructions for foundation arrangement.
i) Erection procedures and checks.
j) Pre-commissioning checks.
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 TITLE : Technical Specification For
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k) Commissioning procedures.
l) Withdrawal arrangement/ material handling instructions.
m) Operation instructions.
n) Maintenance instructions.
o) Trouble-shooting.
p) Safety instructions.

13.0 All drawings/ documents indicated at clause no. 11 & 12 above shall be
computer generated. Drgs. / documents shall be required in soft form
(PDF format) also. All drawings shall be prepared in AUTOCAD latest
version. Drawings & documents shall be submitted in CD also. The
number of copies of various drawings/ documents shall be as per
Annexure -IV.

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 TITLE : Technical Specification For
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ANNEXURE-I

LIST OF O & M SPARES

S.
NO. DESCRIPTION QTY
1 HV bushing with metal parts & gaskets 1 no.

2 LV bushing with metal parts & gaskets 1 no.

3 WTI with alarm & trip contacts 1 no.
4 OTI with alarm & trip contacts 1 no.
5 Magnetic oil level gauge 1 no.
6 Diaphragm of explosion vent 1 no.
7 Buchholz relay 1 no.
8 Silica gel charge Three charge
9 Floats with contacts for Buchholz relay 1 set
10 Set of gaskets 2 sets
11 Set of valves (1 no. of each size & Type) 1 set
12 Set of windings for one limb in a suitable oil 1 no. of each
container (container shall be completely filled rating & type of
with transformer oil) transformer.
13 Contact for tap changer 1 set
14 Pressure relief device for 4MVA transformer 1 no.
15 Hydraulic/screw Jacks 4 no.
16 Any other item considered essential by the
bidder

Note:

1) Wherever set is indicated above, it means the total parts/ accessories

required to replace the particular item for one Transformer.

2) O & M spares shall be supplied along with transformers and packed

separately with proper inscription.

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ANNEXURE-II

TYPE TESTS FOR LT TRANSFORMERS

a) Tank Pressure test

b) Tank Vacuum test

c) Capacitance & tan delta of windings

d) Noise level

e) Measurement of harmonic current in no load current

f) PRD operation test

g) Short circuit test

h) Degree of protection (IP55) test on marshalling box.

i) Degree of protection (IP55) test on cable box.

j) Zero sequence impedance.

k) Temp rise test.

l) Dielectric type test (including chopped wave impulse test)

m) DGA test on oil before and after temperature test.

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 TITLE : Technical Specification For
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ANNEXURE III

TRANSFORMER LOSSES

1. In case a measured loss of transformer during testing exceeds the

declared values, BHEL may accept the transformer with penalty. The rate
of penalty shall be Rs. 1.95 lacs per kW or part thereof. The penalty shall
be calculated for each transformer as given below:

PENALTY = Penalty Rate x [measured No-Load losses - maximum No-

Load losses) + (measured Load losses – maximum Load losses)]

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ANNEXURE- IV

DOCUMENTS/ DRAWINGS DISTRIBUTION SCHEDULE

S. NO. DESCRIPTION No. hard

prints/copies No. of CD- REMARKS
ROMs
1 Master List of Drgs./ 3Copies
Docs.

2 Docs. /drgs. submission 3 Copies

schedule for approval

3 Approved Docs. /Drgs. 4 Copies

submission schedule for 2
distribution

4 Docs. /drgs. for approval 3 copies

(First submission) 2

5 Drgs. / docs. for 3 copies

approval (Second & 2
subsequent submission
till approval)
6 Final approval drgs. / 4 Copies
docs. for Distribution 2

7 Operation & 3 Copies

Maintenance manual for 2
approval

8 Approved Operation & 4 Copies

Maintenance Manual for 2
distribution

9 Type Test Certificates/ 4 Copies

Reports

Page 19 of 35
 ANNEXURE-V

STANDARD QUALITY PLAN

CUSTOMER : PROJECT SPECIFICATION :

TITLE NUMBER :
QUALITY PLAN BIDDER/ : QUALITY PLAN SPECIFICATION
VENDOR NUMBER PED-302-00-Q-001/01 TITLE
SHEET 1 OF 6 SYSTEM ITEM :OIL FILLED TRANSFORMER SECTION VOLUME III
SL. COMPONENT/OPERATION CHARACTERISTICS CAT. TYPE/ EXTENT OF REFERENCE ACCEPTANCE FORMAT AGENCY REMARKS
NO. CHECK METHOD OF CHECK DOCUMENT NORM OF RECORD
CHECK P W V

1 2 3 4 5 6 7 8 9 10 11

1.0 MATERIALS

1.1 M.S. PLATES, MS ANGLES, 1.PHYSICAL MA PHYSICAL SAMPLE BHEL TECH. BHEL TECH. TEST 3/2 - 2
CHANNELS PROPERTIES TEST SPEC/DRG/DATA SPEC/DRG/DATA CERT.
SHEETS SHEETS INSP.
RELEVANT IS RELEVANT IS REPORT
SPEC SPEC

2.DIMENSIONS MA MEASUREMENT -DO- -DO- -DO- -DO- 3/2 - 2

3.SURFACE MA VISUAL 100% -DO- -DO- -DO- 3/2 - 2

CONDITIONS

4.MIL MARK MA VISUAL 100% -DO- -DO- -DO- 3/2 - 2

1.2 HARDWARE (HIGH 1.SURFACE MA VISUAL 100% -DO- -DO- TEST. 3 - 2

TENSILE FASTENERS) CONDITION CERT.

2.MARKING CR VISUAL 100% -DO- -DO- -DO- 3 - 2

1.3 CRGO SHEETS (STAMPINGS) 1.SURFACE MA VISUAL SAMPLE -DO- -DO- -DO- 3/2 - - VARNISHING OF SHEETS
COND. IF REQUIRED TO BE PROVIDED
AFTER ANNEALING
2.THICKNESS MA MEASUREMENT -DO- -DO- -DO- -DO- 3/2 - -

3.ACCEPTANCE MA MECH. & ELECT. SAMPLE -DO- -DO- -DO- 3/2 - 2,1
TEST

1.4 CONDUCTORS 1.SURFACE MA VISUAL 100% FREE FROM SHARP EDGES, BURS INSP. 3/2 - -
FINISH SCRATCH & CUTS REPORT

2.DIMENSIONS MA MEASUREMENT 100% MANUF'S STD MANUF'S STD -DO- 3/2 - -

3.PHYSICAL MA PHY. TEST SAMPLE RELEVANT STD RELEVANT STD -DO- 3/2 - 2
PROPERTIES

4.ELECT. CR ELECT. TEST -DO- -DO- -DO- -DO- 3/2 - 2

PROPERTIES

BHEL PARTICULARS BIDDER/VENDOR

NAME
SIGNATURE
DATE BIDDER'S/VENDORS COMPANY SEAL

Page 20 of 35
 CUSTOMER : PROJECT SPECIFICATION :
TITLE NUMBER :
QUALITY PLAN BIDDER/ : QUALITY PLAN SPECIFICATION :
VENDOR NUMBER PED-302-00-Q-001/01 TITLE
SHEET 2 OF 6 SYSTEM ITEM :OIL FILLED TRANSFORMER SECTION VOLUME III
SL. COMPONENT/OPERATION CHARACTERISTICS CAT. TYPE/ EXTENT OF REFERENCE ACCEPTANCE FORMAT AGENCY REMARKS
NO. CHECK METHOD OF CHECK DOCUMENT NORM OF RECORD
CHECK P W V

1 2 3 4 5 6 7 8 9 10 11

1.5 INSULATING OIL 1.ELECT.PROPT CR ELECT.TEST SAMPLE RELEVANT RELEVANT INSP. 3/2 - 2,1
(BDV, TAN-DELTA) IS SPEC. IS SPEC. REPORT

1.6 INSULATION MATERIAL- 1.ELECT.PROPT CR ELECT. TEST -DO- -DO- -DO- -DO- 3/2 - 2
PAPER, PRESS-BOARDS,
MACANITE ETC.

1.7 GASKETS 1.HARDNESS MA MECH. TESTS SAMPLE MANUF.STD MANUF.STD. LAB 2 - -

COMPATIBILITY REPORT
WITH OIL AT HIGH
TEMPERATURE

1.8 TERMINAL BOX 1.SURFACE MA VISUAL 100% MANUF.STD MANUF.STD. -DO- 3,2 - -
CONDITION

2.DIMENSION MA MEASUREMENT SAMPLE -DO- -DO- -DO- 3,2 - -

3.IR-HV-IR CR ELECT 100% -DO- -DO- -DO- 3/2 - 2 TERMINAL BLOCKS TO BE

PROCURED FROM REPUTED
1.9 SUB-DELIVERY ITEMS 1.ROUTINE MA VISUAL & PHY 100% BHEL DRG./ -DO- BHEL DRG./ -DO- TEST 2 - - SOURCE. ROUTINE TEST
SUCH AS CONNECTORS TEST CERT. CERTIFICATE INSTRUMENT
CONTACTORS, TERMINAL, RELAYS BUSHINGS SHALL BE
BLOCKS, CABLES, SWITCHES VERIFIED BY BHEL
INSTRUMENT , TRANSFORMER
LUGS, GLANDS, VALVES
RELAYS, BUSHINGS,
DIAPHRAGMS, BREATHERS
ETC.

PARTICULARS BIDDER/VENDOR
BHEL NAME
SIGNATURE
DATE BIDDER'S/VENDORS COMPANY SEAL

Page 21 of 35
 CUSTOMER : PROJECT SPECIFICATION :
TITLE NUMBER :
QUALITY PLAN BIDDER/ : QUALITY PLAN SPECIFICATION :
VENDOR NUMBER PED-302-00-Q-001/01 TITLE
SHEET 3 OF6 SYSTEM ITEM :OIL FILLED TRANSFORMER SECTION VOLUME III
SL. COMPONENT/OPERATION CHARACTERISTICS CAT. TYPE/ EXTENT OF REFERENCE ACCEPTANCE FORMAT AGENCY REMARKS
NO. CHECK METHOD OF CHECK DOCUMENT NORM OF RECORD
CHECK P W V

1 2 3 4 5 6 7 8 9 10 11

2.OPERATION/ MA ELECT. & FUNC. 100% -DO- -DO- -DO- 2 - -

FUNCTIONAL CHECK
TESTS

3.DIMENSIONS MA MEASUREMENT SAMPLE -DO- -DO- -DO- 2 - -

4.SURFACE MA VISUAL 100% -DO- -DO- -DO- 2 - -

CONDITION

5.RATING, MA VISUAL 100% -DO- -DO- -DO- 2 - -

MARKING

1.10 PAINT & VARNISH SHELF LIFE MA VISUAL 100% -DO- -DO- INSP. 2 - -
REPORT

2.0 FABRICATION/PAINTING

2.1 FABRICATED TANKS/ 1.DIMENSIONS MA MEASUREMENT 100% ----------APPROVED DRAWINGS--------- INSP. 3,2 - -
RADIATORS/ CONSERVATOR REPORT

2.WELD QUALITY MA VISUAL & PT 100% -----------RELEVANT CODE--------------- -DO- 3,2 - -

HOLIGAN
DETECTORS

3.VACUUM CR VAC. TEST 100% BHEL TECH BHEL TECH -DO- 3,2 - -
TIGHTNESS SPEC, CBIP STD SPEC, CBIP STD

4.LEAK TIGHTNESS CR PRESSURE 100% -DO- -DO- -DO- 3,2 - -

TEST

PARTICULARS BIDDER/VENDOR
BHEL NAME
SIGNATURE
DATE BIDDER'S/VENDORS COMPANY SEAL

Page 22 of 35
 CUSTOMER : PROJECT SPECIFICATION :
TITLE NUMBER :
QUALITY PLAN BIDDER/ : QUALITY PLAN SPECIFICATION :
VENDOR NUMBER PED-302-00-Q-001/01 TITLE
SHEET 4 OF 6 SYSTEM ITEM :OIL FILLED TRANSFORMER SECTION VOLUME III
SL. COMPONENT/OPERATION CHARACTERISTICS CAT. TYPE/ EXTENT OF REFERENCE ACCEPTANCE FORMAT AGENCY REMARKS
NO. CHECK METHOD OF CHECK DOCUMENT NORM OF RECORD
CHECK P W V

1 2 3 4 5 6 7 8 9 10 11

2.2 SURFACE PREPARATION & 1.SURFACE MA VISUAL 100% --FREE FROM GREECE, SCALE, RUST INSP. 3,2 - -
PAINTING CONDITION AND SHALL HAVE UNIFORM ROUGH REPORT
SURFACE------------------------------------

2.THICKNESS MA MEASUREMENT SAMPLE ------BHEL SPEC/DATA SHEETS------- -DO- 3,2 - -

3.ADHESION MA ADHESION TEST -DO- -DO- -DO- -DO- 3,2 - -

3.0 IN PROCESS

3.1 CORE ASSEMBLY 1.DIMENSION MA MEASUREMENT 100% PLANT STD. AS PER DRG. QC RECORD 2 - -

2.TORQUE MA -DO- 100% -DO- PLANT STD. 2 - -

TIGHTNESS

3.CORE MA ELECT. 100% -DO- -DO- -DO- 2 - -

INSULATION

4.CORE LOSS CR ELEC. WITH 100% RELEVANT STD RELEVANT STD -DO- 2 - 1
DUMMY COIL

3.2 COIL ASSEMBLY 1.DIMENSION MA MEASUREMENT 100% PLANT STD PLANT STD -DO- 2 - -

2.TURN OF TURN MA -DO- 100% -DO- -DO- -DO- - 2 -

INSULT.

3.MEASUREMENT MA ELECT.TEST 100% -DO- -DO- -DO- 2 - 1

OF RESISTANCE

PARTICULARS BIDDER/VENDOR
BHEL NAME
SIGNATURE
DATE BIDDER'S/VENDORS COMPANY SEAL

Page 23 of 35
 CUSTOMER : PROJECT SPECIFICATION :
TITLE NUMBER :
QUALITY PLAN BIDDER/ : QUALITY PLAN SPECIFICATION :
VENDOR NUMBER PED-302-00-Q-001/01 TITLE
SHEET 5 OF 6 SYSTEM ITEM :OIL FILLED TRANSFORMER SECTION VOLUME III
SL. COMPONENT/OPERATION CHARACTERISTICS CAT. TYPE/ EXTENT OF REFERENCE ACCEPTANCE FORMAT AGENCY REMARKS
NO. CHECK METHOD OF CHECK DOCUMENT NORM OF RECORD
CHECK P W V

1 2 3 4 5 6 7 8 9 10 11

3.3 CORE-COILASSEMBLY 1.PHY. CONDITION CR VISUAL 100% PLANT STD PLANT STD -DO- 2 - 1
(FINAL DRYING & OIL OF COILS
FILLING
2.DIMENSION CR MEASUREMENT 100% APPD. DRG. APPD. DRG. -DO- 2 - 1

3.BRAZING CR VISUAL, MALLET 100% PLANT STD PLANT STD -DO- 2 - 1

CONNECTION TO MV DROP TEST
TAPCHANGER

4.CLEARANCES CR MEASUREMENT 100% APPD. DRG. APPD. DRG. -DO- 2 - 1

5.DRYNESS (TAN CR ELECT. TEST 100% BHEL SPEC/ BHEL SPEC/ -DO- 2 - 1
DELTA & I.R. PLANT STD PLANT STD
APPD DATA SHEET APPD DATA SHEET

6.TURNS RATIO CR ELECT.TEST 100% -DO- -DO- -DO- 2 - 1

4.0 MARSHALLING KIOSK/BOX 1.DIMENSION MA MEASUREMENT 100% MANUF. STD MANUF. STD INSP. 3,2 - -
REPORT

2.DEGREE OF CR TESTING 1/TYPE MANUF'S DRG/DATA SHEET -DO- 3,2 - 1

PROTECTION

3.PROPER MA VISUAL 100% BHEL/MANUF DRG BHEL/MANUF DRG -DO- 3,2 - -

FITNESS & WIRING

5.0 OLTC/TAP SWITCH 1.SURFACE MA VISUAL 100% BHEL SPEC. BHEL SPEC. -DO- 2 - 2
FINISH MANUF DRG. MANUF DRG.

PARTICULARS BIDDER/VENDOR
BHEL NAME
SIGNATURE
DATE BIDDER'S/VENDORS COMPANY SEAL

Page 24 of 35
 CUSTOMER : PROJECT SPECIFICATION :
BHEL TITLE NUMBER :
QUALITY PLAN BIDDER/ : QUALITY PLAN SPECIFICATION :
VENDOR NUMBER PED-302-00-Q-001/01 TITLE
SHEET 6 OF 6 SYSTEM CABLE ITEM :OIL FILLED TRANSFORMER SECTION VOLUME III
SL. COMPONENT/OPERATION CHARACTERISTICS CAT. TYPE/ EXTENT OF REFERENCE ACCEPTANCE FORMAT AGENCY REMARKS
NO. CHECK METHOD OF CHECK DOCUMENT NORM OF RECORD
CHECK P W V

1 2 3 4 5 6 7 8 9 10 11

2.ROUTINE TEST CR ELECT. 100% -DO- -DO- TEST CERT 3,2 - 2,1

3.(FOR OLTC) CR ELECT. SAMPLE -DO- -DO-

6.0 FINAL ASSEMBLY 1.ROUTINE TEST CR ELECT 100% AS PER BHEL SPEC. IS 2026 TEST 2 1 -
APPROVED DRG. DATA SHEET REPORT

2.TYPE TEST CR ELECT 1 FOR -DO- -DO- -DO- 2 1 -

EACH TYPE

3.LAYOUT AND MA VISUAL 100% -DO- -DO- INSP. 2 1 -

ORIENTATION REPORT

4.DIMENSION MA MEASUREMENT 100% -DO- -DO- -DO- 2 1 -

5.GEN. APPEARANCEMA VISUAL 100% -DO- -DO- -DO- 2 1 -

FINISH AND WORK
MANSHIP

6.CORRECTNESS MA VISUAL 100% -DO- -DO- -DO- 2 1 -

& COMPLETENESS
OF ALL FITTINGS &
ACCESSORIES

7.FUNCTION OF CR FUNCTIONAL 100% -DO- -DO- -DO- 2 1 -

ACCESSORIES CHECKS

8.PAINT SHADE MA VISUAL, MEAS 100% -DO- -DO- -DO- 2 1 -

THICKNESS &
ADHESION

7.0 PACKING 1.SOUNDINGS OF MA VISUAL 100% BHEL SPEC BHEL SPEC -DO- 2 - 1
PACKINGS

NOTE:

LEGEND : P : PERFORMER W: WITNESSER V: VERIFIER (1) BHEL/BHEL's CUSTOMER: 2-VENDOR : 3 SUB VENDOR

PARTICULARS BIDDER/VENDOR
BHEL NAME
SIGNATURE
DATE BIDDER'S/VENDORS COMPANY SEAL

Page 25 of 35
 TITLE : Technical Specification For
4000KVA, 33/0.433 kV Transformer(Oil Filled)

ANNEXURE - VI

SPECIAL TOOLS AND TACKLES REQUIRED FOR INSTALLATION,

COMMISSIONING AND MAINTENANCE OF EQUIPMENT

S.NO. DESCRIPTION QUANTITY

Note:

Bidder shall furnish the list of special tools & tackles and quantity along with the
offer. Price shall be included in the total bid price.

Page 26 of 35
 TITLE : Technical Specification For
4000KVA, 33/0.433 kV Transformer(Oil Filled)

ANNEXURE –VII

COMMISSIONING SPARES FOR EACH TRANSFORMER

S.NO. DESCRIPTION QUANTITY REMARKS

Note:

Bidder shall furnish the list of commissioning spares and quantity for each type of
transformer along with the offer. Price shall be included in the transformer price.

Page 27 of 35
 TITLE : Technical Specification For
4000KVA, 33/0.433 kV Transformer(Oil Filled)

ANNEXURE - VIII
APPLICABLE STANDARDS & CODES FOR TRANSFORMERS

Specification for power IS: 2026 [ ] IEC: 76 [ ] BS: 171 [ ]

transformers
IS:6600 [ ] IEC:354 [ ] IS: 11171 [ ]
Fittings & accessories for power IS: 3639 [ ] IEC: [ ] BS: [ ]
transformer

Specification for new insulation IS: 335 [ ] IEC: 296 [ ] BS: 148 [ ]
oil

Bushing for alternative voltage IS: 2099 [ ] IEC: 137 [ ] BS: 223 [ ]
above 1000 volts

Dimension for porcelain IS: 3347 [ ]

transformer bushings

Current transformers IS: 2705 [ ] IEC: 185 [ ] BS: 3938 [ ]

Gas operated relays IS: 3637 [ ]

Classification of insulating IS:1271 [ ] IEC: 216 [ ]

material for electrical machinery
& apparatus in relation to their
thermal stability in service

Classification of degrees of IS: 12063 [ ] IEC: 529 [ ] IS: 13947 [ ]

protection provided by
enclosures of electrical
equipment
Method of high voltage testing IS: 2071 [ ] IEC: 60 [ ]

Colours for ready mixed paints & IS: 5 [ ]

enamels

Specifications for power & CBIP Publication No275(1999 edition) [ ]

distribution transformers

Guide for loading of oil immersed IS: 6600 [ ] IEC: 354 [ ] BS: [ ]
transformers

Noise level NEMA, STANDARD-TR1

Page 28 of 35
 TITLE : Technical Specification For
4000KVA, 33/0.433 kV Transformer(Oil Filled)

(DATA SHEET-A) for 33/0.433 kV

S. No. Description Unit Particulars

1.0 Quantity 2 4000 kVA

2.0 Service (Unit/Station) Unit/Station

3.0 Installation Out Door

4.0 Type of insulating oil Mineral

5.0 No. of phase No(s) 03

6.0 Frequency Hz 50

7.0 Type of cooling ONAN

8.0 Rated output under site

conditions kVA As indicated

9.0 Rated Voltage

a) HV Winding kV 33.0
b) LV Winding kV 0.433

10.0 No Load transformation ratio 33/0.433

11.0 Vector group Dyn11

Primary (HV) should be delta connected& secondary (LV) should be
Star connected. The load consists of welding generators, welding
Transformers, induction motors& lighting load.

12.0 Impedance voltage at rated

current and frequency Impedance voltage at rated
current and frequency
should be given along with the
offer meeting the requirement
of system fault level& voltage
regulation.

Page 29 of 35
 TITLE : Technical Specification For
4000KVA, 33/0.433 kV Transformer(Oil Filled)

13.0 Total range of tapping and

tapping steps Tappings of the OLTC should be
suitable for +5% to -5% with 4 or 5
steps.

14.0 Type of tap changing equipment OLTC

15.0 Temperature rise

a) Top oil by thermometer deg. C 50 deg. C above
ambient of 50 deg.C
b) Winding by resistance deg. C 55 deg. C above
ambient of 50 deg.C
16.0 System Highest Voltage
a) HV Winding kV 36
b) LV Winding V 433

17.0 Phase Connection

a) HV Winding Delta
b) LV Winding Star

18.0 Insulation Levels

18.1 One minute power frequency withstand voltage

a) HV Winding kV 70
b) LV Winding kV 03

18.2 Impulse withstand voltage

a) HV Winding kV 170
b) LV Winding kV -

19.0 Terminal details

a) HV Line Cable box(XLPE cables)
b) HV Neutral N.A.
c) LV Line Should be suitable for cable.
Flange throat for TPN non-
Segregated AI Busduct
d) LV Neutral One neutral as part of LV
busduct throat and second
neutral with copper earthing
bar for system earthing
brought near the base of
the transformer.

Page 30 of 35
 TITLE : Technical Specification For
4000KVA, 33/0.433 kV Transformer(Oil Filled)

20.0 System Fault Level

a) HV Winding kA 40 kA RMS.
b) LV Winding kA 50 kA RMS

21.0 Method of System Earthing

a) HV System Low resistance earthed to
limit earth fault current to
300-1000A

b) LV System Solidly grounded

c) Through fault withstand time Sec. 2

22.0 Details of Cooling Equipment Detachable tank mounted radiators

23.0 Provision/ accommodation of CTs

LV Neutral CT are to be provided for
protection. The details of
current transformers for
protection system to be
given along with the offer.

24.0 Colour Shade:

a) Interior (For M. Box) As required
b) Exterior As required

25.0 Space/ Layout Limitation if Any

26.0 Cable details

a) HV side
i) Type XLPE
ii) Voltage Grade 33KV Unearthed
iii) Conductor material & size Details to be submitted
along with the offer.
iv) No. of cores & runs Three core, one run
b.)LV side(suitable provision is to be made for cable connection)
i.)Type XLPE Cable
ii.) Voltage Grade 1.1KV
iii.) Conductor material and size Details to be submitted
alongwith the offer
iv.) No. of cores and runs Three and a half
core, one run
27.0 Penalty for Losses

Page 31 of 35
 TITLE : Technical Specification For
4000KVA, 33/0.433 kV Transformer(Oil Filled)

a) Rates for bid evaluation N.A.

b) ‘A’ (for no load loss) Losses not to exceed max.
losses as per annex-III to sec-
B of the specification
‘B’ (for load losses) - Do-
c) Rates for penalty

i) ‘A’ (for no load loss) Rs. 1.95 lacs per kW

ii) ‘B’ (for load loss) Rs. 1.95 Lacs per kW

Page 32 of 35
 TITLE : Technical Specification For
4000KVA, 33/0.433 kV Transformer(Oil Filled)

DATA SHEET-B

(TO BE SUBMITTED ALONG WITH OFFER)

FOR 33kV/0.433V, 4000 KVA

S.No. Description Remarks

1 Rating

2 No Load transformation ratio

3 Maximum No- load losses at rated

frequency and 100% rated voltage

4 Maximum load losses at normal ratio,

rated current and 75 deg. C

5 Overall Dimensions

6 Total weight

7 Total oil Quantity

Page 33 of 35
 TITLE : Technical Specification For
4000KVA, 33/0.433 kV Transformer(Oil Filled)

SCHEDULE OF DEVIATIONS

Sl. No Specification Clause Ref. Technical Deviation Reason for Deviation

We the undersigned hereby certify that the above mentioned are the only
Technical deviations.

Particulars of bidder/Authorized representative:

NAME Designation Signature Date COMPANY SEAL

Page 34 of 35
 TITLE : Technical Specification For
4000KVA, 33/0.433 kV Transformer(Oil Filled)

ANNEXURE – IX

QUALIFYING CONDITIONS

Only those vendors who have designed, manufactured, supplied and

commissioned at least two number 4000 KVA, 33KV/0.433KV, 3-phase, Oil type
Transformers (out door installation) with in last ten years should quote. The
Transformers should be working satisfactorily for more than one year after
commissioning. However, if such Transformer(s) have been supplied to BHEL,
then the same should be presently working satisfactorily for more than six
months after its commissioning and acceptance in BHEL. Following information
should be submitted by the vendor about the companies where above
Transformers have been supplied. This is required from all the vendors for
qualification of their offer.

1. Name of the customer / company where the Transformer is installed.

2. Complete postal address of the customer.
3. Year of commissioning.
4. KVA Rating of the Transformer.
5. Name and designation of the contact person of the customer
6. Phone, FAX no. and email address of the contact person of the customer.
7. Performance certificate from the customers regarding satisfactory performance
of Transformer supplied to them (Original Certificate or Through E-mail directly
from the customer). The original performance certificate may be returned after
verification by BHEL, if required by vendor.

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