Publication No.

317

Manual on
Transformers

Editors
M. Vijayakumaran
V.K. Lakhiani
V.K. Kanjlia
P.P. Wahi

Central Board of Irrigation & Power

Malcha Marg, Chanakyapuri, New Delhi 110021

April 2013
2013

ISBN 81-7336-324-2

“Reproduction of any part of this publication in any form is permissible subject to proper
acknowledgement and intimation to the publisher. The publisher/author/editors have taken
utmost care to avoid erros in the publication. However, the publisher/author/editors are in no
way responsible for the authenticity of data or information given in the book.”

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 Expert Group
CHAIRMAN

Shri M. Vijayakumaran
Sr. Technical Expert
ALSTOM T&D India Ltd
Naini, Allahabad 211008

SUB-GROUP CONVENORS

Shri P. Ramachandran Shri M.M. Goswami

Sr. Advisor - Design & Development General Manager
Power Transformers Division Power Grid Corporation of India Ltd.
ABB Ltd., Maneja Saudamini, Plot No. 2, Sector 29
Vadodara – 390013 Gurgaon – 122001

Shri Dinkar Devate Shri Sanjay Kar Chowdhury

General Manager Sr. Dy. Manager
NTPC Ltd. CESC Ltd.,
A-8A, Sector 24 Poddar Court
Noida – 201301 18, Rabindra Sarani
Kolkata – 700001
Shri A. Kulshreshtha
Addl. General Manager Ms. Elizabeth Johnson
Bharat Heavy Electricals Ltd. Sr. Manager - Technical Solution Group
BHEL, Jhansi (U.P.) – 284129 Alstom Grid
Plot No.46, Zuzuwadi Village
Shri S.K. Mahajan SIPCOT
Dy. General Manager (TRE) Industrial Complex
Bharat Heavy Electricals Ltd. Hosur 635 126
Piplani, Tamil Nadu
Bhopal (M.P.) – 462022

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 Members

Shri Mata Prasad Shri V.K. Lakhiani

Founder President CIGRE India Technical Director
5/100, Vinay Khand Transformers and Rectifiers (India) Limited
Gomti Nagar Survey No. 427 P/3-4, & 431 P/1-2
Lucknow 226010 Sarkhej-Bavla Highway, Moraiya,
Taluka: Sanand, Dist. Ahmedabad–382213

Shri Ratish Kumar Shri R.K. Tiwari

Executive Director – Design E&M General Manager (TCB)
NHPC Ltd. Bharat Heavy Electricals Ltd.
NHPC Office Complex, Sector 33 Piplani,
Faridabad – 121003 Bhopal – 462022

Shri S.K. Ray Mohapatra Shri Y.V. Joshi

Director Executive Engineer – Equip. Engg.
Central Electricity Authority Gujarat Energy Transmission Corp. Ltd.
Sewa Bhavan, R.K. Puram Sadar Patel Vidyut Bhavan
New Delhi 110066 Race Course, Vadodara – 390007

Shri B.V. Raghavaiah Shri Ranjan Banerjee

Unit head General Manager – Technical Services and
Central Power Research Institute R&D – Engg. & Technology
Switchgear Testing & Development Station Larsen & Toubro Limited
Govindpura, Bhopal – 462023 Vadodara - 390 019, Gujarat

Shri M.L. Jain Shri V.M. Varkey

Sr. Vice President (Technology & Quality) Head – Transformer Design
Transformer Business Unit Siemens Ltd.
EMCO Ltd. Transformer Works,
Plot No. F-5, Road No. 28 Thane Belapur Road
Wagle Industrial Estate, Thane (W) 400604 Airoli, Navi Mumbai – 400708

Shri Amit Mittal Shri Anilkumar Bhatia

Addl. General Manager Deputy General Manager -
NTPC Ltd. Design & Technology
A-8A, Sector 24 Crompton Greaves Limited
Noida – 201301 Kanjur Marg (East), Mumbai 400 042

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Shri S. Victor P. Selvakumar Shri J.S. Kuntia
Addl. General Manager (OS) AGM – Design
Power Grid Corporation of India Ltd. BHEL
Plot No. 2, Sector 29, Piplani,
Gurgaon, Haryana Bhopal (M.P.)

Shri R.K. Tyagi Shri Aseem Dhamija

Dy. General Manager AGM (Bushing,Capacitor
Power Grid Corporation of India Ltd. & Instrument Trfr Engg.)
Saudamini, Plot No. 2, Sector 29 BHEL,
Gurgaon – 122001 Bhopal (M.P.)

Shri Sudhir Agarwal Shri S.K. Gupta

Dy. General Manager Dy. General Manager (TRE)
Power Grid Corporation of India Ltd. Bharat Heavy Electricals Ltd.
Saudamini, Plot No. 2, Sector 29 Piplani
Gurgaon – 122001 Bhopal – 462022

Shri T.K. Ganguly Shri N.K. Dahiwale

Sr. General Manager – Engg. DGM – Manufacturing Transformers
EHV Power Transformers Division BHEL,
Vijai Electricals Ltd. Piplani,
Rudraram – 502329, A.P. Bhopal (M.P.)

Shri Oommen P. Joshua Shri R.K. Mohapatra

General Manager (Technical) DGM – TRE
TELK Bharat Heavy Electricals Ltd.
(A joint Venture of Govt. of Kerala & NTPC Piplani,
Ltd), Angamally, Kerala – 683573 Bhopal – 462022

Dr. K. Rajamani Shri Pradeep Singh

Chief Consultant Manager
Reliance Infrastructure Ltd Bharat Heavy Electricals Ltd.
DAKC, I Block, North Wing, Thane Belapur Piplani,
Road, Koparkhairane, Bhopal – 462022
Navi Mumbai - 400 709

Shri B.M. Mehra Shri Manish Kumar

Joint Director Bharat Heavy Electricals Ltd.
Central Power Research Institute Piplani,
Noida Bhopal – 462022

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Shri. N.G. Patel Shri R.S. Thakkar
Divisional Engineer – Testing Junior Engineer
Gujarat Energy Transmission Corp. Ltd. Gujarat Energy Transmission Corp. Ltd.
Sadar Patel Vidyut Bhavan Sadar Patel Vidyut Bhavan
Race Course, Vadodara – 390007 Race Course, Vadodara – 390007

Shri Vibhu Tripathi Shri A.K. Panwar

Assistant Director – I, DP&D Assistant Director – I DP&D
Central Electricity Authority Central Electricity Authority
Sewa Bhavan, R.K. Puram Sewa Bhavan, R.K. Puram
New Delhi 110066 New Delhi 110066

Shri Gunjan Agrawal Shri Minal Kataria

Manager NTPC Ltd.
Power Grid Corporation of India Ltd., A-8A, Sector 24
Plot No. 2, Sector 29, Gurgaon, Haryana Noida – 201301

Shri K. Jayakrishnan Shri Govind Srivastava

NHPC Ltd. Sr. Manager
NHPC Office Complex Siemens Ltd.
Sector 33 Transformer Works,
Faridabad – 121003 Thane Belapur Road,
Haryana Airoli, Navi Mumbai– 400708

Miss Tanvi Srivastava Ms. Mary Mody

Dy. General Manager General Manager
Alstom, Allahabadad EMCO Ltd, Thane

Shri Pramod Srivastava Ms. Anagha Dixit

Dy. General Manager (Design) General Manager - Engineering (E)
Alstom T&D India Limited EMCO Limited

Shri Abhilash Mishra Shri Meet Patel

Alstom T&D India Ltd. L&T Power Ltd.
Vadodara Vadodara

Shri Pravin Jain Shri T. Murlikrishna

Chief Manager (Corp Engineering) Chief Manager (Testing)
The Tata Electric Company The Tata Electric Company
Mumbai Mumbai

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Shri Tarun Garg Shri Vikrant Joshi
Design Head, Power Transformers Crompton Greaves Ltd.
ABB Ltd Mumbai

Shri Abhay Agrawal Shri Manish Yadav

Design Head, Small Power Transformers DGM – Design Testing
ABB Ltd. Crompton Greaves Ltd.

Shri Maneesh Jain Ms. Shubhangi Kulkarni

Business Unit manager - Bushings Sr. Manager Design
ABB Limited Crompton Greaves Ltd.
Maneja, Vadodara - 390013, Gujarat Mumbai

Shri Surojit Roy Shri Prasenjit Paul

Director Head – Technology
Schneider Electric Infrastructure Ltd. Schneider Electric Infrastructure Ltd.
Naini, Allahabad Naini, Allahabad

Shri Subrata Dutta Shri Sameer Gaikwad

Schneider Electric Infrastructure Ltd. Manager, Regional Sales – South Asia
Naini, Doble Engineering Company
Allahabad 2nd Floor “Suvidhi Pride”, Gorwa Refinery
Road, Vadodara 390 003

Shri R.V. Talegaonkar Shri Rakesh Sardana

President President & CEO
Group I Skipper Electricals (India) Ltd.
CTR Mfg Ind Ltd F-667-668, RIICO Indl. Area Ph-II
Nagar Road, Pune 411014 Bhiwadi 301019 Distt. Alwar

Shri S.A. Rajan Shri R. Prakash

Sr. Design Manager Head - Mktg & Service
CTR Mfg. Ind Ltd. Easun - MR Tap Changers Pvt. Ltd.
Nagar Road, 612, (232) M.T.H Road
Pune Thiruninravur - 602 024, Chennai

Shri B.D. Raut Shri D.M. Jadhav

Sr. Development Manager Sr. Applications Manager
CTR Mfg. Ind Ltd. CTR Mfg. Ind Ltd.
Pune Pune

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Shri V.K. Kanjlia Shri P.P. Wahi
Secretary Director
Central Board of Irrigation & Power Central Board of Irrigation & Power
Malcha Marg, Chanakyapuri Malcha Marg, Chanakyapuri
New Delhi 110021 New Delhi 110021

Shri Manish Kataria Shri S.K. Batra

Jt. General Secretary Sr. Manager (Technical)
Hydraulic Trailers Owner’s Association Central Board of Irrigation & Power
(HTOA) Malcha Marg
429, Vyapar Bhavan, P. D’Mello Road, Chanakyapuri
Mumbai 400 009 New Delhi 110021

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 Message

Central Board of Irrigation and Power (CBIP) has been playing a key role to
disseminate the latest technological advancement information covering almost
all aspects of power and renewable sector and it was in 1976, CBIP brought out
detailed first edition of the Transformer Manual.

I understand that the manual issued by CBIP is being widely used by power
engineers as a reference book in the country & elsewhere.

I am happy to note that this manual is being revised/updated now under the
chairmanship of Shri M. Vijayakumaran, Sr. Technical Expert, ALSTOM
T&D India Ltd. and with the help of Expert Group members from all eminent
organizations in the country. This contains the latest updated technological
information on the subject of Transformer.

I congratulate CBIP and all experts of the Expert Group for bringing out this
manual covering latest state-of-art technology and I am sure that this document
will be of great benefit to engineering fraternity as a reference book.

A.S. Bakshi

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 PREFACE
“Manual on Transformers” is the most popular publication
of CBIP. It has been widely appreciated by practising
transformer engineers associated with all facets of
transformers: Design, Materials, Manufacturing, Testing,
Erection and Commissioning. Utility Engineers and End
users have also found this manual, a good guide and
reference book.

Although the transformer is a matured product of Electrical Engineering with

matured science and technology, yet, to keep pace with the needs of changing
times, several technological advancements take place on continuous basis.

To keep pace with the fast changing technology, it is desired that this Manual is
updated from time to time, at least once in 5 years.

Third Revision was undertaken in 2005 with a reprint in 2007 with minor
modifications.

The working group reconstituted in 2012 with experts drawn from Indian
Utilities, Institutes, Transformer Manufacturers etc. reviewed the Manual and
finalized modifications for Fourth revision to be published now in 2013.

The manual is reformatted and divided in to two Volumes: Vol. I to cover

specifications of standard transformers and Vol. II to include various guidelines
and specifications of fittings and accessories used in the transformers. Chapters
have been reorganized in these two volumes being published together.

In this revision, existing sections have been updated as recommended by the

Expert group. New sections viz. 420 kV & 800 kV Shunt reactors, Furnace
transformers, Rectifier Transformers, Traction Transformers etc. have been
added. A chapter on new technologies describing Smart Transformers, UHV
Transformers, Phase shifting transformers etc. has been included to indicate
emerging trends in Technology. A chapter on Reference standards and Books

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also has been added to facilitate readers to locate the standards, as a ready
reckoner.

Technology evolves dynamically. Full-fledged revision is a voluminous task. It

is decided that the revision of Manual shall be normally undertaken in 5 years’
time span. However, a core group has been formed to address urgent amendments
to make the Volumes updated all the time.

Core group shall welcome suggestions / improvements / amendment proposals

from the distinguished users of this Manual.

I am sure that the users will find the Fourth Edition of the Manual more
meaningful.

M. Vijayakumaran
Chairman of the Expert Group

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 Foreword
With the Indian economy growing year by year, the target of
providing reliable power supply to consumers is becoming
increasingly important. To meet this challenge new power
stations are being added and T&D networks are continuously
being strengthened.
As you know, the transformer is one of the most important
and vital asset in a power system. Reliability and availability
of such an asset plays an important role in the operation of
a power system. Emphasis needs to be laid on improved design, quality control
during manufacturing, use of right components / accessories, maintenance and
safety during operation of such vital equipment. The adoption of state-of-art
technology for important components like bushings & OLTC which have been
the major items causing failure of transformer is the urgent need for all concerned
professionals. The review of the protection philosophy would further improve
the performance of the system. The residual life assessment and condition
monitoring of the transformers will also add reliability to the power system.
CBIP has brought out the first Manual on Transformers in 1976. This was updated
in 1987, 1999, 2005 and again in 2007. To incorporate the latest developments
and innovations, this manual has again been updated and new sections viz. 420
kV & 800 kV Shunt reactors, Furnace transformers, Rectifier Transformers,
Traction Transformers etc. have been added. A chapter on new technologies
describing Smart Transformers, UHV Transformers, Phase shifting transformers
etc. have also been included to indicate emerging trends in Technology. For
updating this manual, CBIP had constituted the Expert Group, comprising of
highly experienced engineers from large power utilities, designs organization,
manufacturers etc. This group was headed by Shri M. Vijayakumaran, National
Representative in CIGRE Study Committee A2 on Transformers and Sr. Technical
Expert, ALSTOM T&D India Ltd., who is recipient of many National and
International awards. The expert group after working ceaselessly brainstorming/
working for more than one year have helped CBIP in updation of this document
covering all aspects of Transformers for various voltages as mentioned above.
The Central Board of Irrigation & Power wishes to acknowledge the valuable
contributions made by Shri M. Vijayakumaran, Chairman of the Expert Group

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for revision of this manual. Contribution made by Shri Virendra K. Lakhiani,
Technical Director, Transformers and Rectifiers (India) Limited is deserves
special mention, who has put in the best efforts for updation and synthesizing
this manual.
Our thanks are also due to Conveners Shri P. Ramachandran, Sr. Advisor - Design
& Development, Power Transformers Division, ABB Ltd., Shri M.M. Goswami,
General Manager, Power Grid Corporation of India Ltd., Shri Dinkar Devate,
General Manager, NTPC Ltd., Shri R.K. Tiwari, General Manager (TCB), Bharat
Heavy Electricals Ltd., Shri A. Kulshreshtha, AGM (TRE-SPTR, FES, RPD
& T), Bharat Heavy Electricals Ltd., Shri S.K. Mahajan, DGM (TRE), Bharat
Heavy Electricals Ltd., Ms. Elizabeth Johnson, Sr. Manager - Technical Solution
Group, Alstom Grid, Shri Sanjay Kar Chowdhury, Sr. Dy. Manager, CESC Ltd.
& Members of all the Sub-Group for revision of this manual.
Contibution made by Shri R.K. Tyagi, Dy. General Manager, Power Grid
Corporation of India Ltd., Shri Ranjan Banerjee, General Manager – Technical
Services and R&D – Engg. & Technology, Larsen & Toubro Limited, Shri S.K.
Ray Mohapatra, Director, Central Electricity Authority, Shri B.V. Raghavaiah,
Unit Head, CPRI, Bhopal, Shri M.L. Jain, Sr. Vice President (Technology &
Quality), Transformer Business Unit, EMCO Ltd., Shri Y.V. Joshi, Executive
Engineer – Equip. Engg., Gujarat Energy Transmission Corp. Ltd., Shri
Anilkumar Bhatia, Deputy General Manager - Design & Technology, Crompton
Greaves Limited needs special mention.
I also appreciate the dedication & the contribution made by Shri S.K. Batra, Sr.
Manager, CBIP for getting this document revised.
I trust that this manual would cover the existing knowledge gap on this subject
and help the practising engineers in the power sector as well as students in the
technical institutions in enhancing their technical skills.

V.K. Kanjlia
Secretary
Central Board of Irrigation and Power

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 CONTENTS
Page
Preface (v)
Foreword (vii)

Vol I: Standard Specifications of Transformers

SECTION A General 3
SECTION B Specifications for Outdoor type, Completely Self protected,
3 Phase Distribution Transformers (up to and including 100 kVA) 41
SECTION C Specifications for Outdoor type, Completely Self Protected,
Single Phase Distribution Transformers (Single Phase
11 kV/250 V & 11/√3 kV/250 V, 5, 10, 16 & 25 kVA ratings) 57
SECTION D Specifications for Three Phase Distribution Transformers
(above 100 kVA and up to 33 kV class) 71

SECTION E Specifications for Power Transformers of

Voltage Class below 145 kV 83
SECTION F Specifications for 145 kV Class Power Transformers 91
SECTION G Specifications for 245 kV Class Power Transformers 99
SECTION H Specifications for 420 kV Class Power Transformers 107
SECTION I Specifications for 800 kV Class Power Transformers 119
SECTION J Specification for 420 kV class Shunt Reactors and
associated 145 kV Neutral Grounding Reactors 129
SECTION K Specifications for 800 kV class Shunt Reactors and
associated 145 kV Neutral Grounding Reactor 145
SECTION L Specifications for Earthing Transformers 155
SECTION M Specifications for Furnace Transformers 165
SECTION N Specifications for Rectifier Transformers 175
SECTION O Specifications for Electrostatic Precipitator Transformers 185
SECTION P Specifications for Traction Transformers 191
SECTION Q Specifications for Dry type Transformers 197

Vol II: Application, Standard Fittings and Accessories

SECTION AA Capitalization Formula for Transformer Losses 211
SECTION BB Test Requirements for Transformers 215

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SECTION CC Guidelines for Erection, Commissioning and Maintenance 277
SECTION DD Guidelines for Condition Monitoring and Diagnostic
Techniques for Power Transformers and Reactors 347
SECTION EE Guidelines for Fire Protection of Power Transformers 371
SECTION FF Guidelines for Repair of Power Transformers at Site 386
SECTION GG Guidelines for Voltage Control of Power Transformers 409
SECTION HH Guidelines for Protective Schemes for Power and
Distribution Transformers 427
SECTION II Specifications for Transformer Bushings up to
1200 kV Voltage Class 439
SECTION JJ Specifications for Valves for Transformers 455
SECTION KK Specifications for Cable Boxes for SF6 Gas Insulated
Transformer Terminations for Rated Voltages of
72.5 kV and above 463

APPENDICES
APPENDIX-I New Technologies, UHV AC/DC Transformers, Phase Shifting
Transformers, Controlled Shunt Reactors 479
APPENDIX-II Reference Standards and Books 503
APPENDIX-III Typical Quality Assurance Plan 523
APPENDIX-IV Guaranteed Technical and Additional Technical particulars 527
APPENDIX-V List of Transformer Accessories and test certificates required 537
APPENDIX-VI Design Review Parameters 543
APPENDIX-VII Salient Technical Specifications and Particulars of Power
Transformers for Power Plant Application 549
APPENDIX-VIII Test Windings for Bushing Current Transformers 559
APPENDIX-IX Pictures of Transformer Installations 563

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 Vol. I
Standard Specifications of Transformers
SECTION A

General
 SECTION A
General
1.0 GENERAL DESIGN OF APPARATUS

1.1 Compliance with Specifications

1.1.1 Except where otherwise specified or implied herein, the transformers shall comply with
the latest edition of Indian Standard 2026 (hereinafter referred to as “IS”).

1.2 Design and Standardization

1.2.1 The transformer and accessories shall be designed to facilitate operation, inspection,
maintenance and repairs. All apparatus shall also be designed to ensure satisfactory operation
under such sudden variations of load and voltage as may be met with under working conditions
on the system, including those due to short circuits.

1.2.2 The design shall incorporate every reasonable precaution and provision for the safety
of all those concerned in the operation and maintenance of the equipment keeping in view the
requirements of Indian Electricity Rules.

1.2.3 All material used shall be of the best quality and of the class most suitable for working
under the conditions specified and shall withstand the variations of temperatures and atmospheric
conditions arising under working conditions without undue distortion or deterioration or the
setting up of undue stresses in any part, and also without affecting the strength and suitability of
the various parts for the work which they have to perform.

1.2.4 Corresponding parts liable to be replaced shall be interchangeable.

1.2.5 Cast iron shall not be used for chambers of oil filled apparatus or for any part of the
equipment which is in tension or subject to impact stresses. This clause is not intended to
prohibit the use of suitable grades of cast iron for parts where service experience has shown it to
be satisfactory, e.g., large valve bodies.

1.2.6 All outdoor apparatus, including bushing insulators with their mountings, shall be
designed so as to avoid pocket in which water can collect.

1.2.7 Means shall be provided for the easy lubrication of all bearings and where necessary of
any mechanism or moving part, that is not oil immersed.

1.2.8 All mechanism shall, where necessary, be constructed of stainless steel, brass or gunmetal
to prevent sticking due to rust or corrosion.

1.2.9 All taper pins used in any mechanism shall be of the split type complying with IS: 2393
for these items.

1.2.10 All connections and contacts shall be of ample section and surface for carrying
continuously the specified currents without undue heating and fixed connections shall be
secured by bolts or set screws of ample size, adequately locked. Lock nuts shall be used on stud
5
6 Manual on Transformers

connections carrying current All leads from the winding to the terminal board and bushings shall
be adequately supported to prevent injury from vibration including a systematical pull under
short circuit conditions. Guide pulls shall be used where practicable.

1.2.11 All apparatus shall be designed to minimise the risk or accidental short-circuit caused by
animals, birds or vermin.
1.2.12 Provision shall be made to fix safety fence around top cover of transformers of rating
100 MVA and above, for safe working during installation and servicing for large capacity
transformers.

1.2.13 In tank on load tap changers shall be located such that the space above the diverter
switch chamber will be free of inter connecting pipes etc. for lifting the diverter switch unit for
inspection and maintenance purposes.

1.2.14 Dryness of the insulation may be ensured by measuring the water extraction during
vacuum drying. The water extraction per tonne of insulation per hour may be limited to 5030
grams maximum. Alternatively dryness can be judged by dew point measurement.

1.3 Galvanising

1.3.1 Galvanising where specified shall be applied by the hot-dipped process or by

clectrogalvanising process and for all parts other than steel wires shall consist of a thickness
of’zinc coating equivalent to not less than 610 gm of zinc per square meter of surface. The zinc
coating shall be smooth, clean and of uniform thickness and free from defects. The preparation
of galvanising and the galvanising itself shall not adversely affect the mechanical properties
of the coated material. The quality will be established by tests as per IS: 2633. Alternative to
galvanising, zinc spraying or aluminising can also be considered.

1.3.2 All drilling, punching, cutting, bending and welding of parts shall be completed, and all
burrs shall be removed before the galvanising process is applied.

1.3.3 Galvanising of wires shall be applied by the hot-dipped process and shall meet the
requirements of the relevant Indian Standard. The zinc coating shall be smooth, clean and of
uniform thickness and free from defects. The preparation for galvanising itself shall not adversely
affect the mechanical properties of the wire.

1.3.4 Surfaces which are in contact with oil shall not be eleclrogalvanised/cadmium plated.

1.4 Labels

1.4.1 Labels shall be provided for all apparatus such as relays, switches, fuses, contained in
any cubicle or marshalling kiosks.

1.4.2 Descriptive labels for mounting indoors or inside cubicles and kiosks shall be of material
that will ensure permanence of the lettering. A matt or satin finish shall be provided to avoid
dazzle from reflected light. Labels mounted on dark surfaces shall have white lettering on a
black background. Danger notices shall have red lettering on a while background.

1.4.3 All plates shall be of material which is corrosion resistant.

 General 7

1.4.4 Labels shall be attached to panels with brass screws or with stainless steel screws or
these can be stuck with suitable adhesive also.
1.5 Bolts and Nuts
1.5.1 Steel bolts and nuts exposed to atmosphere shall be of following material:
• Size 12 mm or below - stainless steel
• Above 12 mm - steel with suitable finish like electrogalvanised with passivation
/hot dip galvanised.
1.5.2 All nuts, bolts and pins shall be locked in position with the exception of those external
to the transformer, under gasket pressure.
1.5.3 All bolts, nuts and washers exposed to atmosphere and in contact with non-ferrous parts
which carry current shall be of phosphor bronze.
1.5.4 If bolts and nuts are placed so that they are inaccessible by means of ordinary spanners,
suitable special spanners shall be provided by the supplier.
1.5.5 Bolts and nuts shall not be less than 8 mm in diameter except when used for small wiring
terminals.
1.6 Cleaning and Painting
1.6.1 Before painting or filling with oil or compound, all ungalvaniscd parts shall be completely
clean and free from rust, scale and grease, and all external surface cavities on castings shall be
filled by metal deposition.
1.6.2 All blast cleaned surfaces (except machined faces that have to be protected) must be
cleaned in accordance with ISO specification no. ISO 8501 Part l (This standard specification
is based on and now supersedes Swedish Standard SIS 05 59 00) to a minimum standard of
‘ASa21/2’ or ‘BSa21/2’ prior to paint application.
1.6.3 External and internal surfaces of all transformer tanks and chambers and other fabricated
steel items shall be cleaned of scale, rust and surface dirt by blast cleaning or other suitable
approved method. After cleaning, these surfaces should be immediately covered with paint. Hot
oil resistant varnish on white synthetic enamel/epoxy paint is to be used for painting the inside
of all oil filled chambers, including transformer tanks. Only one thin layer (~ 25 microns) of this
is to be applied.
1.6.4 Except for hardware, which may have to be removed at site, all external surfaces shall
receive at least four coats of paint. The type and thickness of paint shall be chosen to suit
pollution level at site.
1.6.5 Selection of paint system for different environmental conditions shall be in line with
ISO: 12944.
1.6.6 For rural or mild atmosphere, alkyd enamel primer and finish system may be used in
four coats to give a total dry film thickness of at least 80 microns.
1.6.7 For urban or industrial situation two coats of epoxy zinc phosphate or zinc chromate
primer topped with two coats of aliphatic polyurethane glossy finish paint is recommended.
8 Manual on Transformers

The total dry film thickness should preferably be between 100 and 130 microns.

1.6.8 In case of highly polluted area, chemical atmosphere or at a place very near the sea
coast, paint as above with one intermediate coat of high build MIO (Micaceous iron oxide) as
an intermediate coat may be used to give a total dry film thickness of 150 to 180 microns.

1.6.9 All interior surfaces of chambers or kiosks that are in contact with air shall receive
at least three coats of paint, of which the topcoat shall be of a light shade. If heaters are not
provided in the chamber, then the top coat should be of anti condensation type.

1.6.10 Any scratch, bruise or paint damage incurred during transportation and unloading at
site should be made good by the purchaser as soon as the damage is detected. This is to be done
by thoroughly cleaning the damaged area and applying the full number of coats as was applied
originally. Manufacturer should supply the necessary paint for this touch up painting at site.

1.6.11 One coat of additional paint shall be given at site over all external surfaces, including
hardware, after erection by the purchaser. Supplier shall furnish necessary information on the
make and grade of the lop-coat paint. In general, it is possible to apply enamel paint over epoxy
polyurethane coating and the vice versa is not recommended. As far as possible the make and
grade of the recoat shall be same as the original coat.

1.7 Oil

1.7.1 The transformers and all associated oil-filled equipment shall normally be supplied
alongwith the first filling of oil and 5/10 percent (as per user requirement) excess quantity of
oil shall also be supplied in non-returnable drums. The oil shall conform to IS: 335 or IEC
60296 (as per user requirement). Alternatively, if the purchaser so desires, oil may be supplied
in tankers directly from the refinery for transformers which are dispatched from factory to site
in gas filled condition.

1.8 Prevention of Acidity

1.8.1 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.

Special measures, such as nitrogen sealing or the use of inhibited oil shall not be resorted to,
unless otherwise specified by the purchaser.

2.0 ELECTRICAL CHARACTERISTICS AND PERFORMANCE

2.1 Type of Transformers and Operating Conditions

2.1.1 All transformers, unless otherwise specified shall be oil immersed and may be either core
or shell type and shall be suitable for outdoor installation. Normally oil immersed transformer
shall be provided with conservator vessels. Where sealed transformers are specified, there shall
be no conservator but adequate space shall be provided for expansion of oil without developing
undue pressure. The types of cooling shall be as stated in the relevant specifications.
 General 9

2.1.2 Transformers designed for mixed cooling shall be capable of operating under the natural
cooled condition upto the specified load. The forced cooling equipment shall come into operation
by pre-set contacts in WTI and the transformer will operate as a forced cooled unit.

2.1.3 Transformer shall be capable of remaining in operation at full load for 10 minutes after
failure of the oil and/or water circulating pumps or blowers without the calculated winding
hot-spot temperature exceeding 140° C. Transformer fitted with two coolers each capable of
dissipating 50 percent of the losses at Continuous Maximum Rating (CMR) shall be capable of
remaining in operation for 20 minutes in the event of failure of the oil and/or water circulating
pumps or blowers associated with one cooler without the estimated winding hot-spot temperature
exceeding 140° C.

2.2 Continuous Maximum Rating and Overloads

2.2.1 Transformers provided with mixed cooling shall comply, as regards its rating, temperature
rise and overloads, with the appropriate requirements of IS: 2026 when operating with natural
cooling and with mixed cooling.

2.2.2 All transformers, except where stated shall be capable of operation continuously, in
accordance with IS loading guide at their CMR and at any ratio. In case bi-directional flow of
power is required, that shall be specifically stated by the purchaser.

2.2.3 Temperature rise test shall be performed at the tapping as desired by the purchaser. If
nothing has been stated by the purchaser, the test shall be carried out at the tapping with the
highest load losses.

2.2.4 The transformer may be operated without danger on any particular tapping at the
rated kVA provided that the voltage does not vary by more than ±10 percent of the voltage
corresponding to the tapping.

2.2.5 The transformer shall be suitable for continuous operation with a frequency variation of
±3% from normal 50 Hz. Combined voltage and frequency variation should not exceed the rated
V/f ratio by 10%.

Note: Operation of a transformer at rated kVA at reduced voltage may give rise to excessive tosses and temperature rise.

2.3 Voltage Ratio

2.3.1 The voltage between phases on the higher and lower voltage windings of each transformer
measured at no-load and corresponding to the normal ratio of transformation shall be those
stated in the ordering schedule.

2.3.2 Means shall be provided in accordance with clauses 8 and 9 for varying the normal ratio
of transformation.
10 Manual on Transformers

2.4 Electrical Connections

2.4.1 Transformers shall be connected in accordance with the IS vector symbol specified in
ordering schedule of the requirements.

2.4.2 Auto connected and star/star connected transformers shall have delta connected stabilising
windings if specified in the order. Two leads from one open comer of the delta connection
shall be brought out to separate bushings. Links shall be provided for joining together the two
terminals so as to complete the delta connection and earthing it external to the tank.

2.5 Duty under Fault Conditions

2.5.1 Except where modified below, it is to be assumed that the capacity of generating plants
simultaneously connected is such that normal voltage will be maintained on one side of any
transformer when there is a short-circuit between phases or to earth on the other side. Any
transformer may be directly connected to an underground or overhead transmission line and
switched into and out of service together with its associated transmission line.

2.5.2 All transformers shall be capable of withstanding any external short-circuit according to
IS: 2026 without damage.

2.5.3 Transformers with tertiary windings shall be capable of withstanding the mechanical
and thermal effects of any external short-circuit to earth with the short-circuit MVA available at
the terminals not exceeding the values given in the ordering schedule with the neutral points on
both HV and LV windings directly connected to earth as per the requirements of IS: 2026.

2.5.4 Transformers directly connected to generator (generator step-up transformers) shall be

designed for exceptional circumstances arising due to sudden disconnection of the load and shall
be capable of operating at approximately 25 percent above normal rated voltage for a period
not exceeding one minute and 40 percent above normal rated voltage for a period of 5 seconds.
However, the purchaser will install the over fluxing protection device in case of generator step-
up transformers.

Note : All inter-connected Transformers of 50MVA and above shall also be provided with over fluxing protection by
the purchaser.

2.6 Stabilising Windings

2.6.1 If specified in the order, the stabilising winding shall be capable of carrying continuously
the load specified therein.

2.6.2 The design of stabilising winding shall be such as to take care of the effect of transferred
surges and the tenderer shall offer suitable surge protection wherever necessary.
 General 11

2.7 Losses
2.7.1 The accepted losses of each transformer shall be stated in the order. The tolerance on the
losses of each transformer shall be in accordance with IS: 2026, except where maximum losses
are specified.
2.8 Regulation and Impedance
2.8.1 The impedance voltage at principal tap and rated kVA shall be stated in the order and
tolerance shall be in accordance with IS: 2026.
2.8.2 For all transformers, the value of impedance on any other tapping shall be generally
subject to the approval of the purchaser at the time of order. Any specific requirement may be
mentioned at the time of enquiry as a prequalification instead of at the time of order.
2.9 Flux Density
2.9.1 The maximum flux density in any part of the core and yokes, of each transformer at
normal voltage and frequency shall be such that the flux density in over-voltage condition as per
clause 2.2.5 shall not exceed 1.9 Tesla (19,000 lines per cm2).
However, in case of transformers with variable flux the voltage variation which would affect
flux density at every tap shall be kept in view while designing transformers.
2.10 Vibration and Noise
2.10.1 Every care shall be taken to ensure that the design and manufacture of all transformers
and auxiliary plant shall be such as to have minimum noise and vibration levels following good
modem manufacturing practices.
2.10.2 The manufacturers will ensure that the noise level shall not exceed the figures as per
NEMA Pub. No. TR - 1.
2.11 Suppression of Harmonics
2.11.1 All the transformers shall be designed with particular attention to the suppression of
harmonic voltage, especially the third and fifth, so as to eliminate wave-form distortion and
from any possibility of high frequency disturbances, inductive effects or of circulating currents
between the neutral points at different transforming stations reaching such a magnitude as to
cause interference with communication circuits.
3.0 CORES
The cores shall be constructed from high grade cold rolled non-ageing grain oriented silicon steel
laminations or Amorphous Metal. For medium rating transformers, the core may be constructed
of similar to M4 or better grade cold rolled non-aging grain oriented silicon steel laminations.
For larger rating transformers, core may be constructed from high-grade non-aging, cold rolled,
super grain oriented, silicon steel laminations similar to MOH / Hi-B steel or better grade.
The selection of Grade much depends upon loss capitalization formula(Section AA ) for an
optimized design and also upon stipulation in customer specification.
3.1 Magnetic Circuit
3.1.1 The design of the magnetic circuit shall be such as to avoid static discharges, development
of short-circuit paths within itself or to the earthed clamping structure and the production of flux
components at right angles to the plane of the laminations which may cause local heating.
12 Manual on Transformers

3.1.2 Every care shall be exercised in the selection, treatment and handling of core steel to
ensure that as far as is practicable, the laminations are flat and the finally assembled core is free
from distortion.

3.1.3 Adequate oxide/silicate coating is to be given on the core steel. However, laminations
can be insulated by the manufactures if considered necessary.

3.1.4 Oil ducts shall be provided where necessary to ensure adequate cooling. The winding
structure and major insulation shall not obstruct the free flow of oil through such ducts. Where the
magnetic circuit is divided into pockets by cooling ducts parallel to the planes of the laminations
or by insulating material above 0.25 mm thick, tinned copper strip bridging pieces shall be
inserted to maintain electrical continuity between pockets.

3.1.5 The framework and clamping arrangements shall be earthed in accordance with clause 5.2.

3.1.6 When insulation is provided for the core to core bolts and core to clamp plates, the same
shall withstand a voltage of 2000 2500 V AC for one minute.

3.1.7 Transformers shall withstand, without injurious heating, combined voltage & frequency
fluctuations, which produce the following over fluxing condition:

• 110 %- continuous
• 125%- for one minute
• 140%- for five seconds

3.2 Mechanical Construction of Cores

3.2.1 All parts of the cores shall be of robust design capable of withstanding any shocks to
which they may be subjected during lifting, transport, installation and service.
3.2.2 All steel sections used for supporting the core shall be thoroughly sand blasted or shot
blasted after cutting, drilling and welding. Any non-magnetic or high resistance alloy shall be of
established quality.
3.2.3 Adequate lifting lugs shall be provided to enable the core and windings to be lifted.
3.2.4 Adequate provision shall be made to prevent movement of the core and winding relative
to the tank during transport and installation or while in service.
3.2.5 The supporting framework of the cores shall be so designed as to avoid the presence of
pockets which would prevent complete emptying of the tank through the drain valve, or cause
trapping of air during filling.
4.0 WINDINGS
4.1 General
4.1.1 All star connected windings for system of 66 kV and above shall have graded insulation
as defined in IS: 2026. All windings for system voltages lower than 66 kV shall be fully insulated.
All neutral points shall be insulated for the voltages specified in IS: 2026.
 General 13

4.1.2 Power transformers shall be designed to withstand the impulse and power frequency test
voltages as specified in IS: 2026.

4.1.3 The windings shall be designed to reduce to a minimum the out-of-balance forces in the
transformer at all voltage ratios.

4.1.4 The insulation of transformer windings and connection shall be free from insulating
composition liable to soften, ooze out, shrink or collapse and be non-catalytic and chemically
inactive in transformer oil during service.

4.1.5 The slacks of windings shall receive adequate shrinkage treatment before final assembly.
Adjustable devices shall be provided for taking up any possible shrinkage of coils in service.

4.1.6 The coil clamping arrangement and the finished dimensions of any oil ducts shall be
such as will not impede the free circulation of oil through the ducts.

4.1.7 No strip conductor wound on edge shall have a width exceeding generally six times its
thickness.

4.1.8 The conductors shall be transposed at sufficient intervals in order to minimize eddy
currents and equalize the distribution of currents and temperatures along the windings.

4.2 Bracing of Windings

4.2.1 The windings and connections of all transformers shall be braced to withstand shocks
which may occur during transport, or due to switching short-circuit and other transient conditions
during service.

4.2.2 Coil clamping rings, if provided, shall be of steel or of suitable insulating material.

5.0 INTERNAL EARTHING ARRANGEMENTS

5.1 General

5.1.1 All metal parts of the transformer with the exception of the individual core laminations,
core bolts and associated individual clamping plates shall be maintained at same fixed
potential.

5.2 Earthing of Core Clamping Structure

5.2.1 The top main core clamping structure shall be connected to the tank body by a
copper strap. The bottom clamping structure shall be earthed by one or more of the following
methods:

(a) By connection through vertical tie-rods to the top structure

(b) By a connection to the loop structure on the same side of the core as the main earth
connection to the lank
14 Manual on Transformers

5.3 Earthing of Magnetic Circuit

5.3.1 The magnetic circuit shall be earthed to the clamping structure at one point only through
a link placed in an accessible position beneath an inspection opening in the tank cover. The
connection to the link shall be on the same side of the core as the main earth connection. The
link should be brought out using bushing/terminal board on all transformers above 31.5 MVA.

5.3.2 When magnetic circuits are subdivided into separate isolated sections by duels
perpendicular to the plane of laminations all such sections should be earthed.

5.4 Earthing of Coil Clamping Rings

5.4.1 Where coil clamping rings are of metal at earth potential, each ring shall be connected
to the adjacent core clamping structure on the same side of transformer as the main earth
connections.

5.5 Size of Earthing Connections

5.5.1 All earthing connections with the exception of those from the individual coil clamping
rings shall have a cross-sectional area of not less than 0.8 cm, Connections inserted between
laminations of different sections of core as per clause 5.3.2 shall have a cross-sectional area of
not less than 0.2 cm2.

6.0 TANKS

6.1 Tank Construction

All transformer reactor tanks should generally be of conventional type i.e., tank body with top
cover, Bell shaped construction can be specified for 100 MVA and higher rating transformer
unless otherwise mutually agreed between Purchaser and Manufacturer

Top cover of conventional type transformer and Bell type construction may be bolted or welded
to the tank body rim. Transformers with bell type tank may have joint either at tank bottom or
close to bottom of the tank.

Inspection covers shall always be bolted type.

6.1.1 The transformer tank and cover shall be fabricated from low carbon steel suitable for
welding and of adequate thickness. The tanks of all transformers shall be complete with all
accessories and shall be designed so as to allow the complete transformer in the tank and filled
with oil, to be lifted by crane or jacks, transportation by road, rail or ship/boat without over
straining any joints and without causing leakage of oil.

6.1.2 The transformer conservator tank, if equipped with an air cell, need not be designed
for full vacuum but a vacuum-tight valve should be provided in the Buchholz relay pipe
connection.

Alternatively an equalizing connection may be provided between the inside of air cell and
conservator for evacuating the conservator along with air cell, which may be removed after
evacuation and oil filling.
 General 15

6.1.3 The main tank body excluding tap-changing compartments, radiators and coolers shall
be capable of withstanding vacuum given in the following tabic:

Vacuum
Highest system
MVA rating gauge (mm of Hg)
voltage kV
pressure kN/m2
Up to 72 kV Up to 1.6 34.7 250
above 1.6 and up to 20 68.0 500
above 20 100.64 760
Above 72 kV for all MVA
ratings 100.64 760

6.1.4 The base of each tank shall be so designed that it shall be possible to move the complete
transformer unit by skidding in any direction without any damage when using plates or rails.
6.1.5 Normally a detachable base will be used, but in case transport facilities permit, a fixed
base can be used.
6.1.6 Where the base is of a channel construction, it shall be designed to prevent retention of
water.

6.1.7 Tank stiffeners shall be designed to prevent retention of water.

6.1.8 Wherever possible the transformer tank and its accessories shall be designed without
pockets where gas many collect. Where pockets cannot be avoided, pipes shall be provided to
vent the gas into the main expansion pipe. The vent pipes shall have a minimum inside diameter
of 15 mm except for short branch pipes which may be 6 mm minimum inside diameter.

6.1.9 All joints other than those which may have to be broken shall be welded when required
they shall be double welded. All bolted joints to the tank shall be fitted with suitable oil-tight
gaskets which shall give a satisfactory service under the operating conditions and guaranteed
temperature rise conditions. Special attention shall be given to the methods of making hot oil
tight joints between the tank and the cover as also between the cover and the bushing and all
other outlets to ensure that the joints can be remade satisfactorily at site and with ease with the
help of semi-skilled labour.
6.2 Lifting and Haulage Facilities

6.2.1 Each tank shall be provided with:

(a) Lifting lugs suitable for lifting the transformer complete with oil.

(b) A minimum of four jacking lugs, in accessible positions to enable the transformer
complete with oil, to be raised or lowered using hydraulic or screw jacks. The minimum
height of the lugs above the base shall be:

• Transformers upto and including 40 tonnes weight - 300 mm (approx.) so as to

accommodate suitable jacks beneath the jacking parts
16 Manual on Transformers

• Transformers above 40 tonnes weight - 500 mm (approx.) so as to accommodate

suitable jacks beneath the jacking lugs

• When bell joint is at tank bottom and thick bottom plate is used, 300 and 500 mm
jacking pad height may not be applicable.

(c) Suitable haulage holes shall be provided

6.2.2 To facilitate safe handling at site, the longitudinal and transverse axes and the center of
gravity of main transformer tank should be marked permanently on all four sides.
6.3 Tank Cover
6.3.1 Each tank cover shall be of adequate strength, and shall not distort when lifted. Inspection
openings shall be provided as necessary to give easy access to bushings or changing ratio or
testing the earth connection. Each inspection opening shall be of ample size for the purpose for
which it is provided and at least two openings one at each end of the tank, shall be provided.
6.3.2 A ladder (with anti-climbing lock arrangement) shall be provided for tank above 3 m
height.
6.3.3 The tank cover and inspection covers shall be provided with suitable lifting arrangements.
Unless otherwise approved inspection covers shall not weigh more than 25 kg each.
6.3.4 Tank shall be designed so as to avoid collection of rain water at the tank top.
6.3.5 The tank cover shall be fitted with pockets for a thermometer and for the bulbs of oil
and winding temperature indicators. Protection shall be provided, where necessary, for each
capillary tube.
6.3.6 The thermometer pocket shall be fitted with a captive screwed top to prevent the ingress
of water.
6.3.7 The pockets shall be located in the position of maximum oil temperature at CMR and it
shall be possible to remove the instrument bulbs without lowering the oil in the tank.

6.4 AXLES AND WHEELS

6.4.1 Requirement of the roller will be specified for plinth mounted transformers. If required
only one set of roller of each size to be asked for.
6.4.2 If specified, transformers are to be provided with wheels and axles. They shall be of
such dimensions and so supported that under any service conditions they shall not deflect
sufficiently to interfere with the movement of the transformer. Suitable locking arrangements
will be provided to prevent the accidental movement of the transformer.
6.4.3 Roller/skid shall be provided with suitable rail gauge as per user requirement.
6.4.4 All rollers should be detachable and shall be made of cast iron or steel as required. The
direction of withdrawal shall be specified.
 General 17

6.4.5 Wherever specified, flanged wheels shall be provided suitable for use on gauge track as
specified in the detailed specification and shall be so placed that pinch bar can be used to move
the transformer.
6.4.6 If wheels are required to swivel, they shall be arranged so that they can be turned through
an angle of 90° when the tank is jacked up clear of the rails or floor. Means shall be provided for
locking the swivel movements in positions parallel to and at right angles to the longitudinal axis
of the tank.
6.5 Conservator Vessels, Oil Gauges and Breathers
6.5.1 A conservator complete with sump and drain valve shall be provided in such a position
as not to obstruct the electrical connections to the transformer having a capacity between highest
and lowest visible levels of 7.5% of the total cold oil volume in the transformer and cooling
equipment. The minimum indicated oil level shall be with the feed pipe from the main tank
covered with not less than 15 mm depth of oil and the indicated range of oil level shall be from
minimum to maximum. For 10.0 MVA & above rating, the conservator shall be equipped with
aircell separator, unless otherwise specified.
6.5.2 If the sump is formed by extending the feed pipe inside the conservator vessel, this
extension shall be for at least 25 mm. The conservator shall be designed so that it can be
completely drained by means of the drain valve provided, when mounted as in service.
6.5.3 One end of the conservator shall be bolted into position so that it can be removed for
cleaning purposes.
6.5.4 Normally one oil gauge, magnetic/prismatic/plain type as specified shall be provided.
6.5.5 The oil level at 30°C shall be marked on the gauge.
6.5.6 Taps or valves shall not be fitted to oil gauge.
6.5.7 The oil connection from the transformer tank to the conservator vessel shall be
arranged at a rising angle of 3 to 7 degrees to the horizontal up to the Buchholz Relay and
shall consist of:
(a) For transformers up to and including 1000 kVA 25 mm inside diameter pipes as per IS:
3639
(b) For transformers from 1001 to 10,000 kVA 50 mm inside diameter pipes as per IS: 3639
(c) For transformers of over 10,000 kVA 80 mm inside diameter pipes as per IS: 3639
6.5.8 A valve shall be provided at the conservator to cut-off the oil supply to the transformer,
after providing a straight run of pipe for at least a length of five times the internal diameter of
the pipe on the tank side of the gas and oil actuated relay and at least three times the internal
diameter of the pipe on the conservator side of the gas and oil actuated relay.
6.5.9 Each conservator vessel shall be fitted with a breather in which silica gel is the dehydrating
agent and deigned so that:
18 Manual on Transformers

(a) The passage of air is through the silica gel.

(b) The external atmosphere is not continuously in contact with the silica gel.

(c) The moisture absorption indicated by a change in colour of the tinted crystals, can be
easily observed from distance.

(d) All breathers shall be mounted at approximately 1,400 mm above ground level.

(e) Self indicating (blue) silica gel contains the dye cobalt chloride which has potential
health hazards.

An alternative to the blue self indicating silica gel is SILICA GEL ORANGE with
an organic indicator. The color changes from orange to light yellow as it absorbs
moisture. Automatic regenerative breather with internal heater & humidity sensor
are also available.

6.5.10 One non-return valve, which may automatically cut off the flow of oil from conservator
towards the main tank may be provided in the pipe connection between the Buchholz relay and
conservator for transformers 10 MVA and above.

6.6 Filter and Drain Valves Sampling Devices and Air Release Plugs

6.6.1 Each transformer shall be fitted with the following:

(a) The filter and drain valves as specified.

(b) A drain valve as specified below shall be fitted to each conservator.

For diameter up to 650 mm: Size of the valve 15 mm.

For diameter above 650 mm: Size of the valve 25 mm.

(c) A robust oil sampling device shall be provided at the top and bottom of the main tank.
The sampling device shall not be fitted on the filler valves specified under (a) above.

(d) One 15 mm air release plug.

(e) For transformers above 100 MVA rating, one 100 mm bore valve shall be provided
for attaching vacuum connection and with provisions for attaching a vacuum gauge, a
pressure gauge or an oil level indicator.

6.6.2 All other valves opening to atmosphere shall be fitted with blank flanges.

6.7 COOLER AND RADIATOR CONNECTIONS

Valves and valve mountings shall be provided as specified under “Cooling Plant” Clause 7.

6.7.1 All valves up to and including 50 mm shall be of gunmetal or of cast steel. Larger valves
may be of gunmetal or may have cast iron bodies with gunmetal fittings. They shall be of full
 General 19

way type with internal screw and shall be opened by turning counter clock-wise when facing the
handwheel.

6.7.2 Means shall be provided for padlocking the bottom valves in the open and closed
positions. This is required for the valves where opening device like hand-wheel, keys, etc., are
the integral part.

6.7.3 Every valve shall be provided with an indicator to show clearly the position of the
valve.

6.7.4 All valves shall be provided with flanges having machined faces.

6.7.5 The drilling of valve flanges shall comply with the requirements of IS: 3639.

6.8 PRESSURE RELIEF DEVICE

6.8.1 The pressure relief device shall be provided for 16 MVA & above rating transformer.
PRD shall be of sufficient sizes for rapid release of any pressure that may be generated within
the tank, and which might result in damage to the equipment. The device shall operate at a static
pressure of less than the hydraulic test pressure for transformer tank. Means shall be provided to
prevent the ingress of rain water.

6.8.2 Unless otherwise approved the relief device shall be mounted on the main tank, and, if
on the cover, shall be fitted with skirt projecting 25 mm inside the tank and of such a design to
prevent gas accumulation.

6.8.3 If a diaphragm is used it shall be of suitable design and material and situated above
maximum oil level.

6.8.4 If a diaphragm is put at the base of pipe, an oil gauge is required on the stand pipe for
indicating fracture of diaphragm.

6.8.5 One of the following methods shall be used for relieving or equalising the pressure in the
pressure relief device:

(a) An equaliser pipe connecting the pressure relief device to the conservator, or
(b) The fitting of a silica gel breather to the pressure relief device. The breather being
mounted in a suitable position for access at ground level.
6.8.6 If specified, the pressure relief valve (spring operated type) capable of releasing the
pressure in the lank when it rises above a predetermined safe limit, shall be provided. It shall
be provided with a micro switch for actuating trip contact when it operates. It shall also give
a visual indication of valve operation by raising a flag. The flag and the switch shall remain
operated until they are reset manually. The operating pressure of the pressure relief valve shall
always be less than the tank test pressure. The micro switch shall have IP 55 protection and the
fasteners shall be of rust proof material.
20 Manual on Transformers

6.8.7 PRD shall be provided with an outlet pipe which shall be taken right up to the bottom of
the transformer up to the oil catchment pit. This is to avoid injury to personnel in event of PRD
operation and subsequent splashing of oil.

6.9 Accommodation for Auxiliary Apparatus

6.9.1 If specified, facilities shall be provided for the mounting of internal/external neutral
current transformer(s) adjacent to the neutral terminal(s) and tank.

6.10 EARTHING TERMINAL

6.10.1 Two earthing terminals capable of carrying for 4 seconds the full lower voltage. Short
circuit current of the transformer. Provision shall be made at positions close to each of the
bottom two corners of the tank for bolting the earthing terminals to the tank structure to suit
local conditions. The design of earthing terminals shall be as per IS 3639 - Part 3 (Fittings and
accessories for Power Transformers Part 3: Earth Terminals.

6.11 RATING, DIAGRAM AND PROPERTY PLATES

6.11.1 The following plates shall be fixed to the transformer tank at an average height of

about 1750 mm above ground level as shown in Fig. 1.

(a) A rating plate bearing the data specified in the appropriate clauses of IS: 2026

(b) A diagram plate showing the internal connections and also the voltage vector relationship
of the several windings in accordance with IS: 2026 and in addition a plan view of
the transformer, giving the correct physical relationship of the terminals. When links
are provided in accordance with clause 2.3 for changing the transformer ratio, then
approved means shall be provided for clearly indicating ratio for which the transformer
is connected. No load voltage shall be indicated for each tap. R&D plate shall also
consist of copper weight, core weight, commissioning date & factory tested capacitance
value. A warning plate shall also be provided for OCTC operation during de-energized
condition only.

(c) Where specified a plate showing the location and function of all valves and air release
cocks or plugs is to be provided. This plate shall also warn operators to refer to the
maintenance instructions before applying the vacuum treatment for drying (Fig. 2).

6.11.2 The above plates shall be of material capable to withstanding continuous outdoor
service.

6.12 Joints and Gaskets

6.12.1 All gaskets used for making oil tight joints shall be of proven material such as granulated
cork bonded with synthetic rubber or synthetic rubber gaskets conforming to IS: 4253, unless
otherwise specified.
General 21
22 Manual on Transformers
 General 23

Fig. 3 Typical value schedule for power transformer

7.0 COOLING PLANT

7.1 General

7.1.1 Radiators and coolers shall be so designed as to avoid pockets in which moisture may
collect and shall withstand the pressure tests.

7.1.2 Unless the pipe work is shielded by adequate earthed metal the clearance between all
pipe work and live parts shall be more than the clearance for live parts to earth.
24 Manual on Transformers

7.2 Radiators Mounted Directly to the Tank/Banked

7.2.1 Detachable radiators as per Section JJ of this manual.

7.2.2 Valves shall be provided on the tank at each point of connection to the tank.

7.2.3 Where separate radiator banks are provided, the conservator vessels specified in clause
6.5 can be mounted thereon.

7.2.4 All coolers shall be suitable for mounting on a flat concrete base.

7.2.5 The oil circuit of all coolers shall be provided with the following:

(a) A valve at each point of connection to the transformer tank

(b) Removable blanking plates to permit the blanking off the main oil connection of each
cooler.
(c) A drain valve of 25 mm at the lowest point of each bank of cooler
(d) A thermometer pocket fitted with a captive screwed cap on the inlet and outlet oil
branches of each separately mounted cooler bank.
(e) A filter valve as specified in clause 6.6 at the top and bottom of each cooler bank of
cooler.
(f) Air release plugs of 15 mm.

7.2.6 In addition the following are to be provided only with water cooled oil coolers which
shall be as per IS: 6088.

(a) A suitable differential pressure gauge or equivalent suitable device fitted with electrical
contacts to give an alarm when differential pressure between cooler oil outlet and water
inlet pressure drops below a preset value.
(b) Oil and water flow switches, fitted with electrical contacts, in the pipe work adjacent to
the coolers.

7.2.7 The disposition of flow indicators is to be as shown in Fig. 3.

7.2.8 Water cooled oil coolers shall be double tube type in which water shall circulate through
the inner tube and oil in between the outer tube and shell. The design of shell and tube assembly
shall be such as to facilitate cleaning without any risk of water mixing with the oil. The material
of the tube plates and tube shall be such that corrosion shall not take place due to galvanic
action. A water analysis report shall be furnished, in time, to enable supplier to ensure a suitable
material for tube and tube plates.

7.2.9 Any leakage which may take place in the oil cooler shall be of the oil into the water and
not the reverse, and means shall be provided to ensure that the pressure of the oil in the cooler
 General 25

is always greater than the pressure of the water. The water pressure in the cooler will be kept as
low as possible. Further, the cooling water discharge should be free to the atmosphere to reduce
the pressure in the cooler. Provision for leakage detector system shall be provided along with
alarm contacts for water coolers.

7.3 Oil Piping and Flanges

7.3.1 The necessary oil piping shall be provided for connecting each transformer to the coolers
and oil pumps. The oil piping shall be with flanged gasket joints. Cast iron shall not be used.

7.3.2 The drilling of all water and oil pipe flanges shall comply with IS: 3639 and IS: 1536
(Section JJ -specification for valves for transformers.)

Fig. 4 Flow indicators and alarms

26 Manual on Transformers

7.3.3 A suitable expansion piece shall be provided in each oil pipe connection between the
transformer and the separately mounted oil coolers.
7.3.4 Drain valves/plugs shall be provided in order that each section of pipework can be
drained independently.
7.4 Oil Pumps
7.4.1 Each forced oil cooler shall be provided with a motor driven oil pump of the submerged
motor type and of adequate capacity. It shall be possible to remove the pump and motor from
the oil circuit without having to lower the level of oil in the transformer or coolers and without
having to disturb the pump foundation fixing. Oil pump shall be capable of dealing with the
maximum output of transformer and total head which may occur in service and with the varying
head due to changes in the viscosity of the oil.
7.4.2 Each pump assembly shall be furnished with oil flow indicator with alarm contacts to
indicate normal pump operation and oil flow.
7.4.3 For mixed type cooling, the pump should be of axial flow type to permit oil circulation
when pump is idle.
7.4.4 For forced oil cooling, the coolers shall be of 2 X 50% and oil pumps 2 X 100%, one
pump running and one standby in each group.
7.4.5 Under no circumstances, the degree of forced circulation creates a static electrification
hazard in any part of a transformer under any operating condition.
7.5 Air Blowers and Ducts
7.5.1 Air blowers for use with oil coolers or for air blast cooling shall be motor driven. They
shall be suitable for continuous operation outdoors and capable of dealing with the maximum
output and total head required in service. The bearings shall be of sealed type, which does not
require frequent lubrication.
7.5.2 Air blowers shall be capable of withstanding the stresses imposed when brought up to
full speed by the direct application of full line voltage to the motor.
7.5.3 Air blowers shall be complete with all necessary air ducting and coolers shall be designed
so that they operate with a minimum of noise or drumming. In order to reduce the transmission
of noise and vibration the blowers shall be either mounted independently from the coolers or,
alternatively, an approved form of antivibration mounting shall be adopted. It shall be possible
to remove the blower complete with motor without disturbing or dismantling the cooler structure
framework.
7.5.4 Blades or runners fabricated to form hollow sections shall not be used.
7.5.5 Blades shall be suitably painted for outdoor use.
7.5.6 If fans are mounted at a height less than 2.5 m suitably painted wire-mesh guards with
a mesh not greater than 25 mm shall be provided to prevent accidental contact with the blades.
Fans mounted at more than 2.5 m height shall be provided with outside guards against birdage.
Guards shall be provided over all moving shaft and couplings.
 General 27

7.6 Motors

7.6.1 Motors shall be of the squirrel cage totally enclosed weather-proof type and shall comply
with Indian Standards as applicable for continuously rated machine. The motors shall be capable
of operating at all loads without undue vibration and with a minimum of noise. They shall be
suitable for direct starting and for continuous running from 415-240 volts three-phase, 4 wire 50
Hz supply.

7.6.2 All motors shall be capable of continuous operation at any frequency between 48 and
51 Hz, together with any voltage within 5 percent of the nominal value. Motors upon which
the primary equipment depends for its continued operation at full load shall also be capable of
continuous operation at 85 percent of the nominal voltage at normal frequency without injurious
over-heating.

7.6.3 All motors shall have ball or roller bearings and grease lubricators shall be fitted with
hexagon nipples to relevant Indian Standard.

7.6.4 Vertical spindle motors shall have bearings capable of withstanding the thrust due to the
weight of the moving parts and the action of impeller.

7.6.5 The stator windings shall be adequately braced and suitably impregnated to render them
non-hygroscopic and oil resistant. Weather-proof motors shall be provided with suitable means
of breathing and drainage to prevent accumulation of water.

7.6.6 Each terminal box shall be fitted with means of terminating the external wiring for
outdoor use.

7.6.7 Varnished cambric or glass insulation shall be used for connections from the winding to
the terminals. All motor terminals shall be of the stud type and totally enclosed.

7.6.8 Each pump, or blower and its motor shall be mounted on a common base plate and the
drive shall be direct.

7.7 Cooler Control

7.7.1 Each motor or group of motors shall be provided with a three pole electrically operated
contactor and with control gear of suitable design both for starting and stopping the motor
manually and also automatically from the contacts on the winding temperature indicating device
specified in clause 13. Additional terminals for remote manual electrical control of motors shall
be provided. Overload and single phasing protection shall be provided but no-volt release shall
not be fitted. MCB/MCCB shall be provided for the main supply. This equipment shall be
accommodated in the marshalling box specified in clause 15.

7.7.2 Where small motors are connected in groups, the group protection shall be arranged so
that it operates satisfactorily in the event of a fault occurring on a single motor.
28 Manual on Transformers

7.7.3 Where blowers and oil pumps are provided, the connections shall be arranged as to
allow the motors or groups of motors to be started up and shutdown either collectively or
individually.

7.7.4 All motor contactors and their associated apparatus shall be capable of holding in and
operating satisfactorily and without over heating for a period of ten minutes if the supply voltage
falls for the period, to 75 per cent of normal at normal frequency. The motor contactors and
associated apparatus shall be capable of normal operation with a supply voltage of 85 per cent
of the normal value and at normal frequency.

7.7.5 All contacts and other parts which may require renewal, adjustment or inspection shall
be readily accessible.

7.7.6 The control arrangements are to be so designed as to prevent the simultaneous starting
of motors of a total rating of more than 20 HP.

7.7.7 Alarm indication for failure of group of fans and oil pump shall be provided. Also for
forced oil cooled transformers, alarm indication for “low oil flow” shall be provided.

7.7.8 Alarm indication shall be provided to indicate failure of power supply.

7.7.9 The start up or shut down of any pump or combination of pumps must not cause
mal-operation of any gas and oil actuated relay.

7.7.10 For transformers with OFWF cooling required to meet peak load requirements and are
thus switched on or off during the day, the oil pump shall be kept running when the transformer
is off for a short period but water circuit is switched off. In case the transformer is switched off
for a longer time, the oil pump can also be switched off but it shall be ran at least one hour earlier
before the transformer is energised again.

7.7.11 Transformers with only OFAF cooling with unit coolers shall have provision of alarm for
“more than one cooler fail”. Cooler failure alarm shall be interfaced with DCS/ECMS/SCADA
system as applicable.

7.7.12 An alternate to the conventional cooler control “Intelligent Cooler Control & Monitoring
System” which is a PLC based system can be recommended for critical power transformers,
where cooler control and monitoring are interfaced with DCS/ECMS/SCADA system as
applicable.

8.0 VOLTAGE CONTROL (OFF-CIRCUIT TYPE)

Voltage Control (off-circuit type) should conform to Section GG of the specification.

9.0 VOLTAGE CONTROL (ONLOAD TYPE)

Voltage control (on-load type) should conform to Section GG of the specification.

 General 29

10.0 PARALLEL OPERATION OF TRANSFORMERS WITH ONLOAD

TAPCHANGER

10.1 Besides the local and remote electrical control specified in clause 9, on-load tap changers,
when specified, should be suitable for remote electrical parallel control as in clause 10.2.

10.2 Remote Electrical Parallel Control

10.2.1 In addition to the methods of control as in clause 9, the following additional provision
shall be made.

10.2.2 Suitable selector switch be provided, so that any one transformer of the group can at a
time be selected as “Master”, “Follower” or “Independent”.

10.2.3 Necessary interlock blocking independent control when the units are in parallel, shall be
provided.

10.2.4 The scheme will be such that only one transformer of a group can be selected as
“Master”.

10.2.5 An out-of-step device shall be provided for each transformer which shall be arranged to
prevent further tap changing when transformers in a group operating in “Parallel control” are
one tap out-of-step.

11.0 BUSHING INSULATORS AND TERMINALS

The bushing should comply with IS 2099, IS 12676 and Section II of this specification. The over
voltage power frequency test level or the BIL of bushings should be one step higher than that
of the windings.

11.1 Transformers shall be fitted either with bushing insulators or with cable boxes, as stated
in order. Where accommodation for current transformers is required on 72.5 kV bushings and
above, the requisite details will be notified to the supplier at the time of tendering.

11.2 Special precautions shall be taken to avoid ingress of moisture into paper insulation
during manufacture, assembly, transport and erection.

11.3 Each porcelain bushing or insulator, and paper bushing shall have marked upon it the
manufacturer’s identification mark, and such other mark as .may be required to assist in the
representative selection of batches for the purposes of the sample tests.

Clamps and fittings made of steel or malleable iron shall be hot dip galvanised. All fasteners of
size 12 mm and above shall be hot dip galvanised and fasteners of size less than 12 mm shall be
of stainless steel. LV Bushing (rated current≥ 1000 Amps) palm shall be silver/tin plated.

11.4 The bushing flanges shall not be of re-entrant shape which may trap air.
30 Manual on Transformers

11.5 Bushing turrets shall be provided with vent pipes which shall be connected to route any
gas collection through the Buchholz relay. The take off point of the vent pipes shall be the top
most point on the bushing turret so that there will not be any air trapped in the -bushing turret.

11.6 The minimum clearances in air between live conductive parts and conductive parts to
earthed structure shall be as follows:

Highest Voltage for Basic Insulation level Minimum clearances

Equipment (kV) kV peak Phase to Phase to
phase (mm) earth (mm)
12 75 280 140
24 125 330 230
36 170 350 320
52 250 530 480
72.5 325 700 660
145 550 1220 1050
145 650 1430 1270
245 950 2000 1800
245 1050 2350 2150
420 1425 4000 3500
800 1950 6700*/5800* 5800*/5000*

* depending upon lightening & switching impulse level.

Note:
(1) These clearances are applicable for transformers to be installed up to an altitude of 1000 m above mean sea level.
(2) For altitude exceeding 1000 in the clearance should be increased by 3 percent for every additional 300 m.
(3) Air clearance of 3500 mm between phase to earth for 420 kV system can be relaxed by maximum 200 mm as far as
air release pipe emanating from bushing turret is concerned.

11.7 Vertical Bushings for 52 kV & above shall be of the oil filled condenser type (OIP) &
shall be of draw lead/ rod type to facilitate removal. Bushings of rating below 52 kV may be
solid porcelain or oil communicating type. Condenser type bushings shall be provided with :

(1) Oil level gauge

(2) Oil filling plug & drain valve
(if not hermetically sealed)
(3) Tap for capacitance & tan delta test.
An alternate to OIP Bushing is Resin Impregnated Paper (RIP) Bushing. However it has to be
specified by the user.

12.0 CABLE BOXES AND DISCONNECTING CHAMBERS

12.1 Cable boxes shall be suitable for terminating the cables directly or alternatively shall be
in the form of sealing end-chambers for accommodation sealing ends into which the cable will
be terminated, as specified in the order.

12.2 Cable boxes shall be designed to accommodate all the cable joint fittings or sealing ends
 General 31

required by the manufacturers of the cables, including stress/cones or other approved means for
grading the voltage stress on the terminal insulation of cables operating at voltages of 22 kV
and above, between phases. They shall also be provided with expansion chambers for the filling
medium and means of preventing the formation of air spaces when filling. Drain plugs of ample
size shall be provided to enable the filling medium to be removed quickly.

12.3 The cable boxes shall be fitted with suitable non-ferrous wiping glands with combined
armour and earthing clamps. The ends of all wiping glands shall be tinned before dispatch to site.
Wiping glands for single core cables shall be insulated from the box. Wiping glands insulation
cables shall be capable of withstanding a dry high voltage test of 2,000 volts AC for one minute.
Air insulated cable boxes for PVC cables may be provided with compression glands. Sufficient
wiping glands shall be provided for the termination of required number of cables.

12.4 Where cable boxes are provided for three core cables, the seating sockets on the two
outer phases shall preferably be inclined towards the centre to minimize bending of the cable
cores. Where there is more than one core per phase, the socket block shall be so designed as to
minimize bending of the cable cores.

12.5 Where cables for 1 kV and above are terminated in the cable box, oil filled disconnecting
chamber with removable links shall be provided for testing purposes. A barrier shall be provided
on both sides of the disconnecting chamber to prevent ingress of the oil used for filling the
chamber into the cable box or the transformer. It shall only be necessary to remove part of the
oil in the chamber itself when making the necessary testing connections.

12.6 Where sealing end chambers are provided, the disconnecting chamber may be omitted
and the facilities for testing shall be provided in the sealing end chamber itself. A barrier shall
then be provided between the sealing end chamber and the main tank subject to the provision of
the next paragraph.

12.7 The barrier between the main tank and the disconnecting or cable sealing end chamber
may be omitted, where the design is such that the cover of the disconnecting or cable sealing
end chamber can be removed without lowering any oil level other than in the chamber itself, in
order to make the necessary testing connections.

12.8 The disconnecting or sealing end chamber shall have a removable cover and the design
of the chamber shall be such that ample clearances are provided to enable either the transformer
or each cable to be subjected separately to high voltage tests when filled with transformer oil.
Insulating Fire resistant barriers should be provided between each phase of HV cable box.

12.9 An earthing terminal shall be provided in each disconnecting or sealing end chamber to
which the connections from the transformer winding can be earthed during cable testing.

12.10 The cable boxes and disconnecting or sealing end chambers shall also be capable of
withstanding for 15 minutes, both at the time of the first tests on the cables and at any subsequent
time as may be required, between phases and to earth a DC test equal to 2E kV or an AC test
equal to 4E/3 kV.
32 Manual on Transformers

12.11 During these tests the links in the disconnecting or sealing end chamber or cable box
will be withdrawn and the transformer winding with connections thereto will be earthed.

12.12 Unless otherwise approved the creepage distances and clearance to earth and between
phases shall not be less than those specified in Table 1. In case of compound filled cable box with
shrinkable tape, the allowable minimum clearances shall be subject to the agreement between
manufacturer and the user.

12.13 Cable boxes suitable for semi-fluid compound filling shall be tested with transformer oil
at room temperature and at a pressure of 0.7 kg/cm for 12 hours during which no leakage shall
occur.

12.14 Terminals shall be marked in a clear and permanent manner.

12.15 Unless otherwise specified main cabling jointing and filling of cable boxes will be
carried out by the customer. However, filling medium will be supplied as a part of the cable box
by the manufacturer.

Table 1
Highest Insulating Clearance Clearance Creepage Creepage
System medium between to earth over over
Voltage phases direct porcelain to cable
kV similar surface
(mm) (mm)
material (mm)
(mm)
1.1 Ail- 25 20 25 -
3.6 Air 50 50 90 -
7.2 Ail- 90 70 - -
12 Air 130 80 192 192
Compound 50 50 75 125
24 Air 241 140 384 384
Semi-fluid 100 75 125 190
compound or oil
36 Air 351 222 576 576
Semi-fluid 125 100 150 250
compound or oil

13.0 TEMPERATURE INDICATING DEVICES AND ALARM

13.1 Oil temperature indicator shall be provided as required in detail specification, i.e.,
Section E to K.

13.2 All transformers above 10 MVA shall be provided with a device for indicating winding
temperature. The device shall have a dial type indicator and in addition a pointer to register the
highest temperature reached. The number of contacts as specified will be provided.
13.3 Except where outdoor types of indicators are supplied, the temperature indicators shall
be housed in the marshalling box. If specified, for transformers above 10 MVA a remote repeater
indicator electrically operated from winding temperature indicator is to be provided for mounting
 General 33

on the control panels. Unless otherwise specified the remote repeater indicator shall be of flush
mounting type.

13.4 The tripping contacts of winding temperature indicators shall be adjustable to close
between 60°C and 120°C and alarm contacts to close between 50°C and 100°C and both shall
re-open when the temperature has fallen by about 10°C.

13.5 The contacts used to control the cooling plant motors on the above devices shall be
adjustable to close between 50°C and 100°C and re-open when the temperature has fallen by any
desired amount between 15°C and 30°C.

13.6 All contacts shall be adjustable on a scale and shall be accessible on removal of the
cover. Micro switches shall be preferred to mercury switches.

13.7 The temperature indicators shall be so designed that it shall be possible to check the
operation of the contacts and associated equipment.

13.8 Connections shall be brought from the device to terminals placed inside the marshalling
box.

13.9 Cooler failure or oil and water flow alarm shall be provided as specified in clause 7.2.6.

13.10 Accuracy class of temperature indicators shall be ± 1.5% or better.

13.11 An alternate to conventional dial type WTI/OTI is Digital WTI/OTI.

14.0 GAS AND OIL ACTUATED RELAYS

14.1 Each transformer shall be fitted with gas and oil actuated relay equipment to IS; 3637
having contacts which close following oil surge or low oil level conditions. Micro switches shall
be preferred to mercury switches.

14.2 Each gas and oil actuated relay shall be provided with a test cock to take a flexible pipe
connection for checking the operation of the relay.

14.3 Where specified to allow gas to be collected at ground level, a pipe approximately 5 mm
inside diameter shall be connected to the gas release cock of the gas and oil-actuated relay and
brought down to a point approximately 1.25 m above ground level, where it shall be terminated
by a cock.

14.4 A machined surface shall be provided on the top of each relay to facilitate the setting of
the relays and to check the mounting angle in the pipe and the cross level of the relay.

14.5 The design of the relay mounting arrangements, the associated pipework and the cooling
plant shall be such that mal-operation of the relays shall not take place under normal service
conditions.
34 Manual on Transformers

14.6 The pipework shall be so arranged that all gas arising from the transformer shall pass
into the gas and oil-actuated relay. The oil circuit through the relay shall not form a delivery
path in parallel with any circulating oil pipe, nor shall it be tied into or connected through the
pressure relief vent. Sharp bends in the pipework shall be avoided.

14.7 When a transformer is provided with two conservators, the gas and oil actuated relays
shall be arranged as follows:

• If the two conservators are connected to the transformer by a common oil pipe, one relay
shall be installed in the common pipe.
• If the two conservators are piped separately to the transformer, two relays shall be
installed, one in each pipe connection.
• Adequate clearance between oil pipework and live metal shall be provided.

15.0 MARSHALLING BOX

15.1 A steel weather and vermin proof enclosure having degree of protection IP 55 shall be
provided for the transformer ancillary apparatus. The box shall have domed or sloping roofs and
the interior and exterior painting shall be in accordance with clause 1.6.

15.2 The marshalling box, wherever provided shall accommodate the following equipments,
alternatively weather proof instruments can be mounted outdoor.

(a) Temperature indicators

(b) Control and protection equipment for the local electrical control of tap changer, if the
same cannot be accommodated in the motor driving gear housing.
(c) Control and protection equipment for the cooling plant; and
(d) Terminal boards and gland plates for incoming and outgoing cables
(e) Capillary entrance should preferably be from bottom of the box.

15.3 All the above equipments except (d) shall be mounted on panels and back of panel
wiring shall be used for interconnection.

15.4 The temperature indicators shall be so mounted that the dials are not more than 1600
mm from ground level and the door(s) are of adequate size.

15.5 To prevent internal condensation, an approved type of metal clad space heater shall be
provided, controlled by a suitable thermostat. For illumination, a suitable lamp or CFL shall be
provided whose switching shall be controlled by the door switch.
 General 35

15.6 All incoming cables shall enter the kiosks from the bottom and the gland plate shall be
not less than 450 mm from the base of box. The gland plate and associated compartment shall
be sealed in suitable manner to prevent the ingress of moisture.

15.7 Undrilled gland plate shall be provided for accommodating glands for incoming and
outgoing cables.

15.8 Separate kiosk may be provided for control & power circuit of OFAF cooled Power
Transformers.

16.0 CONTROL CONNECTIONS AND INSTRUMENT WIRING, TERMINAL

BOARD AND FUSES

16.1 All wiring connections, terminal boards, fuses and links shall be suitable for tropical
atmosphere. Any wiring liable to be in contact with oil shall have oil resisting insulation and
the bared ends of stranded wire shall be sweated together to prevent creepage of oil along
with wire.

16.2 There shall be no possibility of oil entering connection boxes used for cables or wiring.

16.3 Panel connections shall be neatly and squarely fixed to the panel. All instruments and
panel wiring shall be run in PVC or non-rusting metal cleats of the limited compression type.
All wiring to a panel shall be taken from suitable terminal boards.

16.4 Where conduits are used, the runs shall be laid with suitable falls, and the lowest parts
on the-run shall be external to the boxes. All conduit runs shall be adequately drained and
ventilated. Conduits shall not be run at or below ground level.

16.5 When 415 volt connections are taken through junctions boxes or marshalling boxes they
shall be adequately screened and 415 “VOLTS DANGER” notices must be affixed to the outside
of the junction boxes or marshalling boxes.

16.6 All box wiring shall be in accordance with relevant IS. All wiring shall be of stranded
copper of 660 V grade and size not less than 4.00 sq mm for CT leads and not less than 2.5 sq
mm for other connections.

16.7 All wires on panels and all multicore cables shall have ferrules which bear the same
number at both ends.

16.8 At those points of interconnections between the wiring carried out by separate contractors,
where a change of number cannot be avoided, double-ferrules shall be provided on each wire.
The change of numbering shall be shown on the appropriate diagram of the equipment.

16.9 The same ferrule number shall not be used on wires in different circuits on the same
panels.
36 Manual on Transformers

16.10 Ferrules shall be provided with glossy finish to prevent the adhesion of dirt. They shall
be clearly and durably marked and shall not be affected by damp or oil.

16.11 Stranded wires shall be terminated with tinned Ross Courtney terminals, claw washers
or crimped tubular lugs. Separate washers shall be used for each wire. The size of the washer
shall be suited to the size of the wire terminated. Wiring shall in general be accommodated on
the sides of the box and the wires for each circuit shall be separately grouped. Back of panel
wiring shall be arranged so that access to the connecting stems of relays and other apparatus is
not impeded.
16.12 Wires shall not be jointed or tied between terminal points.
16.13 Wherever practicable, all circuits in which the voltage exceeds 125 volts, shall be kept
physically separated from the remaining wiring. The function of each circuit shall be marked on
the associated terminals boards.
16.14 Where apparatus is mounted on panels, all metal cases shall be separately earthed by
means of copper wire or strip having a cross-section of not less than 2 sq mm where strip is used,
the joints shall be sweated.
16.15 All wiring diagram for control and relay panel shall preferably be drawn as viewed from
the back and shall show the terminal boards arranged as in service. All diagrams shall show
which view is employed.
16.16 Multicore cable tails shall be so bound that each wire may be traced without difficulty to
its cable.
16.17 The screens or screen pairs of multicore cables shall be earthed at one end of the cable
only. The position of the earthing connections shall be shown clearly on the diagrams.
16.18 All terminal boards shall be mounted obliquely towards the rear doors to give easy
access to terminations and to enable ferrule numbers to be read without difficulty.
16.19 Terminal board rows should be spaced adequately not less than 100 mm apart to permit
convenient access to wires and terminations.
16.20 Terminal boards shall be so placed with respect to the cable gland (at a minimum distance
of 200 mm) as to permit satisfactory arrangement of multicore cable tails.
Terminal boards shall have pairs of terminals for incoming and outgoing wires. Insulating barriers
shall be provided between adjacent connections. The height of the barriers and the spacing
between terminals shall be such as to give adequate protection while allowing easy access to
terminals. The terminals shall be adequately protected with insulating dust-proof covers. One
dummy terminal block in between each trip wire terminal shall be provided. No Loop in Loop
out shall be adopted for power circuit.
16.21 No live metal shall be exposed at the back of the terminal boards.
16.22 All fuses shall be of the cartridge type.
16.23 Fuses and links shall be labeled.
16.24 The terminal blocks preferably shall be fully enclosed with removable covers & made of
molded, non-inflammable plastic material with blocks & barriers molded integrally. The terminal
blocks shall be 650V grade & have 10 A continuous rating. At least 20 % spare terminals shall be
 General 37

provided on each panel. Terminal blocks for CT/PT secondary leads shall be provided with test
links & isolating facilities. Also current transformer secondary leads shall be provided with short
circuiting & earthing facilities. All CT/PT terminals shall be provided as fixed type terminals in
M. Box to avoid any hazard due to loose connection leading to CT opening or any other loose
connection. In no circumstances Plug In type connectors shall be used for CT/PT connections in
M. Box. Terminal block shall preferably be stud type suitable for ring (O) type lugs.
17.0 TESTS
17.1 Tests shall be carried out to evaluate the performance of the material and appliance
generally as per the provision of IS: 2026 and as detailed out in Section BB of this
specification.
A test method is referred in Appendix-VIII for Bushing CT Characteristic testing without passing
current to primary winding.
17.1.1 Where customers’ inspection is specified, not less than 15 days notice shall be given
to the customer in order that he may be represented. Four copies of test certificates will be
supplied.
17.2 Tests are not required to be performed on bought out equipments like oil coolers, oil
actuated relays, etc., at the works of the transformer manufacturer. Furnishing test certificates
from the original equipment manufacturer works shall be deemed to be satisfactory evidence.
Inspection of tests at the sub-contractors works will be arranged by the supplier wherever
required.
17.3 Tanks
17.3.1 Routine Tests

(a) Fabrication stage:

(al) The tank shall be tested for leakage by being completely filled with air at a pressure
corresponding to twice the normal head of oil or to normal pressure plus 35 kN/m2 whichever is
lower. The pressure shall be maintained for a period of minimum one hour during which time no
leakage shall occur. The equivalent air pressure corresponding to oil pressure calculated at the
base of the tank to be considered for air pressure test. Permanent deflection of flat plates shall
be measured on one tank of each design, if specified by customer, after the excess pressure has
been released and shall not exceed the figures specified below:
Horizontal length of flat plate Permanent deflection
(total length of tank wall) in mm (in mm)
Up to and including 750 5
751 to 1250 6.5
1251 to 1750 8
1751 to 2000 9
2001 to 2250 11
2251 to 2500 12.5
2501 to 3000 16
Above 3000 19
(a2) The conservator shall be tested for leakage by being completely filled with air at 35
kN/m2. The pressure shall be maintained for a period of one hour during which time no
leakage shall occur.
38 Manual on Transformers

(a3) The radiators shall be tested for leakage by placing them horizontally in a tank filled
with clean water and applying air pressure 2 kg/cm2 for atleast 15 minutes during which
time no leakage shall occur.
(a4) The pipes shall be tested for leakage by applying air pressure of 4 kg/cm2 for 15 minutes
during which time no leakage shall occur.
(b) Transformer assembly stage
Oil pressure test to be conducted on tank with turret and all other accessories as assembled
for routine test by filling completely with oil at a pressure corresponding to twice the
normal head of oil or to normal pressure plus 35 kN/m2 whichever is lower. The pressure
to be maintained for eight hours during which time no leakage shall occur.
17.3.2 Type Tests
(a) Vacuum test (at fabrication stage)
When required by customer, one transformer tank of each design shall be subjected to
the specified vacuum as in clause 6.1.3. The tanks designed for full vacuum (760 mm of
mercury at sea level or the barometric reading at the location of test) shall be tested at a
maximum internal pressure of 3.33 kN/m2 (25 mm of Hg) for one hour i.e., 760-25=735
mm of Hg at sea level and (Barometric reading -25) mm Hg at other location.
The permanent deflection of flat plates after vacuum has been released shall not exceed
the values specified in clause 17.3.1 (al) without affecting the performance of the
transformer.
(b) Pressure test
When specified, one transformer tank of each design with its active part as assembled
for type test (i.e., including pipe work and cooling equipment and excluding PRV and
conservator when air cell is provided) shall be subjected to a pressure corresponding to
twice the normal head of oil or to normal pressure plus 35 kN/m2 whichever is lower
measured at the base of the tank and will be maintained for 8 hours during which time
no leakage shall occur.
Before conducting the pressure test, the following are to be taken care of:
(i) Pressure relief valve/relief vent are to be removed and the opening blanked.
(ii) Transformer and tap changer conservators are to be disconnected.
(iii) Diverter switch compartment of tap changer to be connected with transformer tank for
equalizing the pressure on both sides.
(iv) Oil should be completely filled and all trapped air released.
17.3.3 Note: User may also specify Tank Routine/Type Tests in line with latest revision of IEC
60076-1
When IS eventually gets revised in line with latest revision of IEC, CBIP Manual shall be
amended to fall in line with IS.
 General 39

18.0 QUALITY ASSURANCE

The supplier should include a quality assurance programme (QAP) that will be used to ensure
that the transformer design, materials, workmanship, tests, service capability, maintenance
and documentation, will fulfill the requirements stated in the contract documents, standards,
specifications and regulations. The QAP should be based on and include relevant parts to fulfill
the requirements of ISO-9001.
A quality plan describes:

• Lists of activities involved in design, procurement of raw materials and components,

manufacture, stage inspection and final testing, preparation for dispatch, delivery,
installation and commissioning.
• The identification reference of all documentation, standards, procedures, works
instructions, drawings, test methods, acceptance criteria etc.
Typical QAP format is provided for illustration as Appendix III.

19.0 A list of guaranteed technical particulars and additional technical particulars are given in
Appendix IV. A list of standards for transformers is given in Appendix II. A list of transformer-
accessories and routine test certificate required for them is given .at Appendix V.

20.0 NEUTRAL EARTHING ARRANGEMENT /FORMATION

Neutral terminals of winding of three single phase Transformer shall be formed by connection
to an overhead common copper grounding bars, supported from tank and firewalls by using
insulators. Puncturing/support from firewall may not be permitted.

21.0 DESIGN REVIEW

The design of critical Power Transformer/ Reactor may be reviewed by user/their consultant. The
design review shall be finalized before commencement of manufacturing activity. This design
review may be carried out inline with CIGRE “Guideline for Conducting Design Review”, 204,
SC WG12.22. A format for required Design Review parameters is given in Appendix-VI for
reference.

22.0 REFERENCE TECHNICAL PARTICULARS OF POWER TRANSFORMERS &

SITE PHOTOGRAPHS

Salient Technical Particulars of Power Transformers for Coal Fired or Gas Based Thermal Power
Plants are given in Appendix-VII for reference.

Photographs of transformers & accessories already installed in various power projects are shown
in Appendix-IX.
 SECTION B

Specifications for Outdoor type, Completely Self

Protected, 3 Phase Distribution Transformers (upto
and including 100 kVA)
 SECTION B
Specifications for Outdoor type, Completely Self Protected, 3 Phase
Distribution Transformers (upto and including 100 kVA)

1.0 SCOPE

1.1 This section covers, technical requirements/parameters of Completely Self Protected

distribution transformers of rating upto and including 100 kVA, 11 kV 3 phase and does not
purport to include all the necessary provisions of a contract.

1.2 Standard Ratings

The standard ratings shall be 16, 25, 63 and 100 kVA. For general requirement reference shall
be made to Sections A & BB of this manual.

2.0 STANDARDS

2.1 The materials shall conform in all respects to the relevant Indian / International Standard
Specification, latest, amendments thereof, some of them are listed below:

Indian Standard Title International & Internationally

recognisedstandard
IS-2026 Specification for Power Transformer IEC 60076
IS-1180 Outdoor Distribution Transformer upto and including 100 kVA
IS 12444 Specification for Copper Wire Rod ASTM B-49
IS-3347 Specification for Porcelain Transformer Bushing DIN 42531,23,3
IS-335 Specification for Transformer Oil BS 148, D-1473, D-1533-
1934 IEC Pub 296
IS 5 Specification for Colours for Ready Mixed Paints
IS-2099 Specification for High Voltage Porcelain Bushings
IS-7421 Specification for Low Voltage Bushings
IS-3347 Specification for Outdoor Bushings DIN 42531 to 33
IS-5484 Specification for Al Wire Rods ASTM B-233
IS - 9335 Specification for Insulating Kraft Paper IEC 60554
IS- 1576 Specification for Insulating Press Board IEC 60641
IS/6600 2026-7 Guide for Loading of Oil Immersed Transformers IEC 60076

Refer Appendix II of the Manual for List of Standards.

3.0 SERVICE CONDITIONS

The Distribution Transformers to be supplied against this Specification shall be suitable for
satisfactory continuous operation under the climatic conditions prevailing at site and to be
specified by the purchaser as follows, as per IS 2026 (Part -1) Latest Revision/International
43
44 Manual on Transformers

Standards tabulated above :

(i) Location
(ii) Max ambient air temperature (deg.C) :
(iii) Min. ambient air temperature (deg.C) :
(iv) Max average daily ambient air temperature (deg.C) :
(v) Max. yearly weighted average ambient temperature(deg.C) :
(vi) Max. altitude above mean sea level (meters) :

4.0 STANDARD RATINGS

Transformers shall be suitable for outdoor installation with three phase, 50 Hz, 11 kV system in
which the neutral is effectively earthed and these should be suitable for service under fluctuations
in supply voltage upto plus 10% to minus 15%.

The transformer shall conform to the following specific parameters:

SL. No Item Specification

1. Continuous rated 16kVA 25 kVA 63kVA 100 kVA
capacity
2. System highest Voltage 12 kV 12 kV 12 kV 12 kV

3. Rated Voltage HV 11 kV 11 kV 11 kV 11 kV
4. Rated Voltage LV 433 V 433 V 433 V 433 V
5. BIL 95 kV Peak 95 kV Peak 95 kV Peak 95 kV Peak
6. Frequency 50Hz +/- 5% 50Hz +/- 5% 50Hz +/- 5% 50Hz +/- 5%
7. No. of phases Three Three Three Three
8. Connection HV Delta Delta Delta Delta
9. Connection LV Star (neutral Star (neutral Star (neutral Star (neutral
brought out and brought out and brought out and brought out and
directly earthed directly earthed directly earthed directly earthed
10. Vector group Dyn-11 Dyn-11 Dyn-11 Dyn-11
11. Type of cooling ONAN ONAN ONAN ONAN
12. Percentage impedance at 4.5 4.5 4.5 4.5
75°C
13. Permissible temperature
rise over ambient
(i) Of top oil measured 35 35 35 35
by thermometer
(ii) Of winding
measured by resistance 40 40 40 40
14. Minimum clearances in
air As per IS-1180 As per IS-1180 As per IS-1180 As per IS-1180
(a) HV phase to phase / latest latest latest latest
phase to earth (mm) 255/ 140 255/ 140 255/ 140 255/ 140
(b) LV phase to phase / 75/40 75/40 75/40 75/40
phase to earth (mm)
15. Tap changer Not applicable Not applicable Not applicable Not applicable
 Specifications for Outdoor type, Completely Self Protected, 3 Phase Distribution Transformers (upto 45
and including 100 kVA)

5.0 TECHNICAL REQUIREMENTS

5.1 Core

5.1.1 Material - Cold Rolled Grain Oriented (CRGO) /Amorphous Metal

(a) Material- CRGO
5.1.2 (a) The core shall be stacked / wound type, of high grade cold rolled grain oriented
steel laminations having low loss and good grain properties, coated with hot oil proof
insulation, bolted / banded 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.

The manufacturer should offer the core for inspection and approval by the purchaser during
manufacturing stage. Manufacturer's shall give notice for inspection with the following
documents as applicable as a proof towards use of prime core material

• Invoice of the Supplier

• Mills Test Certificate
• Packing List
• Bill of Lading
• Bill of Entry Certificate to Customs

5.1.3 (a) Core Clamping for CRGO Stacked Core

• MS Channel shall be used on top and bottom

• 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.
• MS Channels shall be painted with varnish or oil-resistant paint.
• Clamping & Tie-rods shall be made of HT steel and shall be parkarised

5.1.4 (a) Core Clamping for CRGO Wound Core

• Core clamping shall be with top and bottom U-shaped core clamps made of sheet steel
clamped with HT steel tie rods for efficient clamping.
• MS core clamps shall be painted with varnish or oil-resistant paint.
• MS rods shall be used as tie rods.
• Suitable provision shall be made in the bottom core clamp / bottom plate of the
transformer to arrest movement of the active part.

5.1.5 (a) The transformers core shall be suitable for over fluxing (due to combined effect
of voltage and frequency) upto 12.5% without injurious heating at full load conditions and
46 Manual on Transformers

shall not get saturated. The Manufacturer shall furnish necessary design data in support of this
situation.

5.1.6 (a) No load current shall not exceed 1% of full load current and will be measured by
energising the transformer at 433 volts, 50 c/s on the secondary. Increase of voltage of 433 volts
by 12.5% shall not increase the no load current beyond 6% of full load current.
(b) Material - Amorphous Metal

5.1.8 (b) 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.

5.1.7 (b) Core Clamping for Amorphous Metal Transformers

• Core clamping shall be with top and bottom U-shaped core clamps made of sheet steel
clamped HT steel tie rods for efficient clamping.
• MS core clamps shall be painted with varnish or oil-resistant paint.
• MS rods shall be used as tie rods.
• Suitable provision shall be made in the bottom core clamp / bottom plate of the
transformer to arrest movement of the active part.
5.1.9 (b) The transformers core shall be suitable for over fluxing (due to combined effect
of voltage and frequency) upto 12.5% without injurious heating at full load conditions and
shall not get saturated. The Manufacturer shall furnish necessary design data in support of this
situation.

5.1.10 (b) No load current shall not exceed 1% of full load current and will be measured by
energising the transformer at 433 volts, 50c/s on the secondary. Increase of voltage of 433 volts
by 12.5% shall not increase the no load current beyond 5% of full load current.
Note : "Equal weightage shall be given to the transformers with Amorphous metal core and CRGO".
5.2 Windings

5.2.1 Material: Super enamel covered copper conductor / double paper covered copper
conductor. Aluminium conductors can also be used with same loss levels as of copper wound
transformers.

5.2.2 LV winding shall be in even layers so that neutral formation is at top.

5.2.3 The winding construction of single HV coil preferred to crossover coil over LV coil
5.2.4 Inter layer insulation shall be electrical grade Epoxy dotted kraft Paper for rectangular
coils.
5.2.5 Proper bonding of inter layer insulation with the conductor shall be ensured.
 Specifications for Outdoor type, Completely Self Protected, 3 Phase Distribution Transformers (upto 47
and including 100 kVA)

5.2.6 Dimensions of winding coils are very critical. Dimensional tolerances for winding coils
shall be with in limits as specified in GTP.
5.3 Oil

The insulating oil shall comply with the requirements of relevant standards IS 335 / IEC 60296
5.4 Insulation Material

5.4.1 Material: Electrical Grade Epoxy Dotted Kraft Paper shall he used for Rectangular
Coil

5.4.2 All spacers, axial wedges / runners used in windings shall be made of pre-compressed
solid press board, conforming to type B 3.1 of IEC 641-3-2. In case of cross-over coil winding
of HV all spacers shall be properly sheared and dovetail punched to ensure proper locking. All
axial wedges / runners shall be properly milled to dovetail shape so that they pass through the
designed spacers freely. Insulation shearing, cutting, milling and punching operations shall be
carried out in such a way, that there is no burr or dimensional variations.

5.5 Losses : The maximum losses at rated voltage and rated frequency permitted at 75 Deg.
C. are indicated below:

Voltage Ratio kVA Rating No load losses in watts Full load losses in watts (Max)
(Max) at 75 Deg C
11000/433-250 V 16 65 425
11000/433-250 V 25 80 615
11000/433-250 V 63 150 1100
11000/433-250 V 100 220 1575

Note: The losses mentioned above are under discussion and finalisation by BIS to revise IS:1180. The above losses
eventually may get revised if any, after said revision.

The above losses are maximum allowable and there would not be any positive tolerance.
Transformers with higher losses than the above specified values would be treated as Non-
responsive.

Transformers with losses less than those specified above will be capitalized during transformer
evaluation as indicated below. (Refer to Loss Capitalisation formula, Section AA, Loss
Capitalization factors:

A. Iron Losses - Rs. 89.67 X Ec / Watt

B. Copper Losses - Rs. 26.9 X Ec / Watt

Where Ec is the cost of energy ( in Rupees per unit at 11 kV feeder level). In case of non
availability of Ec (Energy cost per unit) at 11 kV feeder level, utility should consider the Bulk
Rate Tariff plus 5% as the cost of energy at 11 kV feeder level
48 Manual on Transformers

• PRICE SCHEDULE

The following format shall be filled by the manufacturer for evaluating TOC (TOC) price.

SL. Price Component Rating 1 Rating 2 Rating 3 Rating 4

No
1. Unit ex-works price
2. Freight & Insurance
3. (i) Excise duty
(ii) Educational cess on Ex
cise duty
4. Sales Tax
5. Total Cost per Unit without
Capitalization (1+2+3+4)
6. NLL
7. Cost of NLL/Watt
8. Cost of Total NLL ( 6 x 7 )
9. LL
10. CostofLL/Watt
11. Costoftotal LL(9x 10)
12. TOC price per Unit with
Capitalization (5+8+11)
13. No. of Transformers
14. Type test charges
15. TOC price((12xl3)+14)

5.6 Percentage Impedance

The value of impedance of transformers at 75 Deg. C shall be 4.5% subject to the tolerance
specified in the standard IS:2026.

5.7 Temperature Rise : The temperature rise over ambient of 50 deg. C shall not exceed the
limits given below:

Top oil temperature rise measured by thermometer : 35 Deg.C

Winding temperature rise measured by resistance : 40 Deg.C

Transformers not meeting the above limits of temperature rise shall not be accepted.

5.8 Penalty for Non Performance

5.8.1 During testing, if it is found that the actual measured losses are more than the values
quoted by the manufacturer penalty shall be recovered from the manufacturer at double the
loss capitalization rate arrived at clause 5.5. For fraction of a kW, proportionate penalty will be
recovered.
 Specifications for Outdoor type, Completely Self Protected, 3 Phase Distribution Transformers (upto 49
and including 100 kVA)

5.8.2 Transformers with temperature rise and impedance beyond guaranteed values:

5.8.2.1 Purchaser reserves the right to reject any transformer during the test at supplier's works,
if the temperature rise exceeds the guaranteed values.

5.8.2.2 Purchaser reserves the right to reject any transformer during the test at supplier's works,
if the impedance values differ from the guaranteed values including tolerance.

5.8.2.3 Purchaser also reserves the right to retain the rejected transformer and take it into service
until the manufacturer replaces it with a new transformer at no extra cost. The delivery as per
contract will be counted when the new transformer as per specification is provided by the
manufacture.

5.9 Tank

The transformer tank can be with radiator fins/ rounded or elliptical cooling tubes or made of
corrugated panels.

5.9.1 For Rectangular / Octogonal Plain Tank

The transformer tank shall be of robust construction rectangular /octogonal in shape and shall
be built up of tested MS sheets.

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.

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 varnish/hot oil resistant paint.

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.

The tank shall be reinforced by angle welded 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 octogonal tank and 760 mm of mercury for round tank, shall
not be more than 5 mm upto 750 mm length and 6.5 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.

The radiators can be tube type or fin type or pressed steel type to achieve the desired cooling
and the same shall be capable of giving continuous rated output without exceeding the specified
temperature rise. 4 Nos. welded heavy duty lifting lugs of MS plate 8 mm thick (min) suitably
50 Manual on Transformers

reinforced by vertical supporting flat welded edgewise below the lug shall be provided on the
side wall.

4 Nos. of welded heavy duty pulling lugs of MS plate 8 mm thick (min) shall be provided to pull
the transformer horizontally.

Top cover fixing bolts of Galvanised Iron adequately spaced and 6 mm Neoprene bonded cork
gaskets conforming to IS 4253 part-II shall be placed between tank and cover. The bolts outside
tank shall have 2 flat washers and one spring washer.

5.9.2 Corrugated Tank

Corrugated tanks may be offered for 63 kVA and 100 kVA.

The transformer tank shall be of robust construction corrugation in shape and shall be built up
of CRCA sheets of 1.2 mm thick.

The internal clearance of tank shall be such that, it shall facilitate easy lifting of core with coils
from the tank, with CCA (core-coil assembly), HV & LV bushings mounted on Top cover.

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 varnish / hot oil resistant paint.

Corrugation panel shall be used for cooling. The transformer shall be capable of giving
continuous rated output without exceeding the specified temperature rise.

2 Nos. welded heavy duty lifting lugs of MS plate 8 mm thick (min) suitably reinforced are to
be provided.

Top cover fixing bolts of galvanized iron and 6 mm Neoprene bonded cork gaskets conforming
to IS 4253 part-II / nitrile rubber shall be placed between tank and cover. The bolts outside tank
shall have 2 flat washers and one spring washer.

Tanks with corrugations and without conservator shall be tested for leakage test at a pressure of
0.15kg/sq cm measured at the top of the tank

5.9.3 Sealed Transformer with Radiators

In this type of construction tank is designed to have cover welded to the curb of tank.

Space is provided above the core coil assembly where inert gas cushion system accommodates
the oil expansion under variable pressure. The tank should be of stiff construction able to
withstand pressure of 2 atmospheres.
 Specifications for Outdoor type, Completely Self Protected, 3 Phase Distribution Transformers (upto 51
and including 100 kVA)

5.10 Conservator

On Transformers of 100 kVA rating with rectangular plain tank the provision of conservators is
obligatory. For other ratings manufacturer may adopt their standard practice. Conservator is not
required in transformers with corrugated tank.

When a conservator is provided, oil gauge and the plain or dehydrating breathing devise shall be
fixed to the conservator which shall also be provided with a drain plug and a filling hole (M30
normal size thread) with cover. The capacity of a conservator tank shall be designed keeping in
view the total quantity of oil and its contraction and expansion due to temperature variations. In
addition the cover of main tank shall be provided with an air release plug to enable air trapped
within to be released, unless the conservator is so located as to eliminate the possibility of air
being trapped within the main tank.

The inside diameter of the pipe connecting the conservator to the main tank should be within20
to 50 mm and it should be projected into the conservator so that its end is approximately 20
mm above the bottom of the conservator so as to create a sump for collection of impurities. The
minimum oil level (corresponding to -5 deg C) should be above the sump level.

5.11 Surface Preparation and Painting

5.11.1 For Surface Preparation refer to section A of this Manual

5.12 Bushings

The bushings shall conform to the relevant standards specified and shall be outdoor type.
The bushing rods and nuts shall be made of brass material 12 mm diameter for both HT &
LT. The bushings shall be fixed to the transformers on side with straight pockets and in the
same plane or on the top cover. Arcing horns or lightning arrestors shall be provided on HV
bushings.

For 11 kV, 17.5 kV class bushings and for 0.433 kV, 1.1 kV class bushings shall be used. Bushings
with plain sheds as per IS-3347 shall be mounted on the side of the Tank and not on top cover.

A minimum phase to phase clearance of 75 mm for LV (upto 1.1 kV bushings) and 255 mm for
HV bushings shall be obtained with the bushing mounted on the transformer.

The terminal arrangement shall not require a separate oil chamber not connected to oil in the
main tank.

5.13 Terminal Connectors

The LV bushing and HV bushing stems shall be provided with suitable terminal connectors so
as to connect the jumper without disturbing the bushing stem. Connectors shall be with eye bolts
so as to receive 55 sq mm conductor for HV.
52 Manual on Transformers

5.14 Terminal Markings

High voltage phase windings shall be marked both in the terminal boards inside the tank and on
the outside with capital letter 1U, IV, 1W and low voltage winding for the same phase marked
by corresponding small letter 2U, 2V, 2W. The neutral point terminal shall be indicated by the
letter 2N. Neutral terminal to be brought out and connected to local grounding terminal by an
Earthing strip.

5.15 Current Transformers (for 63 and 100 kVA ratings only)

• CT's shall be provided if required on secondary side.

• Current transformer shall be mounted inside the tank on LV side of the transformer. Ring
Type CTs in air, mounted in LV cable boxes are also accepted
• The current transformers shall be comply with IS: 2705.
• All secondary leads of bushing mounted CT's shall be brought to a terminal box near
each bushing. The CT terminals shall have shorting facility.

CT should not get saturated upto 200% of rated current.

Transformer Rating 63 kVA 100 kVA

Current Ratio 100/5 A 150/5 A
Class 0.5 0.5
Burden 20 VA 20 VA
Application Metering Metering
ISF 5 5

5.16 Lightning Arresters

9 kV, 5 kA Metal Oxide Lightning Arresters as per relevant standard, one number per phase
shall be fitted under the HV bushings with GI earth strip 25x4 mm connected to the body of the
transformer with necessary clamping arrangements. The metal oxide lightning arresters shall be
of reputed make.

5.17 Protection

The transformers shall have the following Completely Self Protection (CSP) features:

(i) Internal HV fuse on the HT side of transformer

Specification for the HV fuses: Expulsion/any other suitable type of fuse placed in series with
the primary winding. This fuse is mounted normally inside of the primary bushing for the three
phases and is connected to the high voltage winding through a terminal block. This has to protect
that part of the electrical distribution system which is ahead of the distribution transformers from
faults which occur inside the distribution transformer i.e., either in the windings or some other
 Specifications for Outdoor type, Completely Self Protected, 3 Phase Distribution Transformers (upto 53
and including 100 kVA)

part of the transformer. It shall be ensured that this fuse does not blow for faults on the secondary
side (LT side) of the transformer i.e., the blowing characteristics of the fuse and LT breaker shall
be so coordinated such that the fuse shall not blow for any faults on the secondary side of the
transformer beyond LT breakers and those faults shall be cleared by the LT breaker only.

(ii) 3 Pole LT circuit breaker

(a) Internally mounted oil immersed LT breaker on the LV side of the transformer:
All LT faults after the breaker shall be cleared by this breaker. As such it shall be designed for
perfect coordination with the HT fuse link. The Manufacturer shall furnish the time / current
characteristics of LT circuit breaker and 11 kV fuses for various current multiples.

The two characteristics shall be drawn on the same sheet to indicate coordination between the
circuit breaker and fuse. The Manufacturer shall carry out coordination test as indicated above
and this forms one of the tests for acceptance test.

The breaker shall be coordinated thermally with the transformer design to follow closely the
variations of coil temperature due to fluctuating loads and ambient temperatures.

This is to be accomplished by connecting the breaker in series between the secondary winding
and the secondary bushings. The breaker shall be located in the same oil as the core and coil
assembly so that the bimetal are sensitive to the temperature of oil as well as the load current

The circuit breaker shall also be closed and opened manually standing on ground. The current
carrying parts of breakers shall be copper plus a set of copper tungsten current interrupting
contacts.

The cross-section of the current carrying parts of the breaker shall withstand the full load current
at a current density not more than 2.5A/sq. mm (for additional mechanical strength the area
should be more).

(b) MCCB

3 pole MCCB (confirming to IS 13947) from reputed manufacturers of appropriate rating with
inverse time characteristics for overload & instantaneous magnetic trip (trip time less than 10
mS at 0.4 lagging p.f.) for short circuits shall be provided after the LT bushing in the distribution
box. All plastic material shall comply to glow wire test as per relevant IS. Type test report from
NABL accredited laboratory shall be submitted.

A distribution box (made of MS or SMC or FRP) shall be provided as an integral part of the
transformer to be mounted on the tank before installation on the pole. LT bushing shall be inside
the distribution box and a facility for sufficient number of outgoing feeders through cable glands
shall be provided. Distribution box shall also have provision for installation of energy meter.

Distribution box shall be designed for out-door duty with minimum IP - 55 protection. It shall
have pad-locking arrangement.
54 Manual on Transformers

(iii) Load Management Signal Light

A signal light shall be provided to give information about the loading condition of the transformer.
It shall forewarn any overloading problem at the installation such that a change out of the existing
transformer with a higher capacity transformer can be planned. The signal light mechanism shall
not reset itself when the load drops from the overloaded condition. The signal light shall remain
lighted once the signal light contacts close due to overload and can be turned off by manual
operation. (The signal light shall not give indication for momentary overloading).

5.18 Fittings

The following standard fittings shall be provided:

(a) Rating and terminal marking plates non-detachable
(b) Earthing terminals with lugs - 2 Nos.
(c) Lifting lugs for main tank & top cover
(d) Pulling lugs - 4 Nos
(e) HV bushings - 3 Nos.
(f) LV bushings - 3 Nos.
(g) Neutral bushings-1 No.
(h) Terminal connectors on the HV/LV bushings
(i) 9 kV 5 kA lightning arrestors on HT side - 3 no.
(j) Thermometer pocket with cap -1 No.
(k) Air release device
(1) Stiffener angle 40 x 40 x 5 mm and vertical strip of 50 x 5 mm flat
(m) Radiators
(n) Prismatic oil level guage
(o) Drain cum sampling valve
(p) Oil filling hole having M30 thread with plug and drain valve on the conservator
(q) Silicagel breather
(r) Pressure relief device or explosion vent.
(s) Base channel 75 x 40 mm
(t) MCCB or Oil immersed LT circuit breaker along with operating rod
(u) HV fuse links
(v) Signal light

5.19 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.
 Specifications for Outdoor type, Completely Self Protected, 3 Phase Distribution Transformers (upto 55
and including 100 kVA)

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 galvanising, except high tensile steel bolts and spring washers which shall
be electro galvanised/ 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.

Taper washers shall be provided wherever necessary.

5.20 Mounting Arrangement

The under base of all transformers shall be provided with two 75 x 40 mm channels 460 mm
long with holes to make them suitable for fixing on a platform or plinth

5.21 Overload Capacity

The transformers shall be suitable for loading as per IS: 6600 / 2026-7.

6.0 TESTS

6.1 Routine Tests

• Ratio, polarity and phase sequence.

• Insulation Resistance (IR) & Polarisation Index (PI)
• Magnetic Balance Test
• No load current and losses at rated frequency, rated voltage and at 90% & 110%
voltage.
• Load loss at rated current and normal frequency
• Impedance voltage test
• Resistance of windings
• Induced over voltage withstand test.
• Separate source voltage withstand test.
• LT Circuit Breaker coordination test.
56 Manual on Transformers

• Efficiency & regulation tests as per cl. 19 of IS 1180.

• Air pressure test on assembled transformer at 0.35 kg/cm2 for 10 min.

6.2 Special Tests

Lightning impulse with chopped on the tail.

Impulse voltage test: As per clause no. 13 (with chopped wave) of IS-2026 part-III as per latest
version. BIL for 11 kV shall be 95 kV peak.

Short circuit test.

Short Circuit Withstand Test: Thermal and dynamic ability including test as per IS 2026
part-V.

6.3 Additional Tests

• Neutral current measurement
• Air pressure test: As per Cl.22.5 of IS -1180 / part-I
• Transformer tank shall be subjected to specified vacuum. The tank designed for vacuum
shall be tested at an internal pressure of 0.35 kg/cm2 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)
Upto & including 750 5.0
751 to 1250 6.5

• Transformer tank together with its radiator and other fittings shall be subjected to
pressure corresponding to twice the normal pressure or 0.35 kg/cm2 whichever is lower,
measured at the base of the tank and maintained for an hour. The permanent deflection
of tie flat plates after the excess pressure has been released, shall not exceed the figures
for vacuum test.
• The pressure relief device shall be subject to increasing fluid/air pressure. It shall operate
before reaching the test pressure as specified in the above clause. The operating pressure
shall be recorded. The device shall seal-off after the excess pressure has been released.
• Oil samples (one sample per lot) to comply with IS 1866.
• Single phase LV excitation current at all three phases (for reference)
6.4 Type Tests to be Conducted on one Unit
In addition to the tests mentioned above the following tests shall be conducted.
• Temperature rise test.
• Lightning impulse withstand voltage test:
Oil samples (before and after short-circuit and temperatures rise test) for each tested
transformer.
 SECTION C

Specifications for Outdoor Type, Completely Self

Protected, Single Phase Distribution Transformers
(Single Phase 11 kV/250 V & 11/√3 kV/250V, 5, 10,
16 & 25 KVA Ratings)
 SECTION C
Specifications for Outdoor Type, Completely Self Protected, Single
Phase Distribution Transformers (Single Phase 11 kV/250 V & 11/√3
kV/250V, 5, 10, 16 & 25 KVA Ratings)

1.0 SCOPE

1.1 This section covers oil immersed naturally cooled 11 kV / 250V* and 11 kV/√3 / 250V*
single phase Completely Self Protected distribution transformers, but does not purport to include
all the necessary provisions of a contract. For general requirements and tests, reference shall be
made to sections A to BB of the Manual.

1.2 Standard Ratings

The Standard Ratings of 1- Phase Transformers shall be 5, 10, 16 & 25 kVA.

2.0 STANDARDS

2.1 The materials shall conform in all respects to the relevant Indian Standard Specifications
with latest amendments/edition thereof:
Note : * REC Specification mention 230 V

Indian Standard Title International and Internationally

recognized standard
IS-2026 (Part-I to IV) Specification for Power Transformer IEC-60076
IS-1180 (Part l& 2) Outdoor Three Phase Distribution Transformer

IS-3347 Specification for Porcelain Transformer Bushings DIN 42531,2,3

IS-7421 Specification for Low Voltage Bushings

IS - 12444 Specification for Copper Wire Rods ASTM B - 49
IS-335 Specification for Transformer Oil BS 148/ASTM DI275, DI533, ILC
Pub 296

1S-3070 Specification for Lightning Arresters 1HC99-1

1S-6600/ Guide for Loading of Oil Immersed Transformers 1EC 60076-7 (ILC 354)
2026-7
1S-2099 High Voltage Porcelain Bushings IEC 60137
IS 9335 Specification for Insulating Kraft Paper IEC 60554
IS 1576 Specification for Insulating Press Board IEC 60641
IS 5 Specification for Colours for Ready Mixed
Paints
Refer Appendix II of the Manual for List of Standards.

59
60 Manual on Transformers

3.0 SERVICE CONDITIONS

The Distribution Transformers to be supplied against this Specification shall be suitable for
satisfactory continuous operation under the climatic conditions prevailing at site and to be
specified by the purchaser as follows as per IS 2026 (Part-I) latest revision. International
Standards tabulated above.

(i) Location :
(ii) Max ambient air temperature (Deg.C) :
(iii) Min. ambient air temperature (Deg.C) :
(iv) Max. average daily ambient air temperature (Deg.C) :
(v) Max. yearly weighed average ambient temperature (Deg.C) :
(vi) Max. altitude above mean sea level (m) :

4.0 STANDARD RATINGS

The transformers shall be suitable for outdoor installation with Single phase, 50 c/s 11 kV
systems in which the neutral is effectively earthed and they should be suitable for service under
fluctuations in supply voltage upto plus 10% to minus 15%.

The transformer shall conform to the following specific parameters.

Rated HV side value (11/√3 or 11 kV) shall be specified in the detailed Guaranteed Technical
Particulars by Purchaser

Table 1

SI. ITEM SPECIFICATION

No
1. Continuous rated capacity 5kVA 10 kVA 16kVA 25 kVA
2. System Voltage (Max) 12 kV 12 kV 12 kV 12 kV

3. Rated Voltage HV 11 kV/√3 or 11 kV 11 kV/√3 or 11 kV 11 kV/√3 or 11 kV 11 kV/√3 or 11

kV
4. Rated Voltage I.V 230 V (250 V Max) 230 V (250 V Max) 230 V(250 V Max) 230 V(250 V
Max)
5. BIL 95 kV Peak 95 kV Peak 95 kV Peak 95 kV Peak
6. Frequency 50 Hz ± 3% 50 Hz ± 3% 50 Hz ± 3% 50 Hz ± 3%
7. No of phases Single Single Single Single
8. Type of cooling ONAN ONAN ONAN ONAN
9. Tap changing arrangement Not provided Not provided Not provided Not provided
10. Percentage impedance at 2.5% (Tolerance as 4 % (Tolerance as 4 % (Tolerance 4% (Tolerance
11. Rated frequency and 75" C per IS: 2026) per IS: 2026) as per IS: 2026) as per IS: 2026)
Permissible temperature rise
over ambient
 Specifications for Outdoor Type, Completely Self Protected, Single Phase Distribution Transformers 61
(Single Phase 11 kV/250 V & 11/√3 kV/250V, 5, 10, 16 & 25 KVA Ratings)

(i) of top oil measured by 35 "C 35 "C 35 "C 35 ' C

thermometer
(ii) of winding measured by 40 "C 40 "C 40 "C 40 "C
resistance
12. Minimum clearances in air
(a) HV phase to phase / 255/ 140 255/140 255/ 140 255/ 140
phase to earth (mm)
(b) LV phase to phase / 75/40 75/40 75/40 75/40
phase to earth (mm)

5.0 TECHNICAL REQUIREMENTS

5.1 Winding Connection and Terminal Arrangements

For 11 kV transformers both ends of primary winding shall be brought out through HV
bushings. For 11 kV/ √3 transformers, neutral end of the primary HV winding shall be bought
out for connecting to ‘Neutral’ supply wire through 1.1 kV bushing. There shall be provision for
connecting ‘Neutral’ terminal, to local ‘Earth’ by way of a tinned Copper strip, of adequate size
and dimension. The secondary winding shall be connected to two LV bushings.

5.2 Core

5.2.1 Core Material

Transformer core shall have wound core construction using new and high quality CRGO steel with
heat resistant insulating coating or Amorphous Metal. The laminations shall be free from burrs
& edge bends. Air gap in the core assembly shall be avoided. The core shall be properly stress
relieved by annealing in inert atmosphere as per core material manufacturer’s recommendations.
Amorphous metal core shall be annealed under magnetic field. The transformer shall be suitable
for over fluxing (due to combined effect of voltage and frequency) upto 12.5% without injurious
heating. The operating flux density shall be such that there is a clear safe margin over the over-
fluxing limit of 12.5%.

Following documents as applicable shall be submitted during inspection as a proof towards use
of prime core material

• Invoice of the supplier

• Mills Test Certificate
• Packing List
• Bill of Lading
• Bill of entry certificate to customs
5.3 Winding

HV and LV windings shall be wound from copper conductors.Aluminium conductors can also
be used with same loss levels as of copper wound transformers. The HV winding conductor
62 Manual on Transformers

shall be covered with Super enamel & LV winding with DPC / Super Enamel. The inter layer
insulation shall consist of epoxy resin coated paper or epoxy resin dotted paper. The windings
shall be progressively wound in LV - HV coil design for better voltage regulation and mechanical
strength. Compression bonding of the windings shall be ensured by deploying suitable press in
the winding process or by curing of epoxy paper insulation in a suitable press. The core coil
assembly shall be dried in an oven. The type of winding shall be indicated, whether LV windings
are of conventional to type or foil wound.

Joints in the winding shall be avoided. However if joining is necessary, the joints shall be
properly brazed & finished.

5.4 Oil

5.4.1 The insulating oil shall be new and shall comply with the requirements of IS 335. Use
of recycled oil is not acceptable.

5.4.2 Oil shall be filtered & tested for BDV & moisture content before filling. Oil filling shall
be carried under vacuum of 5 torrMin.

5.4.3 Testing of oil after filling

Testing of oil sample for BDV & moisture content from assembled transformers shall be carried
out as acceptance test in line with IS 1866.

5.4.4 Insulation Material

The inter layer insulation shall be of epoxy resin bond paper. The core/coil assembly shall be securely held
in position to avoid any movement under short circuit conditions.

5.5 Losses : The maximum losses at rated voltage and rated frequency permitted at 75 Deg.C. are
indicated below:

No load losses (Max) - CRGO No load losses (Max) Full load losses in watts
KVA Rating watts Amorphous watts (Max) at 75 Deg C watts
5 25 8 135
10 30 12 180
16 45 17 230
25 55 25 310

Note: The losses mentioned above are under discussion and finalisation by BIS to revise IS: 1180. The above losses
eventually may get revised if any, after said revision.

The above losses are maximum allowable and there would not be any positive tolerance. Transformers
with higher losses than the above specified values would be rejected.

Transformers with losses less than those specified above will be capitalized during bid evaluation as per
loss capitalization formula as given below.
 Specifications for Outdoor Type, Completely Self Protected, Single Phase Distribution Transformers 63
(Single Phase 11 kV/250 V & 11/√3 kV/250V, 5, 10, 16 & 25 KVA Ratings)

Total Ownership Cost (TOC) after loss capitalization = Quoted Price + NLL X A + LLxB

Transformers with losses less than those specified above will be capitalised during evaluation as
indicated below. (Refer to Loss Capitalisation formula, SectionAA).

Loss Capitalization factors:

A. Iron Losses - Rs. 89.67 x Ec / Watt
B. Copper Losses - Rs. 26.9 x Ec / Watt
Where Ec is the cost of energy ( in Rupees per unit at 11 kV feeder level). In case of non availability of Ec
(Energy cost per unit) at 11 kV feeder level, utility should consider the Bulk Rate Tariff plus 5% as the cost
of energy at 11 kV feeder level.

Price schedule:

The following format shall be filled by the manufacturer for evaluating TOC.

SI. No Price Component

1 Unit ex-works price (Rupees)
2 Freight & Insurance (Rupees)
3 Excise duty (Rupees) (2) Educational cess on Excise duty (Rupees)

4 Sales Tax (Rupees)

5 Total Cost per Unit without Capitalization (1+2+3+4) (Rupees)
6 NLL (Watts)
7 Cost of NLUWatt (Rupees) (A)
8 Cost of Total NLL (6 X 7) (Rupees)
9. LL (Watts)
10. Cost of LL/Watt (Rupees) (B)
11. Cost of total LL(9 x 10) (Rupees)
12. TOC price per Unit with Capitalization (5+8+11) (Rupees)

5.6 Penalty for Non-Performance

5.6.1 Loss values beyond guaranteed values, but less than Max. losses specified at cl. 5.5
-During testing, if it is found that the actual measured losses are more than the values quoted,
penalty shall be recovered from the manufacturer at double the loss capitalization rate arrived at
clause 5.5. For fraction of a Watt, proportionate penalty will be recovered.

5.6.2 Transformers with temperature rise and impedance beyond guaranteed values:

5.6.2.1 Purchaser reserves the right to reject any transformer during the test at supplier’s works,
if the temperature rise exceeds the guaranteed values.
64 Manual on Transformers

5.6.2.2 Purchaser reserves the right to reject any transformer during the test at supplier’s works,
if the impedance values differ from the guaranteed values including tolerance.

5.6.2.3 Purchaser also reserves the right to retain the rejected transformer and take it into
service until the Manufacturer replaces it with a new transformer at no extra cost. The delivery
as per contract will be counted when the manufacturer provides the new transformer as per
specification.

5.6.2.4 Transformers having losses above the values specified in the clause 5.5 shall be
rejected.

5.7 Tank

The oil volume inside the tank shall be such that even under the extreme operating conditions,
the pressure generated inside the tank does not exceed 0.4 kg/cm2 positive or negative. There
must be sufficient space from the core to the top cover to take care of oil expansion.

The tank cover shall have plasticised surface at the top to guard against bird faults. Alternately,
suitable insulating shrouds shall be provided on the bushing terminals.

The Transformer tank shall be of robust construction round in shape and shall be built up of
tested CRCA / MS sheet. The tank shall be capable of withstanding a pressure of 1 kg/cm2 (g)
and a vacuum of 760 mm of Hg for 30 minutes without any permanent deflection (Air pressure
test shall be conducted as per IS -1180)

The L - seam joint, C - seam joint and all fittings and accessories shall be oil tight and no
deflection / bulging should occur during service.

The circular base plate edges of the tank should be folded upward, for at least 25 mm, to have
sufficient overlap with vertical sidewall of the transformer.

Tank shall have permanent lugs for lifting the transformer bodily and there shall be facilities for
lifting the core coil assembly separately.

The transformer tank and the top cover shall be designed in such a manner as to leave no
external pockets in which water can lodge.

The transformer shall be provided with two mounting lugs suitable for fixing the transformer to
a single pole by means of 2 bolts of 20 mm diameter as per ANSI C 57.12.20.

• Both mounting lugs are made with steel of min. 5 mm thickness.

• Minimum Oil level mark shall be embossed inside the tank.

• Jump proof lips shall be provided for upper mounting lug.

• Mounting lugs faces shall be in one plane.

 Specifications for Outdoor Type, Completely Self Protected, Single Phase Distribution Transformers 65
(Single Phase 11 kV/250 V & 11/√3 kV/250V, 5, 10, 16 & 25 KVA Ratings)

• The top cover shall be fixed to the tank through clamping only.
• HV bushing pocket shall be embossed to top side of the top cover so as to eliminate
ingressing of moisture and water.
• The edges of the top cover shall be formed, so as to cover the top end of the tank and
gasket.
Sealing gaskets - Continuous (without joint) oil resistant high quality Nitrile / neoprene /
Polyurethane rubber gaskets conforming to Type-III as per latest IS-11149 shall be provided
between tank & top cover and for fixing the bushings.

Tank sealing - The transformer shall be of sealed tank construction with welded or bolted
cover which seals the interior of the tank from atmosphere and in which gas volume plus oil
volume remains constant. The space on the top of the oil shall be filled with dry air or nitrogen.
The nitrogen plus oil volume inside the tank shall be such that even under extreme operating
conditions, the pressure generated inside the tank does not exceed 0.4 kg/cm2 positive or
negative. The nitrogen shall conform to commercial grade of the relevant Standard.

5.8 Surface Preparation and Painting

For surface preparation refer to section ‘A’ of this Manual.

5.9 Winding Connection & Bushing Terminal Arrangements

For 11/√3 kV Transformers, Neutral end of the primary HV winding shall be brought out
for connection to ‘Neutral’ supply wife through 1.1 kV bushings. ‘Neutral’ terminal shall be
connected to transformer tank by way of a tinned Copper strip of adequate size and dimension.
The secondary winding shall be connected to two LV bushings. HV terminal shall be designed to
directly receive ACSR conductor upto 7/2 59 mm (without requiring the use of lug) and the LV
terminals shall be suitable for directly receiving LT cables (aluminium) ranging from 10 sq mm
to 25 sq mm both in vertical and horizontal position and the arrangements should be such as to
avoid bimetallic corrosion. Terminal connectors must comply as per IS : 5561.

5.10 Bushings

The bushings shall conform to the relevant standards specified.

For HV, 12 kV class bushings shall be used and for LV, 1.1 kV class bushings shall be used.

The HV bushings shall be fixed to the top cover of the transformer and the LV bushings shall
be fixed to transformer on sides and in the same plane. The bushing rods and nuts shall be of
brass.

The terminal arrangement shall not require a separate oil chamber not connected to oil in the
main tank.

The HV bushings shall not have arcing horns.

66 Manual on Transformers

5.11 Rating and Terminal Plates

There shall be a rating plate on the transformer containing the information given in the relevant
Indian Standard. The HV winding terminals shall be marked 1.1 and 1.2 for 11 kV/√3 HV
winding. 1.2 terminal will be connected to neutral. In case of 11 kV HV winding the terminal
shall be marked as 1.1 - 1.2. The corresponding secondary terminal shall be marked as 2.1 and
2.2.

5.12 Protection

The transformer shall have the following CSP features:

5.12.1 Internal HV Fuse on the HT Side of Transformer

Suitable replaceable fuse shall be placed inside the transformer, in series with the primary
winding. The fuse on primary side of the distribution transformer shall take care of any fault
occurring inside the transformer itself. The characteristic of the fuse and LT breaker shall be
well coordinated so that the fuse shall not blow for any faults on the secondary side of the
transformer beyond LT Breaker and those faults shall be cleared by LT breaker only. The fuse
shall confirm to IS 9385 and shall be tested for short circuit current.

5.12.2 LT Circuit Breaker

This breaker shall clear all LT faults after the breaker. As such it shall be designed for perfect
coordination with the HT fuse for various current multiples. The two characteristics shall be
drawn on the same sheet to indicate coordination between the circuit breaker and HV fuse. The
manufacturer shall carry out coordination test as indicated above, and this forms one of the tests
for acceptance. The LT breaker shall also be coordinated with overload characteristics of the
transformer. The reference temperature for calibration shall be 40 Deg C.

Arrangement shall be made so that the circuit breaker can be closed and opened manually
standing on ground.

The cross section of the current carrying parts of the breaker shall withstand the full load current
at a current density not more than 2.5 A/sq.mm (for additional mechanical strength the area
should be more). Rated short circuit breaking capacity of the breaker shall not be less than 2.5
kA. The circuit breaker shall confirm to IS-13947 with power factor 0.4 lagging. Time current
characteristics & other requirements shall be in line with IS 13947 (latest version).

Time current characteristics of LT CB

SL. No. Test current Initial test conditions Time limits of tripping/ no Remarks
tripping
1. 1.05 In Cold l ≥ 2.5h No tripping
2. 1.20 In Immediately after Sl.no. 1 I0 min ≤ t ≥ 2h Tripping
3. 1.30 In Cold t ≤ 30 min Tripping
 Specifications for Outdoor Type, Completely Self Protected, Single Phase Distribution Transformers 67
(Single Phase 11 kV/250 V & 11/√3 kV/250V, 5, 10, 16 & 25 KVA Ratings)

4. 1.40 In Cold t≤10 min Tripping

5. 2.50 In Cold t ≤ 1 min Tripping
6. 4.00 In Cold t ≥ 5S Tripping
7. 6.00 In Cold t≤5S Tripping
8. 12.00 In Cold t ≥ 40mS Tripping

Where In is full load LV current of the transformer.

Manufacturer shall submit the coordination of time-current characteristics of LT & HT side

plotted on the same sheet of paper for approval of the owner.

Manufacturer shall offer either internally mounted oil immersed circuit breaker or MCCB as
specified below. (Utilities may specify any one option).

(a) Internally mounted, Oil immersed ‘LT’ Breaker

The breaker shall be located in the same oil as the core and coil assembly so that the bimetal is
sensitive to the temperature of oil as well as the load.

(b) MCCB

Double pole MCCB (confirming to IS 13947) from reputed manufacturers of appropriate rating
with inverse time characteristics for overload & instantaneous magnetic trip (trip time less
than 10 mS at 0.4 lagging p.f.) for short circuits shall be provided after the LT bushing in the
distribution box. All plastic material shall comply to glow wire test as per relevant IS. Type test
report from NABL accredited laboratory shall be submitted.

A distribution box (made of MS or SMC or FRP) shall be provided as an integral part of the
transformer to be mounted on the tank before installation on the pole. LT bushing shall be inside
the distribution box and a facility for sufficient number of outgoing feeders through cable glands
shall be provided. Distribution box shall also have provision for installation of energy meter.

Distribution box shall be designed for out-door duty with minimum IP - 55 protection. It shall
have pad-locking arrangement.

5.12.3 Signal Light for Tripping of LT Breaker

The distribution box shall be equipped with an LED to indicate tripping of LTCB. On resetting
of LTCB the LED shall be automatically switched off.

5.12.4 11 kV Lightening Arresters

High surge capacity 9 kV, 5 kA metal oxide lightening arrester conforming to 1S-3070 (Pt-III)
shall be mounted on the transformer & clamped securely to the lank, to protect the transformer
and associated line equipment from the occasional high voltage surges resulting from lightning
or switching operations. The Earthing terminal of the lightning arresters shall be connected
68 Manual on Transformers

solidly to the Earthing terminal on the tank body. Lightning arrestors with polymer insulators in
line with relevant IEC shall also be acceptable.

5.12.5 Pressure Release Device

The transformer shall be equipped with a self-sealing pressure release device, designed to
operate at a minimum pressure of 8 psi (0.564 kg/ cm2). The PRD shall be provided in the low-
voltage terminating portion of the tank above top oil level. Inlet port shall be V4 inch or longer
NPT. Resealing pressure shall be 0.3 kg/cm2

5.13 Fittings

The following standard fittings shall be provided:

(i) Rating and Terminal marking plates.
(ii) Earthing terminals - 2 Nos.
(iii) Lifting lugs - 2 Nos.
(iv) HV bushings.
(v) LV bushings.
(vi) Bird guard.
(vii) HV & LV Terminal connectors.
(viii) HV side Neutral ‘Earthing’ strip;
(ix) LV earthing arrangement.
(x) Metal oxide lightning arrestors (9kV, 5kA)
(xi) MCCB or Oil immersed LT circuit breaker along with operating rod
a. (make, type and technical details to be provided.)
(xii) HV fuse links
(xiii) Signal light
(xiv) Oil level indicator
(xv) Top cover fixing clamps.
(xvi) Pressure relief device.
(xvii) Mounting lugs - 2 Nos.
(xviii) 5 year guarantee plate
(xix) Any other fitting necessary for satisfactory performance of the manufacture.

5.14 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.
 Specifications for Outdoor Type, Completely Self Protected, Single Phase Distribution Transformers 69
(Single Phase 11 kV/250 V & 11/√3 kV/250V, 5, 10, 16 & 25 KVA Ratings)

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 galvanising, except high tensile steel bolts and spring washers which shall
be electro-galvanised/ 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.
Taper washers shall be provided where necessary.

6.0 TESTS

6.1 Routine Tests

• Ratio, polarity tests.

• No load current and loss at rated voltage and frequency.
• Load loss at rated current and normal frequency.
• Impedance voltage test.
• Resistance of windings.
• Insulation Resistance (IR) & Polarisation Index (PI).
• Induced over voltage withstand test.
• Separate source voltage withstand test.
• LT Circuit Breaker coordination test.
• Efficiency & regulation tests as per cl. 19 of IS 1180.
• Air pressure test on assembled transformer at 0.35 kg/cm2 for 10 min.

6.2 Special Tests

Lightning impulse with chopped on the tail.

Impulse voltage test: As per clause no. 13 (with chopped wave) of IS-2026 part-III as per latest
version. BIL for 11 kV shall be 95 kV peak

Short circuit test

Short Circuit Withstand Test: Thermal and dynamic ability including test as per IS 2026
part-V.
70 Manual on Transformers

6.3 Additional Tests

• Oil samples test (one sample / lot) to comply with IS 1866

• Air pressure Test: As per clause 24.5.1 of IS-1180/ Part-II.

6.4 Type Tests to be Conducted on one Unit

In addition to the tests mentioned above the following tests shall be conducted.

• Temperature rise test.

• Lightning/Impulse withstand voltage test.
• Oil samples (before and after short circuit and temperature rise test).
 SECTION D

Specifications for Three Phase Distribution

Transformers (above 100 kVA and upto 33 kV class)
 SECTION D
Specifications for Three Phase Distribution Transformers (above 100
kVA and upto 33 kV class)
1.0 SCOPE
1.1 This section covers, Three phase distribution transformers of above 100 kVA to 3150
kVA, 11 & 33 kV (outdoor & indoor use) but does not purport to include all the necessary
provisions of a contract. For general requirements and tests, reference shall be made to sections
A and BB respectively of the Manual.
1.2 Standard Ratings
kVA Voltage Ratio
160
200
250
315
400
500
630
800 11000/433V
1000
1250
1600
2000
2500
3000
3150
315
400
500
630
800
1000
33000/433V
1250
1600
2000
2500
3000
3150
The above ratings are also applicable for 22 /0.433 kV transformers.
2.0 STANDARDS
2.1 The materials shall conform in all respects to the relevant Indian / International Standard
73
74 Manual on Transformers

Specification, with latest amendments thereof, some of them are listed below: However, prior
agreement with customer is necessary for standard to be followed.
Indian Standard Title International & Internationally
recognised standard
IS -2026 Specification for Power Transformer Outdoor IEC 60076
IS- 1180 Distribution Transformer upto and including 100
IS 12444 kVA Specification for Copper Wire Rod ASTM B-49

IS-3347 Specification for Porcelain Transformer Bushing

IS-335 Specification for Transformer Oil DIN 42531,23,3

IS -5 Specification for Colours for Ready Mixed Paints BS 148, D-1473, D-1533- 1934
IS-2099 Specification for High Voltage Porcelain Bushings IEC Pub 296
IS – 7421 Specification for Low Voltage Bushings DIN 42531 to 33
IS– 3347 Specification for Outdoor Bushings ASTM B - 233
IS - 5484 Specification for Al Wire Rods IEC 60137
IS -9335/IS- 1576 Specification for Insulating Kraft Paper
IS – 6600 / Specification for Insulating Press Board
IS 2026-7 Guide forLoading of Oil Immersed Transformers

Refer Appendix II of the Manual for List of Standards.

3.0 SERVICE CONDITIONS

3.1 The Distribution Transformers to be supplied against this Specification shall be suitable
for satisfactory continuous operation under the climatic conditions prevailing at site and to
be specified by the purchaser as follows as per IS 2026 (Part-I) Latest Revision/International
Standards tabulated above :
(i) Location : ----
(ii) Max ambient air temperature (Deg.C) : ----
(iii) Min. ambient air temperature (Deg.C.) : ----
(iv) Max average daily ambient
air temperature (Deg.C) : ----
(v) Max. yearly weighted average
ambient temperature (Deg.C) : ----
(vi) Max. altitude above mean sea level (m) : ----
4.0 TAPPINGS AND TAP CHANGING
4.1 Tappings shall be provided on the higher voltage winding for variation of HV Voltage
from plus 5% to minus 10% in steps of 2.5%. However no. of taps & steps to be decided as per
requirement of the customer. Preference shall be given for off-circuit tap link arrangement. Tap
change arrangement is not preferred in an ideal case.
4.2 Tap changing, if at all provided shall be carried out by means of an off circuit externally
operated self positioning tap switch when the transformer is in de-energised condition. Switch
position No. 1 shall correspond to the maximum voltage tapping. Each tap change shall result in
variation of 2.5% in voltage. Provision shall be made for locking the tap changing switch handle in
position.
 Specifications for Three Phase Distribution Transformers (above 100 kVA and upto 33 kV class) 75

4.3 For ratings greater than 500 kVA On-load tapchanger may be provided for variation of
HV voltage from plus 5% to minus 15% in steps of 1.25%.

5.0 TYPE OF COOLING

The transformers shall be oil immersed with natural oil circulation type-ONAN.

6.0 INSULATION LEVELS

Voltage Impulse voltage (kV Peak) Power frequency (kV)

433 — 3
11000 75 28
33000 170 70

7.0 WINDING CONNECTIONS

HV------Delta. LV------Star

Vector Symbol.......Dyn11

8.0 LOSSES AND IMPEDANCE

Losses and Impedance shall be guided as per recommendations of BEE star rating plan.

Note: 1. Note: The losses mentioned above are under discussion and finalisation by BIS to revise
IS:1180. The above losses eventually may get revised if any, after said revision.
2. For 22/0.433 kV transformers losses of33/0.433 kV shall be applicable.
76 Manual on Transformers

9.0 TECHNICAL REQUIREMENTS

9.1 Core

9.1.1 Material - CRGO

The core shall be stacked type generally of high grade cold rolled grain annealed steel
lamination 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.

9.1.2 Core Clamping for CRGO Stacked Core

MS channel or plate shall be used on top and bottom.

Channel frames on LV side to be reinforced at equidistance, if holes / cutting is done for LT lead
in order to avoid bending of channel.

MS channels/plate frames shall be painted with hot oil-resistant varnish or paint.

9.1.3 The transformers core shall be suitable for over fluxing (due to combined effect of
voltage and frequency) upto 10% without injurious heating at full load conditions and shall not
get saturated.

9.1.4 No load current shall not exceed 1% of full load current for all ratings covered under this
section Increase in secondary voltage of 433 volts by 10% shall not increase the no load current
beyond 6% of full load current for ratings below 315 kVA and 4% of full load current for ratings
above 315 kVA.

9.2 Windings

9.2.1 Material: Super enamel covered/Double paper covered (DPC) Copper / Aluminium
round/strip conductor.

9.2.2 LV winding shall be of strip type copper / Aluminium conductor or copper / aluminium
foil type.

9.2.3 HV coil is wound over LV coil as crossover coils or continuous disc coils.

The choice of copper / aluminium as winding material should be left to customer at the time of
tendering.

9.2.4 Inter layer insulation shall be Kraft paper/Epoxy dotted paper. Proper bonding of inner
layer insulation with the conductor shall be ensured.
 Specifications for Three Phase Distribution Transformers (above 100 kVA and upto 33 kV class) 77

9.3 Oil

The insulating oil shall comply with the requirements of relevant standards IS 335 / IEC:60296

9.4 Temperature Rise

The temperature rise over ambient of 50 deg C shall not exceed the limits described below:
Top oil temperature rise measured by thermometer : 35 Deg.C
Winding temperature rise measured by resistance : 40 Deg.C
9.5 Insulation Material

Material: Electrical grade insulation Kraft paper.

All spacers, axial wedges / runners used in windings shall be made of pre-compressed Pressboard—
solid, conforming to type B 3.1 of IEC 641-3-2. In case of cross-over coil/continuous disc winding
of HV all spacers shall be properly sheared and dovetail punched to ensure proper locking. All axial
wedges / runners shall be properly milled to dovetail shape so that they pass through the designed
spacers freely. Insulation shearing, cutting, milling and punching operations shall be carried out in such
a way, that there is no burr or dimensional variations.

10.0 TANK

10.1 Rectangular Plain Tank

The transformer tank shall be of robust construction rectangular in shape and shall be built up
of tested MS sheet.

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.

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 varnish / hot oil resistant paint.

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.
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.
78 Manual on Transformers

Only Pressed steel radiators shall be used for cooling. The transformer shall be capable of
giving continuous rated output without exceeding the specified temperature rise. 4 Nos. welded
heavy duty lifting lugs of MS plate 8 mm thick (min) suitably reinforced by vertical supporting
flat welded edgewise below the lug shall be provided on the side wall.

Top cover fixing shall be with galvanised iron bolts and 6 mm Synthetic resin bonded cork sheet
gasket (type RC 70C) conforming to IS 4253 part-II shall be placed between tank and cover. The
bolts outside tank shall have 2 flat washers & one spring washer.

10.2 Corrugated Tank

The transformer tank shall be of robust construction corrugated in shape and shall be built
up of CRCA sheets of thickness. Thickness of corrugated CRCA sheet shall be decided by
manufacturer & customer jointly.

The internal clearance of tank shall be such that, it shall facilitate easy lifting of core with coils
from the tank with CCA (core-coil assembly), HV & LV bushings mounted on Top cover.

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 varnish / hot oil resistant paint.

Corrugated panel shall be used for cooling. The transformer shall be capable of giving continuous
rated output without exceeding the specified temperature rise.

2 Nos. welded heavy duty lifting lugs of MS plate 8 mm thick (min) suitably reinforced shall
be provided.

Top cover fixing shall be with GI (Galvanised Iron) bolts and 6 mm Synthetic resin bonded cork
sheet gasket (type RC 70C) bonded cork gaskets conforming to IS 4253 part-II shall be placed
between tank and cover. The bolts outside tank shall have 2 flat washers & one spring washer.

Tanks with corrugations and without conservator shall be tested for leakage test at a pressure of
0.15kg/cm2 measured at the top of the tank.

10.3 Sealed Transformer with Radiators

In this type of construction, tank is designed to have cover welded to the curb of tank. Space is
provided above the core coil assembly where inert gas cushion system accommodates the oil
expansion under variable pressure. The tank should be of stiff construction, able to withstand
pressure of 2 atmospheres.

10.4 Conservator

The provision of conservator is obligatory for plain Tanks mentioned in clause 10.1 above
 Specifications for Three Phase Distribution Transformers (above 100 kVA and upto 33 kV class) 79

i.e., where pressed steel radiators are used for oil circulation. Conservator is not required for
corrugated tanks.

When a conservator is provided, oil gauge and the plain or dehy drating breathing devise shall be
fixed to the conservator, which shall also be provided with a drain plug and a filling hole (M30
normal size thread) with cover. The capacity of a conservator tank shall be designed keeping in
view the total quantity of oil and its contraction and expansion due to temperature variations.

In addition, the cover of main tank shall be provided with an air release plug to enable air
trapped within to be released, unless the conservator is so located as to eliminate the possibility
of air being trapped within the main tank.

The inside diameter of the pipe, connecting the conservator to the main tank, should be within
20 to 50 mm and it should be projected into the conservator so that its end is approximately 20
mm above the bottom of the conservator so as to create a sump forcollection of impurities. The
minimum oil level (corresponding to -5 deg.C.) should be above the sump level.

10.5 Surface Preparation and Painting

For surface preparation refer to section A of this Manual.

11.0 TERMINALS

The terminals arrangement alternatives are given below:

kVA Voltage Details of Terminals

All ratings 11000 17.5 kV porcelain Bushings as per IS 3347 for normally polluted atmosphere, or 3p 1G
air or compound filled cable box suitable for 3core XLPE /PILC aluminium cables.

All ratings 33000 36 kV porcelain Bushings as per IS3347 for normally polluted atmosphere, or 3p 1G
air or compound filled cable box suitable for 3core XLPE /PILC aluminium cables.

160/200 433 4plG air filled cable box suitable for3 l/2 core 135mm2 PVC aluminium cable

250 433 4plG air filled cable box suitable for3 l/2core 400mm2 PVC aluminium cable
315, 400, 500
433 4p2G air filled cable box suitable for3 l/2core 400mm2 PVC aluminium cable

630.800 433 4p4G air filled cable box suitable for3 l/2core 400mm2 PVC aluminium cable

1000,1250 433 4p6G air filled cable box suitable for3 l/2core 400mm2 PVC aluminium cable

1600 433 4p21G air filled cable box suitable for 1 core 1000mm2 PVC aluminium cable

2000, 2500 433 4p28G air filled cable box suitable for 1 core 1000mm2 PVC aluminium cable
3000

Note: (a) Alternatively 433V terminal could be provided with 1.1 kV bushings as per 1S.3347 for normally polluted
atmosphere.
80 Manual on Transformers

(b) Alternatively 433 V terminal could be provided with 1.1 kV bushing suitable for bus duct connections.
(c) Alternatively 433 V terminal could be provided with1.1 kV epoxy bushings in cable box or bus duct.
(d) P & G denote ‘Pole’ and ‘Gland’ respectively.
(e) Epoxy may be used as the filling medium instead of bitumen compound.

(i) The bushings shall conform to the relevant standards specified and shall be outdoor type.
The bushing rods and nuts shall be made of brass material 12 mm diameter for both HT
& LT. The bushings shall be fixed to the transformers on side with straight pockets and in
the same plane or on the top cover. The tests as per IS 2099 / IS 7421 shall be conducted
on the transformer bushings.
(ii) For 0.433/11 kV/33 kV service voltage, 1.1/17.5/36 kV class bushings shall be used.
Bushings of plain sheds as per IS-3347 shall be mounted on the tank/cover. For 1.1 kV
class indoor transformers, 1.1 kV class epoxy busbar bushings /porcelain bushings can be
used. Bushings in HV cable box as per BS2562 may be used for compound filled cable
box or termination in air with boots covering the live terminals.
(iii) Dimensions of the bushings shall conform to the Standards specified.
(iv) A minimum phase to phase clearance of 75 mm for LV (upto 1.1 kV bushings) and 255
mm for HV bushings shall be obtained with the bushings mounted on the transformer.
(v) The bushings shall be fixed on the sides with pockets in the same plane or on the top
cover.
(vi) Brazing of all inter connections, jumpers from winding to bushing shall have cross-section
larger than the winding conductor.
(vii) The design of the cable box internal bushing for LV shall be such as to provide adequate
earth clearance and creepage distance as stipulated in the standards specified. All other
tests as per relevant standards shall be applicable.
(viii) The terminal arrangement shall not require a separate oil chamber not connected to oil in
the main tank.
(ix) HV and LV bushings shall be mounted on top cover in case of corrugated tank.
11.1 Terminal Clearances
The minimum clearance shall be as under:
Voltage Medium Clearance phase to Clearance phase to
phase (mm) terminal earth (mm) terminal
chamber Open Closed chamber Open Closed
433 Air 40 25 40 20
11000 Air 280 165 140 102
*Compound — 60
— 75
33000 Air 351 351 320 222
*Compound — 125 — 100

* Clearances given against compound filled cable box are applicable for same cable box in air if terminals insulated
with boots are used and cable is ofXLPE type.
 Specifications for Three Phase Distribution Transformers (above 100 kVA and upto 33 kV class) 81

For outdoor bare bushings the LV and HV bushing stems shall be provided with suitable terminal
connectors so as to connect the jumper without disturbing the bushing stem.
11.2 Terminal Markings
High voltage and low voltage phase windings shall be marked both in the terminal boards inside
the tank and on the outside with capital letter 1U, IV, 1W and low voltage winding for the same
phase marked by corresponding letter 2U, 2V, 2W. The neutral point terminal shall be indicated
by the letter 2N.
11.3 Fittings to be provided
The following fittings shall be provided for transformers with conservator:
(a) Rating and terminal marking plates.
(b) Two earthing terminals (studs and bolts should be properly galvanized and conform to
IS: 1363 and IS: 1367.
(c) Two lifting lugs to lift core assembly.
(d) Two lifting lugs to lift complete transformer
(e) Lifting lugs for tank cover.
(f) Thermometer pocket in accordance with IS: 3580.
(g) Air release plug on the transformer tank to release air trapped inside the tank when filling
oil through conservator.
(h) Conservator tank shall have inter connection pipe projection, 20 mm above bottom of the
conservator so as to create a sump for collection of impurities. It shall have 30 mm dia
drain valve, oil filling hole with cap on the top of the conservator.
(i) Oil level gauge with toughened glass with “minimum” marking.
(j) De-hydrating breather.
(k) One drain cum sampling valve.
(1) One filter valve on the upper side of the tank
(m) Unidirectional flat rollers.
(n) Inspection hole
For sealed transformers with radiators and nitrogen cushion, the following accessories are
recommended:
(a) Oil level guage
(b) Pressure guage
(c) Oil temperature indicator and winding temperature indicator (optional).
(d) One drain cum sampling valve
(c) One filter valve on upper side of tank.
11.4 Fasteners
Bolts or studs shall not be less than 6 mm in diameter except when used for small wiring terminals.
82 Manual on Transformers

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.

Taper washers shall be provided where necessary.

 SECTION E

Specifications for Power Transformers of Voltage

Class Below 145 kV
 SECTION E
Specifications for Power Transformers of
Voltage Class Below 145 kV

1.0 SCOPE

1.1 This section covers technical requirements/parameters for power transformers for volt-
age below 132 kV. This part specification does not purport to include all the necessary provi-
sions of a contract. For general requirements, loss capitalization and tests, reference shall be
made to Section ‘A’, ‘AA’ and ‘BB’ respectively of this Manual.

For 110 kV / 100 kV class transformers reference can be drawn from section F for appropriate
rating of transformer.

1.2 Standard Rating

1.2.1 66 kV Class Transformers

Three-phase Voltage ratio Cooling
power rating kV
MVA
6.3 66/11 ONAN
8.0 66/11 ONAN
10.0 66/11 ONAN
12.5 66/11 ONAN/ONAF
20.0 66/11 ONAN/ONAF

ONAN rating-60 percent of ONAF.

1.2.2 33 kV Class Transformers

Three-phase Voltage Cooling
power rating ratio
MVA kV
1.0 33/11 ONAN
1.6 33/11 ONAN
3.15 33/11 ONAN
4.0 33/11 ONAN
5.0 33/11 ONAN
6.3 33/11 ONAN
8.0 33/11 ONAN
10.00 33/11 ONAN

85
86 Manual on Transformers

1.2.3 11 kV Class Transformers

Rating MVA Voltage Impedance Cooling

ratio voltage
kV percent

(A) 3.15 11/6.6 6.25 ONAN

4 11/6.6 7.15 ONAN

(B) 3.15 11/3.3 6.25 ONAN

4 11/3.3 7.15 ONAN
5 11/3.3 7.15 ONAN
6.3 11/3.3 7.15 ONAN

2.0 WINDING CONNECTIONS AND VECTOR GROUP

2.1 Transformers of 11 kV and 33 kV Class

HV — Delta

LV — Star

Vector Group — Dy n11

2.2 Transformers of 66 kV Class

HV — Star or Delta

LV — Star

Vector Group — YNyn0 or Dyn 11

Note: No Tertiary Winding is required for 66 kV Class Transformers.

3.0 TAPPINGS

3.1 OLTC is not recommended for 11 kV and below 5 MVA. For other kV class transformers,
this may be provided for higher ratings, if required. In case of off-circuit tap changer, the
tappings shall be such as to provide for a voltage adjustment on the high voltage of + 3 percent
to - 9 percent in steps of 3 percent, the tappings being located on the high voltage winding. In
case of on-load tap changer, the tappings shall also be on the high voltage winding. A voltage
adjustment of high voltage of + 5 to - 15 percent in 16 equal steps is recommended.

With transformers having OLTC, these tappings may be used to get 10 percent over-voltage
on low voltage ‑side at no-load. When under this condition the high voltage side experiences
 Specifications for Power Transformers of Voltage Class below 145 kV 87

an over-voltage, the tappings shall be changed so that the over-excitation is limited to 10

percent only.

4.0 INSULATION LEVELS

Highest Rated lighting Rated Short

Voltage impulse with-stand duration power
for voltage frequency with-
equipment kV peak stand voltage
kV rms kVrms
3.6 40 10
7.2 60 20
12 75 28
36 170 70
72.5 325 140

Note:
(i) 66 kV Windings should be with graded insulation.
(ii) Some utilities are specifying higher lightning impulse level of 350 kVp for 72.5 kV non-uniform winding.

4.1 Clearances of Line Terminals in Air

The minimum clearances in air between live conductive parts and conductive parts to earthed
structure shall be as follows:

Highest System Basic Insulation Minimum clearances

Voltage level
Phase to Phase to
kV kV peak Phase (mm) Earth (mm)

12 75 280 140
24 125 330 230
36 170 350 320
52 250 530 480
72.5 325 700 660
145 550 1220 1050

5.0 TEMPERATURE RISE

For the purpose of standardization of maximum temperature rises of oil and windings, the fol-
lowing ambient temperatures are assumed:

Cooling medium : Air

Maximum ambient temperature : 50°C
Maximum daily average ambient temperature : 40°C
Maximum yearly weighted average temperature : 32°C
88 Manual on Transformers

With the above ambient temperature condition the temperature rises are as given below:
Oil oC Winding oC
50 55

6.0 TERMINALS

• 3.3 kV-3.6 kV porcelain bushings with plain sheds as per IS: 3347.
• 6.6 and 11 kV-17.5 kV porcelain bushings with plain sheds as per IS: 3347.
• 33 kV-36 kV porcelain bushings with plain sheds as per IS: 3347.
• 66 kV-72.5 kV condenser bushings as per section II.
• Transformers shall be fitted either with bushing insulators or cable boxes as required by
the purchaser.
7.0 FITTINGS AND ACCESSORIES

(a) Rating and diagram plate.

(b) 2 Nos. earthing terminals.
(c) Cover lifting lugs.
(d) Lifting lugs.
(e) Skids and pulling eyes on both directions.
(f) Oil-filling hole and cap.
(g) Jacking pads.
(h) Pocket on tank cover for thermometer.
(i) Air release devices.
(j) Conservator with oil filling hole, cap and drain plug-size 19 mm nominal pipe (3/4 in.
BSJ/M 20).
(k) (i) Prismatic oil level gauge for all transformers up to and including 1.6 MVA.
(ii) Magnetic type oil gauge for transformers above 1.6 MVA, with low oil level
alarm contact.
(1) Silica gel breather with oil seal.
(m) Pressure relief device (16 MVA & above)
(n) Valves:
(i) Drain valve with plug or blanking flanges. The same can be used for filtering purpose.
(ii) A sampling valve.
(iii) 1 No. Top & 1 No. Bottom Filter Valve.
(o) Buchholz relay with alarm and trip contacts with one shut-off valve on conservator side
(i) Size of Buchholz relay up to 10 MVA-50 mm
(ii) 10 MVA and above-80 mm
 Specifications for Power Transformers of Voltage Class below 145 kV 89

(p) Oil temperature indicator with one electrical contact shall be provided with anti-vibration
mounting.
(q) Winding temperature indicator with two electrical contacts for alarm and trip purposes.
Switching of fans shall be done by winding temperature indicator for all transformers
having ONAF rating. The winding temperature indicator shall be provided with anti-
vibration mounting.
(r) Tank mounted weather-proof marshalling box for housing control equipment and terminal
connectors. Wiring up to marshalling box with PVC SWA PVC copper cables 660/1100
volts grade.
(s) Air cell (7.5 MVA & above)
(t) Rollers-4 Nos.
Sl. Gauge
Rating Type
No. Shorter axis Longer axis
1 Up to 5 MVA Flat, uni-directional As per manufacturer’s practice,
however, not to exceed 1000 mm
2 6.3 MVA Flanged, bi-directional 1435 mm 1435 mm
3 10 MVA and above Flanged, bi-directional 1676 mm 1676 mm

(v) Cooling accessories

ONAN/ONAF cooling
(i) Radiators with shut-off valves and air release plugs.
(ii) Fans.
(iii) Filter valves.
(iv) Drain and sampling device.
(v) Air release device.
 SECTION F

Specifications for 145 kV Class Power Transformers

 SECTION F
Specifications for 145 kV Class Power Transformers
1.0 SCOPE

1.1 This section covers technical requirements/parameters for power transformers of 145
kV class. This part specification does not purport to include all the necessary provisions of a
contract. For general requirements, loss capitalization and tests, reference shall be made to
Sections ‘A’, ‘AA’ and ‘BB’ respectively of this Manual.

For 100/110 kV class transformers, reference can be drawn from this section for appropriate
rating of the transformers.

1.2 Standard Ratings

1.2.1 Two Winding Transformers

Three-phase Voltage Impedance

power rating ratio voltage Cooling
MVA kV per cent
(a) 16 132/33 10 ONAN/ONAF
16 132/33 10 ONAN/ONAF
16 132/33 12.5 ONAN/ONAF
(b) 16 132/11 10 ONAN/ONAF
25 132/11 10 ONAN/ONAF
31.5 132/11 12.5 ONAN/ONAF

(i) Connections : HV-Star with neutral directly earthed

LV-Star with neutral directly earthed
Vector Group : YNyn0
Alternatively
HV-Star with neutral directly earthed

LV-Delta Vector Group : YNd 11

(ii) Tappings : On-load tappings at the neutral end of HV winding for

HV variation. Tapping
Range : + 5 to -15 per cent in 16 equal steps.
(iii) ONAN rating for 16 MVA, 25 MVA and 31.5 MVA transformers shall be 10, 16 and 20
MVA respectively.

93
94 Manual on Transformers

1.2.2 Interconnecting Auto-Transformers

Three-phase Impedance
Voltage
power rating voltage per Cooling
ratio kV
MVA cent
50 132/66 10 ONAN/ONAF
63 132/66 10 ONAN/ONAF

(i) Connections : HV and LV

- Star auto with neutral directly earthed.
Vector Group : YNao
Note : (i) No stabilizing winding up to 100 MVA for 3-Phase, 3 limbed core type construction.
ii) Tappings: On-load for the variation of 66 kV voltages from - 5 to + 15 per cent in 16 steps.
iii) ONAN rating shall be 60 per cent of ONAF rating.
1.2.3 Generator Transformers

Three-Phase Impedance
Voltage
Power Rating voltage Cooling
ratio
MVA per cent
140 11/138 12.5 ONAN/ONAF or
ONAN/OFAF or
ODAF or
OFWF/ODWF
140 13.8/138 12.5 -do-
250 15.75/138 14.5 ONAN/ONAF or
ONAN/OFAF or
ODAF or
OFWF/ODWF

(i) Connection : HV-Star with neutral directly earthed LV-Delta

Vector Group : YNd11/ YNd1/ YNd7 /YNd5 (As per User’s requirement)

(ii) Tappings : Off-circuit taps on HV for HV variation from +2½ to -7½ percent
in 2½ per cent steps or On-load tap changer on HV for HV variation from + 5 per cent
to -10 per cent in 1.25 per cent steps.

(iii) ONAN rating in case of ONAN/ONAF, ONAN/OFAF, cooling shall be 60 per cent of
OFAF rating. OFAF/ODAF = 100 per cent.

(iv) The standardized ratings are for three-phase units only. If single phase units are required
due to transport limitations, then these ratings will be one-third of the three-phase
unit.
 Specifications for 145 kV Class Power Transformers 95

2.0 INSULATION LEVELS

Rated lightning Rated short duration
Highest voltage for impulse with- stand power frequency with-
equipment kVrms voltage kV peak stand voltage kVrms
12 75 28
17.5 95 38
36 170 70
72.5 325* 140
145 550** 230**

* Some utilities specify lightning impulse level of 350 kVp

** Some utilities specify 650 kVp lightning impulse and 275 kVrms power frequency voltage level.

2.1 Clearances of Line Terminals in Air

The minimum clearances in air between live conductive parts and conductive parts to earthed
structure shall be as follows:

Highest System Voltage Basic Insulation level Minimum clearances

kV kV peak Phase to Phase to

phase (mm) earth (mm)

12 75 280 140

24 125 330 230

36 170 350 320

52 250 530 480

72.5 325 700 660

145 550 1220 1050

145 650 1430 1270

3.0 COOLING EQUIPMENT

(a) ONAN/ONAF 1-100 per cent tank or separately mounted cooling system
consisting of radiators and fans and one standby fan 2-50 per
cent group and 2 standby fans, one in each 50 per cent group

(b) ONAN/OFAF or ODAF 2-50 per cent groups

2-100 per cent pumps per group, one of which will be standby
for each 50 per cent bank
2-standby fans one in each 50 per cent group
96 Manual on Transformers

3-50 per cent group with independent pump and fans out of
which one group to act as standby,
(c) OFWF or ODWF 2-100 per cent heat exchangers out of which one is standby.
4.0 TEMPERATURE RISE

For the purpose of standardization of maximum temperature rises of oil and winding the
following ambient temperatures considering the transformer to be operating at extreme tap
position incurring extra copper losses
Cooling medium Air Water
Maximum ambient temperature 50°C 30°C
Maximum daily average ambient temp. 40°C 25°C
Maximum yearly weighted average temp. 32°C –

With the above ambient temperature conditions temperature rises considering the transformer to
be operating at extreme tap position incurring extra copper losses are as given below :

External Cooling Medium

Part
Air Water
Winding (measured 55. when the oil circulation 60, when the oil circulation is
by resistance) °C is natural or forced non- natural or forced non-directed.
directed. 60, when the oil 65, when the oil circulation is
circulation is forced directed. forced directed.

Top oil (measured by 50 55

thermometer) °C

5.0 TERMINAL BUSHINGS

(a) Two-winding and auto-transformers

The terminal bushings shall be as per Section II of the manual.
(b) Generator transformer
LV side : LV bushings shall be mounted on turrets suitable for
connection to busbars in isolated phase bus ducts.
HV side : As per Section II.

6.0 FITTINGS AND ACCESSORIES

(a) Rating and diagram plate.

(b) 2 Nos. earthing terminals.
(c) Lifting bollards.
(d) Jacking pads.
(e) Haulage lugs.
(f) Pocket on tank cover for thermometer.
(g) Air release devices.
 Specifications for 145 kV Class Power Transformers 97

(h) Conservator with oil filling hole, cap and drain valve, aircell (above 7.5 MVA).
(i) Magnetic type oil level gauge with low oil level alarm contacts of 0.5 A, 220 V DC rating.
(j) Silica gel breather with oil seal-2 Nos. of 100 per cent for 140 and 250 MVA ratings.
(k) Pressure relief device.
(1) Valves
(i) Oil valve between each cooler and main tank.
(ii) Drain valve.
(iii) 2 Nos. filter valves, one on top and another at bottom on diagonally opposite corners.
(iv) 2 Nos. sampling valves at top and bottom of main tank.
The sampling valve shall be provided with provision for fixing PVC pipe.
(m) Valve schedule plate for transformers above 31.5 MVA.
(n) Buchholz relay with alarm and trip contacts of 0.5A, 220 V DC rating and one shut-off
valve size 80 mm.
(o) (i) Oil temperature indicator with maximum-pointer and one electrical contact.
(ii) Oil temperature indicator with maximum pointer and two sets of contacts for above
31.5 MVA.
(p) Winding temperature indicator with ‘maximum pointer and 3 sets of contacts for ONAN/
ONAF and 4 sets of contacts for ONAF/OFAF or ODAF and 2 sets of contacts for OFWF/
ODWF.
(q) Repeater dial of winding temperature indicator for remote indication for transformers
above 16 MVA. For transformer above 50 MVA, the remote indication shall be a separate
measuring system.
(r) Rollers.
Gauge
Rating Type Shorter Longer
axis axis
1. Two winding Flanged bi-directional 1676 mm 1676 mm
and auto with locking and bolting
transformers device.
2. Generator Flanged, bi-directional 2 rails with 2 rails with
transformers with locking and bolting 1676mm gauge 1676mm gauge
device.
Alternatively 3 rails with
1676 mm gauge between
adjacent rails. Alternatively
4 rails in two pairs with 1676
mm gauge for each pair and
centre distance between pair
3486 mm.

(s) Inspection cover.

(t) Wiring up to marshalling box with PVC copper cables, 660/1100 volts grade.
(u) Tank mounted/floor mounted weather-proof marshalling box for housing control
equipment and terminal connections.
(v) On-load tap changing gear with remote control panel as required.
98 Manual on Transformers

(w) Cooling accessories:

(I) ONAN/ONAF Cooling
(i) Requisite number of radiators with top and bottom shut-off-valves, air release
plug and drain plug.
(ii) Fans.
(iii) For header mounted radiator 2 Nos. valves, one at top header and other at
bottom header to be used for filtration and oil filling. Bottom valve to be used
as drain valve also.
(iv) Drain and sampling device.
(v) Air release device.
(II) ONAN/ONAF-OFAF/ODAF Cooling
(i) Requisite number of radiators with shut-off-valves.
(ii) Fans.
(iii) Oil pumps.
(iv) Oil flow indicator with one alarm contact.
(v) For header mounted radiators 2 Nos. valves, one at top header and other at
bottom header to be used for filtration and oil filling. Bottom valve to be used
as drain valve also.
(vi) Drain-cum-filter valve for cooling system.
(vii) Air release plug.
(III) OFAF/ODAF Cooling
(i) OFAF coolers with integral fans.
(ii) Oil pumps.
(iii) Oil flow indicator with one alarm contact.
(iv) Brass encased thermometers.
(v) Drain plug and air release devices.
(TV) OFWF/ODWF Cooling.
(i) Oil/Water heat exchangers.
(ii) Oil pumps.
(iii) Oil flow indicator with one alarm contact.
(iv) Water flow indicator with one alarm contact.
(v) Pressure gauges.
(vi) Brass encased thermometers.
(vii) Differential pressure gauge with one alarm contact.
(viii) Reflux valves (Non-return).
(ix) Drain-cum-filter valve for cooling system.
 SECTION G

Specifications for 245 kV Class Power

Transformers
 SECTION G
Specifications for 245 kV Class Power Transformers
1.0 SCOPE
1.1 This section covers technical requirements/parameters for power transformers of 245
kV voltage class but does not purport to include all the necessary provisions of contract. For
general requirements, loss capitalization and tests, reference shall be made to Sections ‘A’, ‘AA’
and ‘BB’ respectively of this Manual.

1.2 Standard Ratings

1.2.1 Two Winding Transformers

(A)
Three-phase Voltage Impedance Cooling
power rating ratio voltage
MVA kV percent
50 220/66 12.5 ONAN/OFAF or
ONAN/ODAF
100 220/66 12.5 ONAN/OFAF or
ONAN/ODAF

(i) Connections : HV—Star with neutral effectively earthed.

LV—Star with neutral effectively earthed.
Stabilizing
winding : No stabilizing winding up to 100 MVA for 3-phase, 3 limbed
core type construction.
(ii) Vector Group : YNyn0.
(iii) Tapping : On-load tappings at the neutral end of HV for HV
±10 per cent in 16 equal steps.
(iv) Cooling : ONAN : 60 per cent
OFAF : 100 per cent
ODAF : 100 per cent
The rating under ONAF condition although not guaranteed should
be about 80 percent.
(B)
Three-phase Voltage Impedance Cooling
power rating ratio kV voltage per-
MVA cent
50 220/33 12.5 ONAN/OFAF or
ONAN/ODAF
100 220/33 15.0 ONAN/OFAF or
ONAN/ODAF

101
102 Manual on Transformers

(i) Connections : HV—Star with neutral effectively earthed.

LV—Delta. Alternatively star with neutral effectively earthed.
Vector Group : Yd11. Alternatively YNyno.
Stabilizing : No stabilizing winding for YNyn0 up to 100 MVA for 3-phase,
3 limbed core type construction.
(ii) Tappings : On load tappings at the neutral end of HV for HV variation from
+10 to -10 per cent in 16 equal steps.
(iii) Cooling : ONAN : 60 per cent
OFAF : 100 per cent
ODAF : 100 per cent
Note : The rating under ONAF condition although not guaranteed shall be about 80 per cent.
1.2.2 Auto-Transformers
Three-phase Voltage Percentage Cooling
power rating ratio impedance
MVA voltage
ONAN/OFAF or
100 220/132 12.5 ONAN/ODAF
ONAN/OFAF or
160 220/132/11 12.5 ONAN/ODAF
ONAN/OFAF or
200 220/132/11 12.5 ONAN/ODAF

ONAN/ONAF cooling can also be specified for above transformers.

(i) Connections : HV and LV — Star auto with neutral effectively earthed.
(ii) Stabilizing
winding : Delta. (No stabilizing winding for 100 MVA 3 phase 3
limbed Core type construction)
(iii) Vector Group : YNa0dl
(iv) Tappings : On-load for the variation of 132 kV voltage from-5 to
+15 per cent in 16 equal steps.
(v) Cooling ONAN : 60 per cent
OFAF/ODAF : 100 per cent.
Note :
(1) In case auto-transformers are provided with L. V. winding (Tertiary Winding) for loading purpose then the MVA
rating, voltage rating, percentage impedance between HV winding to L. V. winding and IV winding to L.V. winding
shall be specified by the customer. The minimum rated lightning impulse withstand voltage level shall be 170 kV
peak. Rated short duration power frequency voltage shall be 70 kV.
(2) Rating under ONAF condition although not guaranteed shall be about 80 per cent.
1.2.3 Generator Transformers for Thermal Stations

Three-phase power Voltage Percentage

Cooling
rating MVA Ratio impedance voltage
140 11/235 12.5 ONAN/OFAF or ODAF or
OFWF/ ODWF
140 13.8/235 12.5 ONAN/OFAF or ODAF or
OFWF
250 15.75/235 14.0 ONAN/OFAF or ODAF or
OFWF/ODWF
315 15.75/235 14.0 -do-
 Specifications for 245 kV Class Power Transformers 103

(i) Connection : HV — Star with neutral effectively earthed.

LV — Delta.
(ii) Vector Group : YNd11/ YNd1/ YNd5/ YNd7 (As per User’s requirement)
(iii) Tappings : Off-circuit taps on HV for HV variation from + 2½ to -7½ percent
in 2½ per cent steps or On-load tap changer on HV for HV variation
from + 5 percent to -10 per cent in 1.25 per cent steps.
(iv) The standardized ratings are for three phase units only. If single phase units are required
due to transport limitations then these ratings will be one-third of the three-phase unit.
(v) Cooling : ONAN : 60 per cent
OFAF/ODAF : 100 per cent.
Two 50% cooling radiator banks shall be provided. Each bank shall have one stand by fan and
one stand by pump.
2.0 INSULATION LEVELS
Highest voltage Rated lightning Power frequency rated
for equipment impulse withstand short duration withstand
kV rms voltage kV peak voltage kV rms
12.0 75 28
17.5 95 38
36 170 70
72.5 325* 140
145 550** 230**
245 950*** 395***

* Some utilities specify lightning impulse level of 350 kVp

** Some utilities specify 650 kVp lightning impulse and 275 kVrms power frequency voltage level.
*** Some utilities specify 1050 kVp lightning impulse and 460 kVrms power frequency voltage level.
2.1 Clearances of Line Terminals in Air
The minimum clearances in air between live conductive parts and conductive parts to earthed
structure shall be as follows:

Highest Minimum clearances

Basic Insulation
System level
Voltage Phase to Phase to
kV kV peak phase (mm) earth (mm)
12 75 280 140
24 125 330 230
36 170 350 320
52 250 530 480
72.5 325 700 660
145 550 1220 1050
145 650 1430 1270
245 950 2000 1800
245 1050 2350 2150
104 Manual on Transformers

3.0 COOLING EQUIPMENT

(a) ONAN/OFAF - 2-50 per cent groups

or ODAF 2-100 per cent pumps for each 50 per cent bank,
One of which will be standby.
2-Standby fans one in each 50 per cent group, or
3-50 per cent groups with independent pumps and
fans out of which one group to act as standby
(b) OFWF or ODWF - 2-100 per cent heat exchangers out of which one is
standby.
4.0 TEMPERATURE RISE

For the purpose of standardization of maximum temperature rises of oil and winding, the
following ambient temperatures are assumed:

Cooling medium Air Water

Maximum ambient temperature 50°C 30°C
Maximum daily average ambient temperature 40°C 25°C
Maximum yearly weighted average temperature 32°C -

With the above ambient temperature conditions, temperature rises are as given below:

External cooling-medium
Part
Air Water
°C °C
Windings (measured by 55, when the oil circulation is 60, when the oil circulation is
resistance) natural or forced non-directed. natural or forced non directed.
60, when the oil circulation is 65, when the circulation is
forced directed. forced directed.

Top oil 50 55
(measured)
by thermometer)

5.0 TERMINAL BUSHINGS

(a) Two windings and Auto-Transformers. The terminal bushings shall be as per Section II.
(b) Generator Transformer
LV Side : LV bushings shall be mounted on turrets suitable for connection to bus
bars in isolated phase bus ducts.
HV Side : As per Section II.
 Specifications for 245 kV Class Power Transformers 105

6.0 FITTINGS AND ACCESSORIES

(a) Rating and diagram plate.
(b) 2 Nos. earthing terminals.
(c) Lifting bollards.
(d) Jacking pads.
(e) Haulage lugs.
(f) Pocket on tank cover for thermometer.
(g) Air release devices.
(h) Conservator with oil filling hole, cap drain valve.
(i) Magnetic type oil gauge with low oil level alarm contacts of 0.5 A, 220 V DC.
(j) Silicagel breather with oil seal-2 Nos.
Note: In addition to the silicagel breather more advanced oil preservation system like air dryers, molecular sieve
flexible membrane can also be considered.
(k) Required Nos. of pressure relief vents or spring operated pressure relief devices. For
transformer above 50 MVA, the remote indication shall be a separate measuring system.
(1) Valves
(i) Oil valve between each cooler and main tank.
(ii) Drain valve
(iii) 2 Nos. filter valves on diagonally opposite corners.
(iv) 2 Nos. sampling valves at top and bottom of main tank. The sampling valve shall be
provided with provision for fixing PVC pipe.
Rating Type Gauge
Shorter axis Longer axis

1 2 3 4 5
1. Two winding and Flanged 1676 mm 1676 mm
auto-transformers bidirectional with
locking and bolting
device.

Generator Flanged 2 rails with 2 rails with

2. Transformers bidirectional With 1676 mm 1676 mm
locking and Bolting gauge gauge
device.
Alternatively 3
rails with 1676
mm gauge between
adjacent rails.
Alternatively 4
rails in two pairs
with 1676 mm
gauge for each pair
and centre distance
between pair 3486
mm.
(m) Valve schedule plate.
(n) Buchholz relay with alarm and trip contacts of 0.5A, 220 V DC and one shut-off valve on
conservator side, size 80 mm.
106 Manual on Transformers

(o) Oil temperature indicator with maximum-pointer and two sets of contacts.
(p) Winding temperature indicator with maximum pointer and 3 sets of contacts of ONAN/
ONAF and 4 sets of contacts for ONAF/OFAN or ODAF and 2 sets of contacts for OFWF/
ODWF.
(q) Repeater dial of winding temperature indicator for remote indication.
(r) Rollers.
(s) Inspection cover.
(t) Wiring up to marshalling box with PVC copper cables, 660/1100 volts grade.
(u) Tank mounted/floor mounted weather-proof marshalling box for housing control equip-
ment and terminal connections.
(v) On-load tap changing gear with remote control panels as required.
(w) Cooling accessories.
(I) ONAN/OFAF or ODAF Cooling
(i) Requisite number of radiators with shut-off-valves.
(ii) Fans.
(iii) Oil pumps.
(iv) Oil flow indicator with one alarm contact.
(v) For header mounted radiators 2 Nos. valves, one at top header and other at bo tom
header to be used for filtration and oil filling. Bottom valve to be used as drain
valve also.
(vi) Drain-cum-filter valve for cooling system size.
(vii) Air release plug of size 19 mm nominal pipe (3/4in. BSP).
(II) OFAF/ODAF Cooling
(i) OFAF/Coolers with integral fans.
(ii) Oil pumps.
(iii) Oil flow indicator with one alarm contact.
(iv) Brass encased thermometers.
(v) Drain plug and air release devices.
(III) OFWF/ODWF Cooling
(i) Oil / Water heat exchangers
(ii) Oil pumps.
(iii) Oil flow indicator with one alarm contact.
(iv) Water flow indicator with one alarm contact.
(v) Pressure gauges.
(vi) Brass encased thermometers.
(vii) Differential pressure gauge with one alarm contact.
(viii) Reflux valves (Non-return)
(ix) Drain-cum-filter valve for cooling system.
 SECTION H

Specifications for 420 kV Class Power

Transformers
 SECTION H
Specifications for 420 kV Class Power Transformers
1.0 SCOPE

1.1 This section covers technical requirements/parameters for power transformers of 420
kV class but does not purport to include all the necessary provisions of a contract. For general
requirements, loss capitalization and tests reference shall be made to Sections ‘A’, ‘AA’ & ‘BB’
respectively of this Manual.

1.2 Standard Ratings

1.2.1 Generator Transformers

Three Voltage Tapping Percent Cooling

phase ratio range impedance
rating MVA per cent voltage
250 15.75 A-Off circuit taps
or
315 or 16.5 + 2.5% to- 7.5% 14.5 ONAN/OFAF
or OFAF or
/420 B-On-load taps OFWF or
+ 5% to -10% ONAN/ ODAF or
ODAF or ODWF

600 or 780 20 to 27 kV A-Off circuit taps

or 945MVA /420
Bank
B - On load taps 13.5 to 16.0 ONAN/
OFAF or
OFAF or
OFWF or
ONAN/
ODAF
or ODAF
or ODWF

Note : The ratings of generator transformers for hydro generating sets have not been standardized as the sizes of
these sets depend upon site characteristics.
The purchaser shall specify the type of cooling required.
Other Parameters

(i) Connections HV Star neutral effectively earthed, LV delta

(ii) Connections symbol YNd11/YNd1/ YNd5/ YNd7 (As per User’s requirement)
(iii) Tappings
Full power tappings on HV winding for HV voltage variation. Tap changing shall be by:

(a) Off-circuit tap changer, tapping range + 2.5% to - 7.5% in steps of 2.5 per cent alternatively
(b) On-load tap changer, tapping range + 5% to - 10% in steps of 1.25 per cent

109
110 Manual on Transformers

(iv) Three-phase rating should be understood as three phase bank rating and not necessarily
three-phase unit rating. Wherever transport restrictions impose, single phase ratings equal
to one-third of the three phase bank rating may be specified.
(v) ONAN rating shall be guaranteed at 60 per cent of the OFAF, or ODAF rating. Rating
under ONAF condition shall be about 80 per cent. Two 50% cooling radiator banks shall
be provided. Each bank shall have one stand by fan and one stand by pump.
(vi) Air core reactance of HV winding shall not be less than 20 per cent and knee point voltage
shall not be less than 1.1 pu.
(vii) Short circuit level Transformer shall be suitable for connection to
for 420 kV system the system having the following short circuit
and duration levels and duration: 40,50 and 63 kA for one
second.
(viii) Terminal Bushings
(a) LV Terminals: Oil - sealed / Oil communicating Condenser type bushings mounted on
turrets suitable for connections to busbars in isolated phase busducts which shall have
spacing of 1250 mm for 250 MVA three-phase unit and 1500 mm for each 200 MVA
single-phase unit of a 600 MVA three-phase bank.
(b) HV Terminals-Line End: 420 kV oil filled condenser bushing. No arcing horns shall be
provided. For details refer Section II.
Neutral End: 17.5 kV porcelain bushing. No arcing horns shall be provided.

1.2.2 Auto - Transformers

The purchaser may specify auto-transformer with constant ohmic value of impedance or constant
percentage impedance as given below:

Standard Ratings

(a) Auto - Transformers (Constant Percentage Impedance)

Three-phase Voltage Tapping range Percent impedance voltage Cooling

ratio
HV/IV/LV per cent
MVA HV-1V HV-LV IV-LV
100/100/33.3 400/132/33 + 10% to-10% 16 12.5 27 12 ONAN/OFAF
steps of 1.25%
200/200/66.7 400/132/33 + 10% to -10% 12.5 36 22 ONAN/OFAF or
16 steps of 1.25% ONAN/ODAF
250/250/83.3 400/220/33 + 10% to-10% 16 12.5 45 30 ONAN/OFAF or
steps of 1.25% ONAN/ODAF
315/315/105 400/220/33 + 10% to-10% 16 12.5 45 30 ONAN/OFAF or
steps of 1.25% ONAN/ODAF
500/500/166.7 400/220/33 + 10% to-10% 16 12.5 45 30 ONAN/OFAF or
steps of 1.25% ONAN/ODAF
630/630/210 400/220/33 + 10% to-10% 12.5 45 30 ONAN/OFAF or
16 steps of 1.25% ONAN/ODAF
 Specifications for 420 kV Class Power Transformers 111

(b) Auto-Transformers (Constant Ohmic Impedance)

Three-Phase HV/ Voltage Ratio Tapping Range Per cent impedance Cooling
IV/LV per cent voltage
MVA HV-IV HV-LV IV-LV
(min)*
+ 10 to-10% ONAN/OFAF
100/100/33.3 400/132/33 12.5 45 30
16 steps of 1.25% ONAN/OFAF
+ 10 to-10% ONAN/ODAF
200/200/66.7 400/132/33 12.5 45 30
16 steps of 1.25% ONAN/OFAF
+ 10 to-10% ONAN/ODAF
250/250/83.3 400/220/33 12.5 60 45
16 steps of 1.25% ONAN/OFAF
+ 10 to-10% ONAN/ODAF
315/315/105 400/220/33 12.5 60 45
16 steps of 1.35% ONAN/OFAF
+ 10 to - 10% ONAN/ODAF
500/500/166.7 400/220/33 12.5 60 45
16 steps of 1.25% ONAN/OFAF
+ 10 to-10%
630/630/210 400/220/33 12.5 60 45 ONAN/ODAF
16 steps of 1.25%

* No limit is specified on higher side.

ONAN/ONAF cooling can also be specified for 100,200,260 1nd 315 MVA ratings.
Other Parameters

(i) Connections HV Star auto with neutral

IV effectively earthed
LV Delta
(ii) Connection symbol YNa0d11
(iii) Full power tappings shall be provided on series winding for the variation of voltage on
HV side. The tap changers shall be suitable for bi-directional flow of rated power. The tap
changers shall be in accordance with Section GG.
(iv) Three-phase rating should be understood as three phase bank rating and not necessarily
three phase unit rating. Wherever transport restrictions impose, single phase ratings equal
to one third of the three phase bank ratings may be specified.
(v) ONAN rating shall be guaranteed at 60 per cent of the OFAF or ODAF rating. Rating
under ONAF condition although not guaranteed shall be about 80 per cent.
(vi) For these transformers the temperature rise of the top oil refers to the specified loading
combination for which the total losses are highest. Individual winding temperature rises
shall be considered relative to that specified loading combination which is the most severe
for the particular winding under consideration.
(vii) Air core reactance of HV winding shall not be less than 20 per cent and knee point voltage
shall not be less than 1.1 pu.
(viii) The specified percentage impedance voltage is at principal tapping and on the MVA base
112 Manual on Transformers

corresponding to HV/TV rating. Tolerance on percentage impedance voltage shall be as under:

Pairs of windings Tolerance
HV-IV (normal tap) ±10 per cent
HV-IV (max & min tap) ±15 per cent

For constant percentage impedance auto-transformer

HV-LV ±15 percent
IV-LV ± 15 per cent

1.2.3 Short Circuit Level

Transformer shall be suitable for connection to the system having the following short circuit level:

• 420 kV 40,50 and 63 kA (rms), 1 second

• 245 kV 40 kA (rms), 1 second

• 145 kV 31.5/40 kA (rms), 1 second

1.2.4 Terminals
(a) LV Terminals: 52 kV oil-filled condenser bushings. The bushing shall be arranged in a
line with 1000 mm spacing to allow mounting of phase to phase barriers.
No arcing horns shall be provided.
(b) IV Terminals: 145/245 kV oil-filled condenser bushings with test taps. No arcing horns
shall be provided.
(c) HV Terminals - Line End: 420 kV oil-filled condenser bushing. No arcing horns shall be
provided.
For details refer Section II.
Neutral End: 17.5 kV porcelain bushing. No arcing horns shall be provided.
1.2.5 Insulation Levels
1.2.5.1 Lightning Impulse And Power Frequency Voltage Test Level

Highest voltage Rated lightning Rated power

for equipment impulse withstand frequency, short
kV (rms) voltage kV (peak) duration withstand
voltage kV (rms)
12 75 28
17.5 95 38
24 125 50
145 550* -
245 950** -
420 1300*** -
* Some utilities specify lightning impulse level of 650 kVp
** Some utilities specify lightning impulse level of 1050 kVp.
*** Some utilities specify lightning impulse level of 1425 kVp.
 Specifications for 420 kV Class Power Transformers 113

1.2.5.2 Rated Switching Surge kV (Peak) 1050 Or 1175 Withstand Voltage

For 400 Kv Terminal.

1.2.5.3 Partial Discharge At 1.5 Um/√3 Shall Be Limited To 500 Pc.

Notes :
(i) Insulation of tertiary winding of auto-transformer should be adequate to withstand the transferred surge voltage
appearing across them due to an impulse striking on HV or IV terminals. Therefore, 33 kV LV winding shall be
designed for a minimum lightning impulse withstand voltage of 250 kV (peak) and short duration power frequency
withstand voltage of 95 kV (rms).
(ii) The shunt reactor or capacitors connected to the LV side would be required to be frequently switched on and off.
The LV winding should be capable of withstanding the stresses as may be caused by frequent switching.

1.2.5.4 TEMPERATURE RISES

Air - cooled Water-cooled
transformers transformers
(a) Temperature rise of top oil 50°C 55°C
(b) Measured by thermometer
Temperature rise of winding
Measured by resistance:
- When oil circulation 55°C 60°C
Natural or forced non-directed
- When oil circulation is 55°C 65°C
Forced directed

Notes :
(i) For the purpose of standardization of maximum temperature rises of oil and winding as measured by resistance,
the following ambient temperatures are assumed :

Air Water
Cooling medium ambient temperature 50°C 30°C
Maximum daily average ambient temperature 40°C 25 °C
Maximum yearly weighted average temperature 32°C -
(ii) Maximum yearly weighted temperature is based on ambient temperature cycle and its duration.
(iii) Wherever ambient temperatures are higher than those specified above, the temperature rises, reduced by
corresponding amount, shall be specified.
(iv) Guaranteed temperature rise limits are valid for all the tappings.
(v) The above temperature rises are applicable to transformers required for operation at an altitude notexceeding
1000 metres above sea level.

1.3 Cooling

1.3.1 ONAN/OFAF or ONAN/ODAF Two 50 per cent banks. One number of pump
and one standby pump in each bank. Adequate
number of fans and one standby fan in each 50
per cent bank.
114 Manual on Transformers

1.3.2 OFAF or OD AF Adequate number of coolers with one cooler as

standby (6x 20% OFAF coolers or 4x33%
OFAF coolers can be adopted).
1.3.3 OFWF or ODWF Two 100 per cent coolers.
Notes :
(i) The transformer shall be filled up with mineral oil, conforming to IS: 335 or IEC 60296.
(ii) For auto transformers 100 per cent cooling equipment should be capable of dissipating losses occurring in all the
three windings, at any tap. It is required only in case specifically called fort.

1.4 Bushings

1.4.1 The voltage and current ratings, basic insulation level and creepage distances of the
bushings shall be in accordance with the following table:
SI. Voltage rating Current Creepage Basic
No. kV (rms) rating distance insulation
(Amps) (mm) level (kVP)
1. 420 1250 10500 1425
1250
2. 245 2000 6125 1050
3. 145 800 3625 650
4. 52 1250 1300 250
3150

1.4.2 The Dimensions of Bushings are as per Section II.

1.5 Clearances of Line Terminals in Air

Clearances in air between live parts and to earthed structures for LV terminals of generator
transformers and auto-transformers shall be determined as per spacing given in clause 1.1.1 (viii)
and 1.2.1.4 respectively. The clearances for HV and IV terminals shall be as tabulated below:
Clearances
Highest voltage for equipment kV
(rms) Phase to phase Phase to
earth (mm) (mm)
12 280 140
24 330 230
36 350 320
52 530 480
72.5 700 660
145 1220 1050
145 1430 1270
245 2000 1800
245 2350 2150
420 4000 3500
 Specifications for 420 kV Class Power Transformers 115

Air clearances of 3500 mm between phase to earth can be relaxed to the extent of maximum of
200 mm so far as air release pipe emanating from bushing turret is concerned.

1.6 Fittings and Accessories

(a) Rating and diagram plate.

(b) Two earthing terminals.
(c) Lifting bollards.
(d) Jacking pads.
(e) Haulage lugs.
(f) Pocket on tank cover for thermometer.
(g) Air release devices,
(h) Sudden/Rapid Pressure Rise Relay (Optional)
(i) Conservator with oil- filling hole, cap and drain valve (size: 25 mm.)
(j) Magnetic type oil gauge with low oil level alarm contacts (ratings: 0.5 Amp, 220 Volts
DC.) Dial size 250 mm.
(k) Silica gel breather with oil seal.
(l) Air cell type oil preservation system.
(m) Pressure relief device (atleast 2 Nos) capable of resealing after release of pressure.
(n) Valves
• Oil valves between cooler and main tank
• Drain valve preferably with padlocking arrangement (size 100 mm).
• Two filter valves (size: 50 mm) on diagonally opposite ends - one at top and
other at bottom preferably with padlocking arrangement on bottom valve.
• Two sampling valves (size: 15 mm) at top and bottom of main tank.
(o) Oil flow indicator with alarm contacts (ratings, 0.5 Amps, 220 Volts DC) with each
pump.
(p) Valve schedule plate.
(q) Buchholz relay with alarm and trip contacts (Ratings: 1.0 Amp 220 Volts DC) shall
have:
• One number shut-off valve (Size: 80 mm) on conservator side
• Test cock
• Gas collection box and gas check valve at ground level. Copper tube interconnection
between gas collection box and relay shall also be provided. In transformers, for
installation in areas subject to high seismic forces, i.e., horizontal acceleration of 0.3
g or more at and above a frequency of 8 Hz pitot type or reed type of gas and oil relay
shall be used.
(r) Dial type oil temperature indicator with ‘maximum-reading’ pointer and two sets of
contacts (ratings, 5 Amps, 220 Volts DC).
(s) 1 No. dial type winding temperature indicator for a two winding transformer and
one dial type windings temperature indicator for each winding of a multi winding
transformer with ‘maximum-reading’ pointer and two sets of contacts rating : 5 Amps,
116 Manual on Transformers

220 Volts DC (for OFAF/ODAF and OFWF/ODWF) and four sets of contacts (for
ONAN/OD AF/OFAF).
(t) Remote indication for each winding temperature shall be through a separate
measuring system.
(u) Cover lifting lugs.
(v) Provision for mounting bi-directional flanged rollers with locking and bolting device for
rail gauge specified below:
Type of construction Shorter axis Longer axis
Single-phase Two rails with 1676 mm gauge Two rails with 1676 mm gauge

Three-phase 2/3/4 rail combination according to Two rails with 1676 mm gauge
layout and size of the transformer

(w) Weather proof marshalling box for housing control equipment and terminal
connections.
(x) Wiring up to marshalling box with PVC SWA copper cables of 650/1100 volt grade.
(y) Cooling accessories.
I ONAN/OFAF or ONAN/ODAF cooling
(i) Requisite number of radiators provided with:
- One shut off valve on top (size: 80 mm)
- One shut off valve at bottom (size: 80 mm)
- Air release device on top
- Drain and sampling device at bottom
- Lifting lugs
(ii) Fans
(iii) Oil pumps with shut off valve on both sides (if required for ONAN cooling
pumps can be by-passed using by-pass pipes and valves).
(iv) Expansion joints, one each on top and bottom cooler pipe connections.
(v) Air release device and oil drain plug on oil pipe connections.
II OFAF or ODAF cooling
(i) OFAF coolers with integral fans
(ii) Oil pumps with shut-off valves on both sides.
(iii) Brass encased thermometers.
(iv) Air release devices and oil pipe connections.
(v) Lifting lugs.
III OFWF or ODWF Cooling
(i) Oil/water heat exchangers with segregated oil and water headers
 Specifications for 420 kV Class Power Transformers 117

(ii) Oil pumps with shut-off valves on both sides.

(iii) Water flow indicator with alarm contacts (ratings: 0.5 Amp, 220 Volts DC).
(iv) Brass encased thermometer.
(v) Pressure gauges.
(vi) Differential pressure gauge with alarm contacts, operating when difference
between oil outlet pressure and water inlet pressure is less than 0.2 kg./cm2
(vii) Reflux valve if required as per scheme.
(viii) Drain and sampling device on cooler pipe connection.
(z) Online DGA
(aa) Online Moisture Removal (for GT).
 SECTION I

Specifications for 800 kV Class Power

Transformers
 SECTION I
Specifications for 800 kV Class Power Transformers
1.0 SCOPE
1.1 This section covers power transformers of 800 kV class but does not purport to include
all the necessary provisions of a contract. For general requirements, capitalization and tests
reference shall be made to Sections ‘A’, ‘AA’&‘BB’respectively of this Manual.
1.2 Standard Ratings
1.2.1 Generator Transformers
Single Voltage Tapping Percent Cooling
phase ratio range impedance
rating MVA kV Voltage
OFAF/OFWF
200 21/765√3 ± 5% in 8 15-16% (with ODAF/ODWF
steps with ±5% tolerance) at principal
off circuit tap
260 24/765√3 taps/ links
315 27/765√3

Three single-phase units will form a bank of 3-phase.

Note : The purchaser shall specify the type of cooling required before purchase.

Above mentioned Transformer rating (in Table) shall be decided by the Utility based on generator rating,
power factor & system requirement.

Other Parameters
(i) Connections - HV star neutral effectively earthed, LV delta
(ii) Connections symbol – YNd11 / YNd1/ YNd5/ YNd7(As per User’s requirement)in
3-phase bank.
(iii) Tappings - Full power tappings on HV winding for HV voltage variation.
(iv) Air core reactance of HV winding shall not be less than 20 per cent and knee point voltage
shall not be less than 1.1 pu.
(v) Short circuit level
Transformer shall be suitable for connection to the system having the following short
circuit level:
800 kV - 40 kA or 50 kA (rms) for 1 second as required.
(vi) Terminal bushings
(a) LV Terminals: 36 kV, 12500 Amps. Oil filled condenser type bushings mounted
on turrets, suitable for connections to bus bars in isolated phase bus ducts which
shall have spacing of 1500 mm for each 200 MVA single-phase unit of a 600 MVA
three-phase bank.
121
122 Manual on Transformers

For 260 MVA single-phase unit of a 780 MVA three-phase bank, 1 no. 36 kV,
16000 Amps, rating.
(b) HV Terminals-Line End: 800 kV, 1250/2000/2500 Amps,oil filled condenser
Bushing with test tap. No arcing horns shall be provided. For details refer
Section II.
(c) Neutral End: 36 kV porcelain bushing. No arcing horns shall be provided. (vii)
Temperature rises
(a) Top oil measured by Thermometer - 40°C
(b) Winding rise measured by Resistance method - 45°C
(c) Maximum design ambient temperature - 50°C
(also refer para 1.4 note i)
Total capacity of coolers for each transformer shall be minimum 120% of actual requirements.
1.2.2 Auto - Transformers

Single-phase rating Voltage ratio Tapping range Per cent impedance voltage at Cooling
HV/TV/LV principal tap
MVA kV HV-IV HV-LV IV-LV
333.33/333.33/111.1 765/400/33 ± 5.5% in 22 14.0 60 45 ONAN/ONAF/
√3 √3 steps OFAF or ODAF
Alternatively
ONAN/ONAF1/
ONAF2

500/500/167.67 765/400/33 ± 5.5% in 22 14.0 195 180 -do-

√3 V3 steps
tolerance tolerance tolerance
±10% ±15% ±15%

Note : Three single-phase units will form a bank of 3-phase. Rating of stabilizing LV winding may be of 1/3rd
reactive rating. However, continuous thermal rating shall be at least 5 MVA Active loading.

Other Parameters
(i) Connections - HV/IV Star auto with neutral effectively earthed LV Delta
(ii) Connection symbol - YNa0d11(3-phase)
(iii) ONAN rating shall be guaranteed at 60 per cent of the OFAF or ODAF rating. Rating
under ONAF condition although not guaranteed shall be about 80 per cent. Alternatively
ONAN/ONAF 1/ONAF2 (60%/ 80%/ 100%) cooling with 2 x 50% or with radiator banks
or 4x33.3% unit coolers can be used.
(iv) For these transformers the temperature rise of the top oil refers to the specified loading
combination for which the total losses are highest. Individual winding temperature rises
shall be considered relative to that specified loading combination which is the most severe
for the particular winding under consideration.
 Specifications for 800 kV Class Power Transformers 123

(v) Air core reactance of HV winding shall not be less than 20 per cent and knee point voltage
shall not be less than 1.1 pu.

(vi) Short circuit Level

Transformer shall be suitable for connection to the system having the following short
circuit level:

800 kV – 40, 50 kA (rms) for 1 second

420 kV – 40,50 and 63 kA (rms) for 1 second

(vii) Terminals

(a) LV Terminals: 52 kV oil-filled condenser bushings. The bushing shall be arranged

in a line with 1000 mm spacing. No arcing horns shall be provided.

(b) IV Terminals: 420 kV oil-filled condenser bushings with test taps. No arcing horns
shall be provided.

(c) HV Terminals: 800 kV oil-filled condenser bushing with test tap. No arcing horns
shall be provided.

Neutral End: 36 kV porcelain bushing. No arcing horns shall be provided.

(viii) Temperature Rises:

(a) Top oil measured by thermometer - 40°C

(b) Winding rise measured by resistance method - 45°C

(c) Maximum design ambient temperature - 50°C

(Also refer to Notes under clause 1-4)

1.3 Insulation Levels

1.3.1 Impulse and Power Frequency Voltage Test Level for Transformer Windings.

Highest voltage Rated lightning impulse Rated switching impulse Rated power frequency
for equipment withstand voltage withstand voltage short duration withstand
Urn kV (rms) kV (peak) kV (peak) voltage kV (rms)
17.5 (Neutral) 95 — 38
24 125 — 50
52 (LV of Auto 250 — 95
Transformer)
420 1300 1050 —
800 1950 1550 —
124 Manual on Transformers

1.3.2 Partial discharge at 1.5 Um/√3 shall be limited to 500 pC

Notes

(i) Insulation of tertiary winding of Auto-transformer should be adequate to withstand the transferred surge
voltage appearing across it due to an impulse striking on HV or IV terminals. Therefore, 33 kV LVwinding shall
be designed for a minimum lightning impulse withstand voltage of 250 kV (peak) andshort duration power
frequency withstand voltage of 95 kV (rms).Surge Absorbers may be adopted between Tertiary winding Terminals
to limit transferred surge value to 250 kVp and is a discretion between purchaser and manufacturer.

(ii) The shunt reactor or capacitors connected to the LV side would required to be frequently switched onand off.
The LV winding should be capable of withstanding the stresses as may be caused by frequentswitching.

1.4 Temperature Rises

Notes

(i) For the purpose of standardization of maximum temperature rises of oil and winding as measured by resistance,
the following ambient temperatures are assumed.

Air Water
Cooling medium ambient temperature 50°C 30”C
Maximum daily average ambient temperature 40ºC 25°C
Maximum yearly weighted average temperature 32°C -

(ii) Maximum yearly weighted temperature is based on ambient temperature cycle and its duration.
(iii) Wherever ambient temperature is higher than those specified above, the temperature rises, reduced by
corresponding amount, shall be specified.
(iv) Guaranteed temperature rise limits are valid for all the tapping.
(v) The above temperature rises are applicable to transformers required for operation at an altitude not exceeding
1000 meters above sea level.
1.5 Cooling
1.5.1 ONAN/OFAF or ONAN/ODAF Two 50 percent banks. One number of pump
and one standby pump in each bank. Adequate
number of fans and one standby fan in each 50
per cent bank.
1.5.2 ONAN/ONAF1/ONAF2 Two 50 percent banks or four 33.3% unit coolers.
Adequate number of fans and one standby fan in
each 50 per cent bank or in each 33.3% bank.
1.5.3 OFAF or ODAF Adequate number of coolers with one cooler as
standby.
1.5.4 OFWF or ODWF Two 100 per cent coolers.
Note:-
(i) The transformer shall be filled up with mineral oil, conforming toIS: 335 or IEC 60296.
(ii) Tor auto transformers 100 per cent cooling equipment should be capable of dissipating losses occurring in all
the three windings, at any tap.
 Specifications for 800 kV Class Power Transformers 125

1.6 Bushings
1.6.1 The voltage and current ratings, basic insulation level and creepage distances of the
bushings shall be in accordance with the following table:

Voltage rating Current rating Creepage distance Basic impulse Switching impulse
kV (rms) (Amps) (mm) level (kVp) level (kVp)
800 2500 16,000 2100 1550
420 1250 / 2000 10500 1425 1050
52 3150 / 5000 1300 250 --

1.6.2 Partial Disc/large Level Pico-Coulombs :as per IEC 60137.500 at 1.5 p.u.
1.7 Clearances of Line Terminals in Air
Clearances in air between live parts and to earthed structures for LV terminals of generator
transformers and auto - transformers shall be determined as per spacing given in clause 1.1.1
(ix) and 1.2.1 (x) respectively.
The clearances for HV and IV terminals shall be as tabulated below:

Highest voltage for equipment kV Clearances

(rms)
Phase to phase Phase to earth
(mm) (mm)
12 280 140
24 330 230
36 350 320
52 530 480
72.5 700 660
145 1220 1050
145 1430 1270
245 2000 1800
245 2350 2150
420 4000 3500
800 5800* / 6700* 5000* / 5800*

* depending upon lightening & switching impulse level.

Airclearances between phase to earth can be relaxed to the extent of maximum of 200 mm so far
as air release pipe emanating from bushing turret is concerned.
1.8 Fittings and Accessories
(a) Rating and diagram plate.
(b) Two earthing terminals,
(c) Lifting bollards.
(d) Jacking pads.
(e) Haulage lugs.

(f) Pocket on tank cover for thermometer.

126 Manual on Transformers

(g) Air release devices.

(h) Conservator with oil- filling hole, cap and drain valve (size: 25 mm )

(i) Magnetic type oil gauge with low oil level alarm contacts (ratings: 0.5 Amp, 220 Volts
DC.) Dial size 250 mm.

(j) Silicagel breather with oil seal.

(k) Air cell type oil preservation system. Aircell rupture detector may be provided.

• In addition to provision of air cell in conservators for sealing of the oil system against
the atmosphere, an on line insulating oil drying system shall be provided. This on line
insulating oil drying system shall be designed for very slow removal of moisture that may
enter the oil system or generated during cellulose decomposition.

(1) Required number of pressure relief device capable of resealing after release of pressure.

(m) Valves

• Oil valves between cooler and main tank

• Drain valve preferably with padlocking arrangement (minimum size 80 mm).

• Two filter valves (size: 50 mm) on diagonally opposite ends - one at top and other at
bottom preferably with padlocking arrangement on bottom valve.

• Two sampling valves (size: 15 mm) at top and bottom of main tank.

(n) Oil flow indicator with alarm contacts (ratings, 0.5 Amps, 220 Volts D.C.) with each
pump.

(o) Valve schedule plate.

(p) Buchholz relay with alarm and trip contacts (Ratings: 1.0 Amp. 220 Volts D.C.) shall
have

• One number shut-off valve (Size: 80 mm) on conservator side

• Test cock

• Gas collection box and gas check valve at ground level. Copper tube interconnection
between gas collection box and relay shall also be provided. In transformers, for installation
in areas subject to high seismic forces, i.e., horizontal acceleration of 0.3 g or more at and
above a frequency of 8 Hz pitot type or reed type of gas and oil relay shall be used.

(q) Online dissolved gas monitoring device.

(r) Dial type oil temperature indicator with maximum reading pointer and two sets of contacts
(ratings, 0.5 Amps, 220 Volts D.C).
 Specifications for 800 kV Class Power Transformers 127

(s) 1 No. dial type winding temperature indicator for a two winding transformer and one dial
type windings temperature indicator for each winding of a multi winding transformer with
‘maximum reading’ pointer and two sets of contact ratings: 5 Amps, 220 Volts D.C. (for
OFAF/ODAF and OFWF/ODWF) and four sets of contacts (for ONAN/ODAF/OFAF).

(t) Remote indication for each winding temperature shall be through a separate measuring
system.

(u) Cover lifting lugs.

(v) Provision for mounting bi-directional flanged rollers with locking and bolting device for
rail gauge specified below:

Type of construction Shorter axis Longer axis

Single-phase 2/3 rail combination with 1676 Two rails with
mm gauge according to layout 1676 mm gauge
and size of Transformer

(w) Weather proof marshalling box for housing control equipment and terminal connections.

(x) Wiring up to marshalling box with PVC SWA copper cables of 650/1100 Volt grade.

(y) Cooling accessories.

(I) ONAN/OFAF or ONAN/ODAF cooling

(i) Requisite number of radiators provided with:

- One shut off valve on top (minimum size: 80 mm)

- One shut off valve at bottom (minimum size: 80 mm)

- Air release device on top

- Drain and sampling device at bottom

- Lifting lugs

(ii) Fans

(iii) Oil pumps with shut off valve on both sides (if required for ONAN cooling pumps
can be by-passed using by-pass pipes and valves).

(iv) Expansion joints, one each on top and bottom cooler pipe connections.

(v) Air release device and oil drain plug on oil pipe connections.

(II) OFAF or ODAF cooling

128 Manual on Transformers

(i) OFAF coolers with integral fans

(ii) Oil pumps with shut-off valves on both sides.

(iii) Brass encased thermometers.

(iv) Air release devices and oil pipe connections.

(v) Lifting lugs.

(III) OFWF or ODWF cooling

(i) Oil/water heat exchangers with segregated oil and water headers

(ii) Oil pumps with shut-off valves on both sides.

(iii) Water flow indicator with alarm contacts (ratings: 0.5 Amp, 220 Volts DC).

(iv) Brass encased thermometer.

(v) Pressure gauges.

(vi) Differential pressure gauge with alarm contacts, operating when difference between
oil outlet pressure and water inlet pressure is less than 0.2 kg/cm2

(vii) Reflux valve if required as per scheme.

(viii) Drain and sampling device on cooler pipe connection.

 SECTION J

Specification for 420 kV Class Shunt Reactors &

Associated
145 kV Class Neutral Grounding Reactors
 SECTION J
Specification for 420 kV Class Shunt Reactors & Associated
145 kV Class Neutral Grounding Reactors
A. Specifications for 420 kV Class Shunt Reactors

1.0 Scope

1.1 This section covers technical requirements/parameters for Shunt Reactors of 420 kV
class but does not purport to include all the necessary provisions of a contract. For general
requirements, loss capitalization and tests, reference shall be made to Sections ‘A’, ‘AA’ & ‘BB’
respectively of this Manual.

1.2 Introduction

The AC power system networks are operated as voltage source networks. One essential
requirement, therefore is that under all operating conditions of load the voltage, profile of entire
network should be maintained nearly flat, regulating the voltage of each bus within narrow band
of permitted tolerance. No special compensation facilities are needed when the Power transfer
is over small distances. With increase in power network and generating station connected to
load centers employing long transmission lines, this requirement becomes difficult to meet. The
need, thus arises to compensate these long transmission lines (generally above 200 km).

1.3 Problem Associated with- Reactive Power

Power transmission lines are characterised by their line inductance and shunt capacitance. For
shorter lines their inductive reactance dominates. As a result, when they carry load current,
which normally is inductive in nature, the receiving end voltage reduces in magnitude and hence
shunt reactors are not required for such lines. Long transmission lines present a problem of a
different kind; once energised the line charging becomes a source of reactive power. Under light
load conditions the VAR generation exceeds the VAR consumption which causes excessive
voltage at mid-point. The consumed reactive power is equal to generated power for a certain
transmitted load. This transmitted load is called surge impedance or natural load of the line.
Voltage profile under these conditions becomes flat. Under Heavy load condition, generation of
reactive power in lines reduces while its consumption increases substantially.

1.4 Function of Shunt Reactor

In practice, on account of the transient stability considerations, the permissible loading of long
-lines is kept below surge impedance loading and therefore one faces the challenge to restrict
over voltage along the length of the line. This is accomplished by the connection of shunt reactor
at intermediate buses. This solution is satisfactory but, when used, the total transmission capacity
of the line is reduced. Mid-point shunt compensation not only improves the voltage profile but
also enhances the power transfer capacity of a long line. Shunt Reactors are, thus, important
components-for better utilization of existing and new lines since they compensate for large
capacitive currents generated by HV transmission lines over long distances, restricting optimum
system operation under low load conditions.

131
132 Manual on Transformers

Capacitive energy is thus balanced with reactive energy and the shunt reactors:

• Maintain grid voltage within limits compatible with the systems insulation level under
normal service conditions. (Lightly loaded condition.)

• Control dynamic over voltage under abnormal conditions (loss of system, interconnections.
resulting from load shedding operations. or from a line-ground fault)

• Take care of switching transients.

1.5 Reactors may be permanently connected, or switched in and off type, depending upon
voltage variations.

1.6 Connection In The System

The reactor is connected either directly on the line and or HV bus or connected to a low-voltage
tertiary winding of a large transformer.

1.7 Applicable Standard

Except otherwise specified or implied herein, the Reactors shall comply with latest edition of
International Standard IEC 60076-6.

1.8 Standard Ratings

Based on length of transmission lines & reactive power compensation in India following three
phase ratings of Shunt Reactor have been standardised for 400 kV lines –

1. 50 MVAR

2. 63 MVAR

3. 80 MVAR

4. 125 MVAR

Note: Single Phase Rating option also possible for specific requirement.

1.9 Major Technical Parameters

1.9.1 Type: Gapped Core or Magnetically Shielded Air Core type Construction

1.9.2 Application & Operation: Shunt Reactors will be connected to the 400kV transmission
system for Reactive Power Compensation and shall be capable of controlling the dynamic over
voltages occurring in the system due to load rejection.

1.9.3 Shunt Reactors shall be capable of operating continuously at a voltage 5% higher than
their rated voltage without exceeding hot spot temperature of 140°C at any part of the reactor.

1.9.4 The Neutral Grounding Reactors(NGR) are required for grounding of the neutral point
 Specification for 420kV Class Shunt Reactors & Associated 133
145 kV Class Neutral Grounding Reactors

of Shunt Reactors to limit the secondary arc current & recovery voltage to a minimum value
in case Shunt Reactor is connected in the line termed as “Line Reactor”. The Reactor directly
connected to the bus termed as “Bus Reactor” and shall have its neutral directly earthed without
NGR. In such cases utility may decide to have BIL for Neutral of Shunt Reactor as 95 kVp &
38kVrms with 36 kV Neutral Bushing.

1.9.5 The Reactor shall be capable of withstanding Switching Surge Overvoltage of 2.5 p.u
and temporary overvoltage of the order of 2.3 p.u for few cycles followed by power frequency
overvoltage upto 1.5 p.u.

1.9.6 Rating (MVAR) 50/63/80/125

(a) Rated voltage 420kV (1.0 pu)

(b) System Fault Level 40/50/63 kA as per System Requirement
(c) Connection Star with Neutral brought Out
(d) Tolerance on Impedance -0 to +5%
(e) Ratio of Zero sequence Reactance to positive 0.9 to 1.0
Reactance (X0/X1)
(f ) Range of Constant Impedance (Linearity) Up to 1.5 pu
(g) Harmonic Content in Phase Current The crest value of the third harmonic component in
phase current not to exceed 3% of the crest value at
rated voltage
(h) Permissible unbalance current among different phase ±2%
(i ) Vibration Level at rated voltage & frequency 200 microns p-p, 60 microns average
(j) Stress on tank wall 2 kg/mm2 maximum
(k) Noise Level 80 dB
(l) ONAN with separate/tank mounted radiator bank*
*OFWF/OFAF due to space constraint/ customer
specific requirement
ONAN - One 100% bank
Cooling OFAF - Adequate number of coolers with one cooler
as standby
OFWF - Two 100 per cent coolers
Radiator bank/ Cooler can be tank or separately
mounted
(m) Maximum Partial Discharge level 500 pico coulomb at 1.5 pu (as per IEC 60076-3)
(n) Temperature Rises*
Temperature rise of top oil measured by 40oC
thermometer
Temperature rise of winding measured by resistance 45oC

Notes:
(i) For the purpose of standardization of maximum temperature rises of oil and winding as measured by resistance, the
following ambient temperatures are assumed :
Cooling medium ambient temperature Air at 50°C, Water at 30°C
Maximum daily average ambient temperature Air at 40°C, Water at 25°C
Maximum yearly weighted average temperature Air at 32°C
(ii) Maximum yearly weighted temperature is based on ambient temperature cycle and its duration.
(iii) Wherever ambient temperatures are higher than those specified above, the temperature rises, reduced by
corresponding amount, shall be specified.
(iv) The above temperature rises are applicable to transformer reactors required for operation at an altitude not
exceeding 1000 metres above sea level.
134 Manual on Transformers

1.10 Terminals
Line Terminals: 420 kV oil-filled condenser bushings with test taps. No arcing horns shall be
provided.
Neutral Terminal: 145 kV oil-filled condenser bushings with test taps. No arcing horns shall be
provided.
1.10.1 Technical Parameters Bushings

Parameter Bushing Bushing

Line Terminal Neutral Terminal
(a) Rated Voltage (kV) 420 145
(b) Rated Current (A) 1250 1250
(c) Creepage distance (mm) 10,500 3625
(d) Mounting Tank Cover Tank Cover
(e) Rated Lightning Impulse withstand voltage (kVp) 1425 650
(f ) Rated Switching Impulse withstand voltage (kVp) 1050 -
(g) One minute Power frequency withstand voltage (kVrms) 695 305

Notes-
(i) The 1250 amps bushings shall be suitable for draw lead type assembly
(ii) The Dimensions of Bushings are as per Section II.
(iii) In case of GIS termination, bushing to meet the requirements as per IEC 61639.

1.11 INSULATION LEVEL WINDINGS

Parameter Line End Neutral End

(a) Lightning Impulse withstand voltage (kVp) 1300 550
(b) Switching Impulse withstand voltage (kVp) 1050 -
(c) Power frequency withstand voltage (kVrms) - 230

1.12 Clearances of Line Terminals in Air Clearances

(a) Highest voltage for equipment kV (rms) Phase to Phase Phase to Earth
420 4000 mm (Min) 3500 mm (Min)
145 NA 1050 mm (Min)
Note - Air clearances of 3500 mm between phases to earth can be relaxed to the extent of maximum of 200 mm so far
as air release pipe emanating from bushing turret is concerned.

1.13 TESTS

1.13.1 Routine Tests

(a) Measurement of winding resistance.

(b) Measurement of insulation resistance between winding & earth by 5 kV megger.
 Specification for 420kV Class Shunt Reactors & Associated 135
145 kV Class Neutral Grounding Reactors

(c) Measurement of impedance by bridge method.

(d) Measurement of loss and current by bridge method at rated voltage and ambient
temperature. Correction factor per degree centigrade shall be established for each rating of
reactor by measuring losses at ambient temperature and elevated temperature. Correction
factor thus established shall be applied for computation of losses at 75oC. Loss value thus
obtained shall be corrected to rated current.
For purpose of similarity for applying this coefficient the shunt reactor under test shall
have identical rating & guaranteed losses within ±5%.
(e) Measurement of Capacitance and Tan delta
(f) Jacking test on reactor tank without fitting & accessories.
(g) Frequency response analysis test.
(h) Measurement of vibration & stress.
(i) Isolation test between Core-End Frame, End-frame-tank and Core-Tank by 2.5kV AC for
one minute.
(j) Dielectric Test
(i) Separate source voltage withstand test at 230 kV AC for one minute.
(ii) Induced over voltage withstand test with P.D. indication at 412 kV AC (1.7pu/√3)
for 5 minutes and at 364 kV AC (1.5pu//√3) for one hour.
Note: Large value of reactive compensation is required during induced over voltage test on reactors. Considering
the test plant limitations level of 1.7pu can be omitted for larger ratings of Shunt Reactors as per the agreement
between the manufacturer and customer. This is permitted by IEC.

(iii) Full wave lightning impulse voltage withstand test at 1300 kVp on line terminals.
(iv) Switching impulse voltage withstand test at 1050 kVp on line terminals.

1.13.2 Type Test (On One Unit Only)

(a) Temperature rise test as per IEC 60076-2 along with DGA before and after
temperature rise test.
(b) Measurement of acoustic noise level

1.13.3 Special Test (On One Unit Only)

(a) Measurement of zero sequence reactance.(for three phase reactors only)

(b) Full wave lightning impulse voltage withstand test at 550 kVp on neutral terminal.
(c) Magnetization curve test/ knee point voltage measurement.
(d) Measurement of Harmonics
(e) Measurement of Mutual Reactance (for three phase reactors only)

1.13.4 Test on Reactor Tank

(a) As per requirements of GENERAL section

136 Manual on Transformers

1.13.5 Reactor Oil Testing

The following tests are to be conducted on oil samples for the reactor tank assembled for testing.
Acceptance norms for insulating oil after filling into reactor shall be as given below –
Characteristic Permissible limit ( IEC 60422)
Electrical strength 60 kV (min.)
Water content 10 ppm (max.)
Ten Delta at 90oC 0.01 (max.)
Resistivity at 90 C
o
6 x 1012 ohm-cm (min.)
Interfacial tension 0.035 N/m (min.)

1.14 GUARANTEED TECHNICAL PARTICULARS

1. Manufacture name & country

2. Type of reactor (Gapped/ Air core)
3. Standards applicable
4. Rated MVAr capacity
5. Rated voltage (kV)
6. Type of cooling
7. Thermal data
a) Temperature rise in oil above ambient temperature (Deg C)
b) Temperature rise of winding by resistance above ambient temperature
(Deg C)
c) Rated frequency (Hz)
8. Number of phases
9. Guaranteed max. losses at rated voltage and frequency at rated output
at 75 Deg C (kW)
10. Noise level & reference (dB)
11. Insulation level (winding & bushing) Winding Bushing Line/ Neutral
Line/ Neutral
a) Lightning impulse (1.2/50 microsecs.) withstand voltage (kVp)
b) Power frequency withstand voltage (kVrms)
c) Switching surge withstand voltage (kVp)
12. Range of voltage upto which impedance will be constant (p.u.)
a)
b) Impedance value at 1.0 pu (ohms)
c) Impedance value at 1.5 pu (ohms)
13. X0/X1
14. Vibration & maximum stress on the tank
a)
b) Vacuum withstand capacity of tank
 Specification for 420kV Class Shunt Reactors & Associated 137
145 kV Class Neutral Grounding Reactors

15. Harmonic content in phase current

16. Shipping weights & Dimensions
(a) Size of largest package (mm)x(mm)x(mm)
(b) Weight of largest package (kg)
(c) Gross weight to be handled (kg)
(d) Gross volume to be handled (cu.m)
(e) Approx. overall dimension (lxbxh) (mm)
(f) Approx. quantity of oil required for first filling
(g) Un tanking height
17. Proposed method of transportation
18. Compliance to technical specification w.r.t. parameter specified for
(a) Oil
(b) Bushing CT
(c) Bushings
(d) Terminal connectors
19. Whether similar equipment are type tested & are in successful
operation for at least two years (If yes, furnish type test reports)
20. Overall general arrangement drawing of Shunt Reactor with all
accessories to be enclosed
21. Additional Data
1. System Fault Level
2. Connection
3. Amount of unbalanced current in each phase when connected to
symmetrical voltages
4. Tolerance on Current
5. Capacitance Value (Phase to ground)
6. Clearances from 400 kV terminal
(a) Phase to phase
(b) Phase to ground
(c) Neutral to ground
7. Tank
(a) Type
(b) Material
(c) Thickness
8. Gasket Details
(a) Material
(b) Temperature withstand capability
9. Conservator
(a) Total Volume
138 Manual on Transformers

(b) Volume between highest & lowest visible oil level

(c) Type of Conservator
10. No. of Pressure Relief device provided
(a) Operating Pressure
11. Temperature Indicators
(a) OTI/WTI
(i) Make
(ii) Range (oC)
(iii) Accuracy (%)
(b) RWTI
(i) Make
(ii) Range (oC)
(iii) Accuracy (%)
(iv) Auxiliary Supply required
12 Winding
(a) Material
(b) Cross-sectional area of conductor
(c) Current density
13. Core
(a) Type of Core
(b) Justification for type of Core adopted
(c) Technical details of the core (No. of limbs)
(d) Material of Core, its grade & thickness
14. Bushings Line (400 kV) Neutral(145 kV)
(a) Type
(b) Maker’s Name
(c) Standard Applicable
(d) Visible discharge voltage for falling power frequency voltage
(e) One minute power frequency withstand voltage
(i) Dry
(ii) Wet
(f) Full wave Impulse withstand voltage
(g) Switching Impulse withstand voltage
(h) Total Creepage distance in air (Approx.)
(i) Weight of assembled bushing (Approx.)
(j) Cantilever Strength (Approx.)
(k) Rated Current
15. Radiator
 Specification for 420kV Class Shunt Reactors & Associated 139
145 kV Class Neutral Grounding Reactors

(a) Make
(b) Material
(c) Thickness
(d) Pressure Withstand Capability
(e) Vacuum Withstand Capability
16. Marshalling box
(a) Type of Mounting
(b) Degree of Protection
17. Bushing Current Transformer
(a) Line Side
(i) Type or voltage class
(ii) Ratio
(iii) Accuracy class
(iv) Burden (VA)
(vi) Knee point voltage (Volts) (Minimum)
(vii) Maximum resistance of secondary winding (ohms)
(viii) Maximum exciting (mA) current
(b) Neutral Side (Before/ After Neutral formation)
(i) Type or voltage class
(ii) Ratio
(iii) Accuracy class
(iv) Burden (VA)
(vi) Knee point voltage (Volts) (Minimum)
(vii) Maximum resistance of secondary winding (ohms)
(viii) Maximum exciting (mA) current

B. SPECIFICATION FOR NEUTRAL GROUNDING REACTORS

1.0 Scope

1.1 This section covering specification for Neutral Grounding Reactors, does not purport to
include all the necessary provisions of a contract. For general requirements and tests, reference
shall be made to other Sections ‘A’ and ‘BB’ of the Transformer Manual.

2.0 General

2.1 Unless otherwise modified in this section the earthling transformers shall comply with
latest versions of IEC 60076

2.2 Single phase Neutral Grounding Reactors are connected between neutral point of 400
kV Shunt Reactors and earth, where neutral of Shunt Reactor is designed for 145 kV class
insulation.
140 Manual on Transformers

2.3 In the high voltage transmission system installed with shunt reactor and when single
pole reclosing is envisaged, a small inductor called neutral grounding reactor is required to be
put between neutral of shunt reactor and earth to compensate the capacitive current during single
line to earth fault.

2.4 Thus NGR is required to carry high current for a very short time.

2.5 In a shunt reactor maximum permissible unbalance current among different phases is
2%, which implies that for 125 MVAR shunt reactor current of 3.5Amp may flow through
continuously.

2.6 Based on above consideration NGR is designed for continuous current of 10 Amp & 60
Amp for 10 seconds (time during which the fault would be definitely cleared).

2.7 NGR consists of air core coil of suitable impedance (as specified in the contract based
on system requirement) immersed in oil filled tank. The Line terminal is brought out through
145kV OIP condenser Bushing which is connected to neutral terminal of shunt reactor. Neutral
terminal is brought out through 36 kV porcelain bushing.

2.8 As continuous losses of NGR are negligible, reactor tank surface is adequate for
dissipation of these losses & therefore no cooling equipment is required.

3.0 TECHNICAL PARAMETERS

(a) Rated Voltage from insulation strength 145 kV

consideration

(b) Rated frequency 50 Hz

(c) No. of Phases 1

(d) Type Outdoor

(e) Insulation Graded

(f ) Max. Continuous Current 10A(rms)

(g) Rated Short time current for 10 seconds 60A(rms)

(h) Rated Impedance at rated Short time current 400 to 2500 ohm (actual value to be defined by
Customer)

(i) Cooling System Natural Oil Cooling(ONAN)

(j ) Max Temperature rises over 50°C ambient Winding measured by resistance : 50°C
Top Oil measured by Thermometer: 45°C

(k ) Connection Between neutral of Shunt Reactor and Ground

(l) Line Terminal 145 kV oil-filled condenser bushings with test taps. No
arcing horns shall be provided

(m) Neutral Terminal 36 kV Porcelain bushing. No arcing horns shall be

provided.
 Specification for 420kV Class Shunt Reactors & Associated 141
145 kV Class Neutral Grounding Reactors

3.1 Technical Parameters of Bushings

Line Terminal Neutral Terminal
(a) Rated Voltage (kV) 145 36
(b) Rated Current (A) 1250 630
(c) Creepage distance (mm) 3625 600
(d) Mounting Tank Cover Tank Cover
(e) Rated Lightning Impulse withstand voltage (kVp) 650 170
(f ) One minute Power frequency withstand voltage 270 305 75 77
(kVrms)
Notes:
(i) The 1250 amps bushings shall be suitable for draw lead type assembly.
(ii) The Dimensions of condenser Bushings are as per Section II.
(iii) In case of GIS termination, bushing to meet the requirements as per IEC 61639

3.2 Insulation Level Windings

Line End Neutral End

Lightning Impulse withstand voltage (kVp) 550 95
Power frequency withstand voltage (kVrms) 230 38

3.3 Clearances of Line Terminals in Air

Voltage Level Phase to Earth

145 1050
24 230

3.4 Method of Grounding : Solidly

3.5 Tests

(a) Measurement of winding resistance.

(b) Measurement of insulation resistance between winding & earth by 5 kV megger.
(c) Measurement of impedance by V/I method at 10A & 60A.
(d) Separate source voltage withstand test at 38 kV AC for one minute.
(e) Full wave lightning impulse voltage withstand test at 550 kVp on line terminals.
(f) Jacking test on reactor tank without fitting & accessories.
142 Manual on Transformers

3.6 Tests on Reactor Tank

3.6.1 As per requirements of GENERAL section

3.7 Guaranteed Technical Data

1. Manufacture name & country of manufacture

2. Type of reactor (gapped/ air core)
3. Standards applicable
4. Type of cooling
5. Rated voltage (kV)
6. Max. continuous current (Amps)
7. Rated short time current at 10 sec. (Amps)
8. Ohmic value (ohms)
Rated reactive capacity for continuous operation at rated voltage (MVAR)
9. Thermal data:
(a) Temperature rise in oil at rated current above ambient temperature of 500C (Deg C)
(b) Temperature rise of winding over ambient temperature of 500C (Deg C)
10. Rated frequency (Hz)
11. Guaranteed max. losses at rated voltage and frequency at rated output (kW)
12. Insulation level (winding & bushing)
(a) Lightning impulse (kVp)
(b) Power frequency (kVrms)
(c) Neutral brought out at (kV)
13. Type of insulation (Graded or Uniform)
14. Overall dimensions & weights
(a) Length with coolers (mm)
(b) Breadth with coolers (mm)
(c) Height with bushing (mm)
(d) Quantity of oil (kl)
(e) Un tanking heights (mm)
15. Shipping data
(a) Size of largest package (mm)x(mm)x(mm)
(b) Weight of largest package (kg)
(c) Gross weight to be handled (kg)
(d) Gross volume to be handled (cu.m)
16. Compliance to technical specification w.r.t. parameter specified for
(a) Oil
(b) Bushing CT
(c) Bushings
 Specification for 420kV Class Shunt Reactors & Associated 143
145 kV Class Neutral Grounding Reactors

(d) Terminal connectors

17. Whether similar equipment are type tested & are in successful operation for at least two years (If yes, furnish
type test reports)
18. Overall general arrangement drawing of Neutral Grounding Reactor with all accessories to be enclosed
19. Bushing Current Transformer
(a) Line Side
(i) Type or voltage class
(ii) Ratio
(iii) Accuracy class
(iv) Burden (VA)
(v) Accuracy limit factor
(vi) Knee point voltage (Volts) (Minimum)
(vii) Maximum resistance of secondary winding (ohms)
(viii) Maximum exciting (mA) current
(b) Neutral Side
(i) Type or voltage class
(ii) Ratio
(iii) Accuracy class
(iv) Burden (VA)
(v) Accuracy limit factor
(vi) Knee point voltage (Volts) (Minimum)
(vii) Maximum resistance of secondary winding (ohms)
(viii) Maximum exciting (mA) current
 SECTION K

Specifications for 800 kV Class Shunt Reactors &

Associated
145 kV Neutral Grounding Reactor
 SECTION K
Specifications for 800 kV Class Shunt Reactors & Associated
145 kV Neutral Grounding Reactor
A. Specifications for 800 kV Class Shunt Reactors

1.0 Scope

1.1 This section covers technical requirements/parameters for Shunt Reactors of 800 kV
class but does not purport to include all the necessary provisions of a contract. For general
requirements, loss capitalisation and tests, reference shall be made to Sections ‘A’, ‘AA’ & ‘BB’
respectively of this Manual.

1.2 Refer clause no. 1.2 ,1.3, 1.4, 1.5, 1.6, 1.7 of Section J “Specifications for 420 kV Class
Shunt Reactors” for general information , functions & application.

1.3 Standard Ratings

Based on length of transmission lines & reactive power compensation in India ,following single
phase ratings of Shunt Reactor have been standardised for 800kV lines –
1. 80 MVAR - 765kV
2. 110 MVAR - 765kV
1.4 Major Technical Parameters

1.4.1 Type: Gapped Core or Magnetically Shielded Air Core type Construction

1.4.2 Application & Operation: Shunt Reactors will be connected to the 800 kV transmission
system for Reactive Power Compensation and shall be capable of controlling the dynamic over
voltage occurring in the system due to load rejection.

1.4.3 Shunt Reactors shall be capable of operating continuously at a voltage 5% higher than
their rated voltage and thermal and cooling system shall be designed accordingly.

1.4.4 The Neutral Grounding Reactors are required for grounding of the neutral point of Shunt
Reactors to limit the secondary arc current & recovery voltage to a minimum value in case
Reactor is connected in the line termed as “Line Reactor”. The Reactor directly connected to the
bus termed as “Bus Reactor” and its neutral is directly earthed.

1.4.5 The Reactor shall be capable of withstanding Switching Surge Overvoltage of 1.9
p.u and temporary overvoltage of the order of 1.4 p.u for about 10 cycles followed by power
frequency overvoltage upto 1.8 p.u.

147
148 Manual on Transformers

1.4.6

(a) Rating (MVAr) 80/110 single phase at 765/√3 kV

(b) (i) Rated voltage 765/√3 kV
(ii) Max. continuous operating voltage(Um) 800/√3 kV
(c) System Fault Level 40/50/63 kA as per System requirement
(d) Connection Star after 3 phase bank formation
(e) Tolerance on Impedance -0 +5 %
(f) Ratio of Zero sequence Reactance to positive 0.9 to 1.0
Reactance (X0/X1)
(g) Range of Constant Impedance (Linearity) Up to 1.25 pu
(h) Harmonic Content in Phase Current The crest value of the third harmonic component in
phase current not to exceed 3% of the crest value
of the crest value of fundamental when reactor is
energized at rated voltage with sinusoidal wave form
(i) Permissible unbalance current among different phases +/- 1%
of a bank
(j) Vibration Level at 800√3 kV voltage & 50Hz 200 microns p-p, 60 microns average
(k) Stress on tank wall at 800√3kV 2 kg/mm2 max.
(l) Noise Level at 800/√3kV 80 dBA
(m) Cooling ONAN with separate radiator bank

(n) Maximum Partial Discharge level 500 pico coulomb at 1.5 pu (as per IEC 60076-3)
(o) Temperature Rises over an ambient temp. of 50 Deg.
Cent. And at 800/√3kV
Temperature rise of top oil measured by thermometer 400C
Temperature rise of winding measured by resistance 450C
The above temperature rises are applicable to reactors required for operation at an altitude not exceeding 1000
metres above sea level.

1.5 Terminals

Line Terminals : 800 kV oil-filled condenser bushings with test taps.

Neutral Terminal: 145 kV oil-filled condenser bushings with test taps. No arcing horns shall be
provided.

1.5.1 Technical Parameters Bushings

Parameter Line Terminal Neutral Terminal

(a) Rated Voltage (kV) 800 145
(b) Rated Current (A) 1600/2500 1250
(c) Creepage distance (mm) 20000 3625
(d) Mounting Tank Cover Tank Cover
 Specifications for 800kV Class Shunt Reactors & Associated 149
145 kV Neutral Grounding Reactor

(e) Rated Lightning Impulse withstand 2100 650

voltage (kVp)
(f) Rated Switching Impulse withstand 1550 -
voltage (kVp)
(g) One minute Power frequency withstand 970 275 305
voltage (kVrms)
Notes:
(a) The bushings shall be suitable for draw lead type or draw rod type assembly
(b) The Dimensions of Bushings are as per Section II.
(c) In case of GIS termination, bushing shall meet the requirements as per IEC 61639.

1.6 Insulation Level Windings

Parameter Line End Neutral End
(a) Lightning Impulse withstand 1950 550
voltage (kVp)
(b) Switching Impulse withstand 1550 -
voltage (kVp)
(c) Power frequency withstand - 230
voltage (kVrms)

1.7 Clearances of Line Terminals in Air Clearances

(a) Highest voltage for Phase to earth

equipment kV (rms) Clearance (mm)
800 5800 mm (Min)
145 1050 mm (Min)

1.8 TESTS
1.8.1 Routine Tests

(a) Measurement of winding resistance.

(b) Measurement of insulation resistance between winding & earth by 5 kV megger.
(c) Measurement of reactance by bridge method.
(d) Measurement of loss and current by bridge method at rated voltage and ambient
temperature. Correction factor per degree centigrade shall be established for each rating of
reactor by measuring losses at ambient temperature and elevated temperature. Correction
factor thus established shall be applied for computation of losses at 75ºC. Loss value thus
obtained shall be corrected to rated current.
(e) Measurement of Capacitance and Tan delta
(f) Jacking test on reactor tank without fitting & accessories.
(g) Frequency response analysis test.
(h) Measurement of vibration & stress.
150 Manual on Transformers

(i) Isolation test between Core-End Frame, End-frame-tank and Core-Tank by 2.5kV AC for
one minute.
(j) Dielectric Test
(i) eparate source voltage withstand test at 230 kV AC for one minute.
(ii) Induced over voltage withstand test with P.D. indication at 785 kV AC (1.7pu/√3)
for 30 seconds and at 693kV AC (1.5pu/√3) for one hour.
Note: Large value of reactive compensation is required during induced over voltage test on reactors. Considering the
test plant limitations level of 1.7pu can be omitted for larger ratings of Shunt Reactors as per the agreement
between the manufacturer and customer. This is permitted by IEC.

(iii) Full wave lightning impulse voltage withstand test at 1950 kVp on line terminals.
(iv) Switching impulse voltage withstand test at 1550 kVp on line terminals.

1.8.2 Type Test (On One Unit Only)

(a) Temperature rise test as per IEC 60076-2 & DGA before and after temperature rise test.
(b) Measurement of acoustic noise level at 800/√3kV

1.8.3 Special Test (On One Unit Only)

(a) Full wave lightning impulse voltage withstand test at 550 kVp on neutral terminal.
(b) Magnetization curve test/ knee point voltage measurement.
(c) Measurement of Harmonic content of current

1.8.4 Test on Reactor Tank

(a) As per requirements of GENERAL section

1.8.5 Reactor Oil Testing

The following tests are to be conducted on oil samples for the reactor tank assembled for testing.
Acceptance norms for insulating oil after filling into reactor shall be as given below –

Characteristic Permissible limit ( IEC 60422)

Electrical strength 70 kV (min.)
Water content 10 ppm (max.)
Ten Delta at 900C 0.01 (max.)
Resistivity at 900C 6 x 1012 ohm-cm (min.)
Interfacial tension 0.035 N/m (min.)

1.9 Guaranteed Technical Particulars

Refer Clause no 1.14 of Section J “Specification of 420 kV Class Shunt Reactors”

 Specifications for 800kV Class Shunt Reactors & Associated 151
145 kV Neutral Grounding Reactor

B. SPECIFICATION FOR NEUTRAL GROUNDING REACTORS

1.0 Scope

This section covering specification for Neutral Grounding Reactors, does not purport to include
all the necessary provisions of a contract. For general requirements and tests, reference shall be
made to other Sections ‘A’ and ‘BB’ of the Transformer Manual.

2.0 General

2.1 Unless otherwise modified in this section the Neutral Grounding Reactors shall comply
with latest versions of IEC 60076

2.2 Single phase Neutral Grounding Reactors are connected between neutral point of 800
kV Shunt Reactors and earth, where neutral of Shunt Reactor is designed for 145 kV class
insulation.

2.3 In the high voltage transmission system installed with shunt reactor and when single
pole reclosing is envisaged, a small inductor called neutral grounding reactor is required to be
put between neutral of shunt reactor and earth to compensate the capacitive current during
single line to earth fault.

2.4 Thus NGR is required to carry high current for a very short time.

3.0 Technical Parameters

(a) Rated Voltage from insulation strength 145 kV
consideration
(b) Rated frequency 50 Hz
(c) No. of Phases 1
(d) Type Dry type air core for outdoor application
(e) Insulation Graded
(f ) Max. Continuous Current 20A (rms)
(g) Rated Short time current for 60 seconds 240A (rms) (However the NGR shall be
designed for a current rating of 600A(rms) short
time current to ensure mechanical robustness)
(h) Rated Impedance at rated Short time current Actual value to be defined by Customer
(Ohms)
(i ) Cooling System Natural Air Cooled
(k) Connection Between neutral of Shunt Reactor and Ground
(l) Line Terminal 145 kV oil-filled condenser bushings with test
taps. No arcing horns shall be provided
(m) Neutral Terminal 36 kV Porcelain bushing. No arcing horns shall
be provided.
152 Manual on Transformers

3.1 Technical Parameters of Bushings

Line Terminal Neutral Terminal

(a) Rated Voltage (kV) 145 36
(b) Rated Current (A) 1250 630
(c) Creepage distance (mm) 3625 600
(d) Mounting Tank Cover Tank Cover
(e) Rated Lightning Impulse 650 170
withstand voltage (kVp)
(f) One minute Power 305 77
frequency withstand
voltage (kVrms)
Notes
(i) The 1250 amps bushings shall be suitable for draw lead type assembly.
(ii) The Dimensions of condenser Bushings are as per Section P.
(iii) In case of GIS termination, bushing to meet the requirements as per IEC 61639

3.2 Insulation Level Windings

Line End Neutral End
(a) Lightning Impulse withstand voltage (kVp) 550 95
(b) Power frequency withstand voltage (kVrms)
230 38

3.3 Clearances of Line Terminals in Air Clearances

Phase to Earth
(a) 145 1050
(b) 36 230

3.4 Method of Grounding: Solidly

3.5 Mounting of NGR : On Pedestal Insulator
3.5.1 Requirement of Pedestal Insulator
Type Porcelain/ Silicon rubber
(a) Minimum Creepage 438 mm
(b) One minute Power frequency 55 kVrms
withstand voltage
(c) Lightning Impulse Withstand 125 kVp
voltage
(d) Mounting Structure Non magnetic material

3.6 Tests

(a) Measurement of winding resistance.

(b) Measurement of insulation resistance between winding & earth by 5 kV megger.
 Specifications for 800kV Class Shunt Reactors & Associated 153
145 kV Neutral Grounding Reactor

(c) Measurement of impedance by V/I method

(d) Separate source voltage withstand test at 38 kV AC for one minute.
(e) Full wave lightning impulse voltage withstand test at 550 kVp on line terminal.

3.7 Test on Reactor Tank

3.7.1 As per requirements of Section A

3.8 Guaranteed Technical Data

1. Manufacture’s name & country of manufacture

2. Type of reactor
3. Standards applicable
4. Type of cooling
5. Rated voltage (kV)
6. Max. continuous current (Amps)
7. Rated short time current for 10 sec. (Amps)
8. Ohmic value (ohms)
Rated reactive capacity for continuous operation at rated voltage (MVAR)
9. Rated frequency (Hz)
10. Guaranteed max. losses at rated voltage and frequency at rated output (kW)
11. Insulation level (winding & bushing)
(a) Lightning impulse (kVp)
(b) Power frequency (kVrms)
(c) Neutral brought out at (kV)
12. Type of insulation (Graded or Uniform)
13. Overall dimensions & weights
(a) Length (mm)
(b) Breadth (mm)
(c) Height (mm)
(d) Un tanking heights (mm)
14. Shipping data
(a) Size of largest package (mm)x(mm)x(mm)
(b) Weight of largest package (kg)
(c) Gross weight to be handled (kg)
(d) Gross volume to be handled (cu.m)
15. Compliance to technical specification w.r.t. parameter specified for
(a) Bushing CT
(b) Bushings
(c) Terminal connectors
154 Manual on Transformers

16. Whether similar equipment are type tested & are in successful operation for at least two
years (If yes, furnish type test reports)
17. Overall general arrangement drawing of Neutral Grounding Reactor with all accessories
to be enclosed
18. Bushing Current Transformer
(a) Line Side
(i) Type or voltage class
(ii) Ratio
(iii) Accuracy class
(iv) Burden (VA)
(v) Accuracy limit factor
(vi) Knee point voltage (Volts) (Minimum)
(vii) Maximum resistance of secondary winding (ohms)
(viii) Maximum exciting (mA) current
(b) Neutral Side
(i) Type or voltage class
(ii) Ratio
(iii) Accuracy class
(iv) Burden (VA)
(v) Accuracy limit factor
(vi) Knee point voltage (Volts) (Minimum)
(vii) Maximum resistance of secondary winding (ohms)
(viii) Maximum exciting (mA) current
 SECTION L

Specifications for Earthing Transformers

 SECTION L
Specifications for Earthing Transformers

1.0 SCOPE

1.1 This section covering specification for earthing transformers, does not purport to include
all the necessary provisions of a contract. For general requirements,loss capitalization and tests,
reference shall be made to Sections ‘A’, ‘AA’ and ‘BB’ of the Transformer Manual.

2.0 GENERAL
2.1 Unless otherwise modified in this section the earthling transformers shall comply with
latest versions of IS 5553 (Part 6) and IS 2026.

2.2 Three phase earthing transformers provide an artificial neutral and are used for the
following purposes :

(a) to earth an otherwise unearthed system.

(b) to connect single phase loads between lines and neutral.
(c) to connect an arc suppression coil.
(d) to limit fault current during a line to earth fault determined by the zero sequence
impedance of earthing transformers and also by the possible addition of resistors and
thereby permitting selective protection.
*Note : The provision of the earthing transformer does not necessarily make the system effectively earthed.

(e) Earthing transformers with zigzag (inter-star) connected winding can have a star connected
secondary winding to provide an auxiliary supply.
2.3 Construction of earthing transformer is similar to conventional oil filled transformer.
Usually cooling specified is ONAN type.

3.0 WINDING CONNECTIONS

Earthing transformers are usually connected either in zigzag (inter-star) or star-delta. For star-
delta transformer the secondary delta winding shall always be connected in closed delta. The
neutral of star connected main winding is earthed. Earthing transformer which consists of a
single winding connected in inter-star may also be provided with, an auxiliary (secondary)
winding. This secondary winding when provided shall be connected in star.

(a) Primary - Zigzag (inter-star), Secondary - Star

(b) Primary - Star Secondary - Delta
(c) Primary - Zigzag (inter-star)
3.1 For the purpose of fault current limitation resistors/reactors can be inserted either
between primary neutral point and earth or in series with primary terminals of inter-star or star
connected primary windings to adjust the zero sequence impedance (Figs. 1 and 2).

157
158 Manual on Transformers

For star-delta connected earthing transformer the delta connected winding may be of the
open type in order to permit the insertion of a resistor or reactor to adjust the zero sequence
impedance.

3.2 Also connecting the resistor/reactors at the neutral end would be preferable.

4.0 TAPPINGS AND TAP CHANGING

4.1 For zigzag connected earthing transformer having auxiliary winding if tappings are
required for voltage variation, it shall be provided on zigzag connected main winding. Equal and
uniform number of tappings shall be provided on both zig and zag windings of main windings.

Fig. 1 Interconnected star (zigzag) neutral earthing transformer

Fig. 2 3 phase star-delta neutral earthing transformer

Rangeof variation: +5 to -5% in steps of 2.5%

 Specifications for Earthing Transformers 159

4.2 Tap changing shall be carried out by means of an off circuit externally operated self-
positioning switch (when the transformer is in de-energised condition. Position No. 1 shall
correspond to maximum plus tappings. Provisions shall be made for locking the tap changing
switch handle in position.

4.3 However, tappings are not preferred for earthing transformer.

5.0 INSULATION LEVEL

The insulation level for the line terminals of an earthing transformer shall correspond to those
specified for transformers as per IS: 2026 (Part 3).

6.0 LOSSES AND IMPEDANCE

6.1 Losses

6.1.1 Only no-load losses should be specified for earthing transformer not provided with
additional auxiliary windings. The tolerance on specified no. load losses will be subject to limits
specified in IS: 2026.

6.1.2 Both no-load and load losses will be specified for earthing transformers provided with
windings’ suitable for supplying auxiliary loads. The load losses specified should be based on the
rating of the auxiliary winding. These losses are also subject to tolerance in accordance with IS :
2026.

6.2 Impedance

6.2.1 Zero sequence impedance of each earthing transformer shall be specified in ohms per
phase and this impedance will be subject to a tolerance of +20%. -0%.

6.2.2 When earthing transformers are provided with auxiliary winding impedance between the
auxiliary winding and the main inter-star (zigzag) winding must be specified and this impedance
shall be subject to tolerance as per IS : 2026.

However, if any difficulty arises to achieve both the specified zero sequence impedance of main
winding and the percentage impedance between the main winding and auxiliary winding, in
such cases either external resistors/reactors may be provided on main windings to adjust the zero
sequence impedance or current limiting resistors/reactors may be provided on auxiliary side to
limit the fault current on auxiliary side to the specified value.
7.0 CONTINUOUS AND SHORT TIME CURRENT RATING

7.1 Continuous Current

7.1.1 Rated Neutral Continuous Current

Continuous neutral current is specified either in the case where phase unbalance of the system
exists or when the earthing transformer is to be designed for connection of single phase loads
between line and the neutral.
160 Manual on Transformers

7.1.2 Rated Continuous Current

The current flowing through the line terminals continuously when a rated power of a secondary
winding is specified.
Note : The earthing transformer shall carry the specified neutral or rated continuous current and comply as regards
the temperature rise with appropriate requirements of IS : 2026 when it is energised at rated voltage and frequency

7.2 Rated Short Time Current in the Neutral

The earthing transformer shall carry the specified neutral fault current for the specified duration
without exceeding the winding temperature of 250°C for copper and a temperature of 200°C
for aluminium.

When an earthing transformer is designed for the neutral point to be connected to a current
limiting impedance in the connection to earth, it should also be capable of withstanding, for
a period of 5 seconds, the maximum earth fault current that can flow without the additional
impedance in circuit. This safe guard is necessary should, for instance, the bushing of an earth
resistor flash over.

When earthing transformer are operated without external resistor, the rated short time current
and zero sequence impedance shall have the following relationship :

3. Vph
Ish =
Zo

Vph is the maximum permissible operating phase voltage

Zo is the zero sequence impedance per limb of earthing transformer

Ish is the short time neutral current of the transformer

7.3 Ability to Withstand Rated Short Time Current

7.3.1 The earthing transformers shall be capable of withstanding the mechanical and thermal
stresses caused by the rated short time current flowing for the specified duration.
The thermal ability can be demonstrated by calculation using the following formula as per clause
9.1 of IS 2026 (Part 5)
θ1 = θ0 + a J2t x 103 °C

where
Q1 is the highest average temperature attained by the winding due to short time current
maintained over the specified duration and shall not exceed 250°C for copper winding and
200°C for aluminium winding.
 Specifications for Earthing Transformers 161

θo is the initial temperature in degree Celsius

J is the short time current density in ampere per square millimetre

t is the duration in seconds

a is a function of 1/2 (θ2 + θ0), in accordance with Table 1.

θ2 is the maximum permissible average winding temperature, 250°C for copper and 200°C for
aluminium.

7.3.1.1 Where earthing transformers are used with external resistor/reactors to limit the earth
fault current, the earthing transformer should also be able to withstand dynamically and thermally
the maximum earth fault current without external resister/reactors for a period of 5 seconds.

7.3.1.2 For earthing transformers without secondary winding θ0 shall be taken as the sum of the
maximum ambient temperature and manufacturers guaranteed average oil temperature rise of
the earthing transformer under normal operating conditions.

7.3.2 For earthing transformer with loaded secondary windings θ0 shall be the sum of the
appropriate maximum ambient temperature and the relevant temperature is specified inIS : 2026
measures by change in resistance.
Table 1

a - function of 1/2(Ө1 + Ө2) °C

1/2(Ө0 + Ө2)
Copper windings Aluminium windings
140 7.41 16.5
160 7.80 17.4

180 8.20 18.3

200 8.59 19.1
220 8.99 -
240 9.38 -

7.3.3 Ability of earthing transformer to withstand mechanical stresses due to the rated short time
current flowing in the windings under fault conditions shall be determined by tests described as
per clause 8.6 of IS 5553 (part 6).

8.0 TESTS

8.1 Type Test

• Impulse Voltage Withstand Test (IS : 2026 (Part 3)).

• Heat run test (IS : 2026 (Part 2)).
Applicable only in the case of earthing transformers having auxiliary winding.
162 Manual on Transformers

8.2 Special test

• Short circuit withstand test.
Clause 8.6 of IS : 5553 (Part 6).
8.3 Routine Test
• Measurement of winding resistance IS : 2026 (Part 1).
• Measurement of insulation resistance IS : 2026 (Part I).
• Measurement of zero sequence impedance IS : 2026 (Part I).
Note : Zero sequence impedance may be measured at any current between 25 per cent to 100 per cent rated short time
neutral current and is expressed in ohms per phase. It shall be ensured that the applied current shall not exceed
the current carrying capability of the winding or metallic constructional parts.

• Measurement of no load loss and no load current IS : 2026 (Part I).

• Measurement of impedance voltage and loss (in case of auxiliary winding)
• Dielectric tests (IS: 2026 (Part 3).
• Separate source voltage withstand Test IS : 2026 (Part 3).
• Induced over voltage test IS : 2026 (Part 3).Applicable only in the case of earthing
transformer with a secondary winding.
• Check of voltage vector relationship and polarity IS : 2026 (Part 1).
• Measurement of voltage ratio IS : 2026 (Part 1). Applicable only in the case of earthing
transformer with a secondary (auxiliary) winding.
• Ratio measurement of zigzag connected earthing transformer with star connected auxiliary winding.
For a zigzag connected earthing transformer the zig and zag windings constituting one phase arc
physically wound on two different limbs of the core. Hence if a single phase supply is applied
between line and neutral of inter-star (zigzag) connected winding, the voltage induced in zig
and zag winding, will be different. Due to this, voltage induced on secondary winding of same
phase will not be the same as that defined by the per phase voltage ratio of the transformer.
Thus voltage ratio measurement with single phase application will give misleading results if
application and measurement is made on per phase basis, (ie between line and neutral).
A vector diagram of a 33/0.435 kV ZNynl connected earthing transformer is given as Fig. 3. The
zig and zag windings per limb are designed for 11 kV and LV is designed for 0.435/3kV. Here
3 phase voltage ratio is defined as the ratio of the HV line to neutral voltage to LV line to line
voltage (IR-IN/2R-2Y) ie 33/3/0.435 = 43.799

Fig. 3 Vector and voltage relationship or a 33/0.435 kV ZNynl connected earthing transformer For single phase
application, the ratio IR-IN/2R-2Y will be :
 Specifications for Earthing Transformers 163

11 kV x 2/0435 x2
√3 = 33 /3 x 2 /0.435 / 3 x 2
= 33/√3/ 0.435 kV
= 43.799
i.e., for a zigzag connected earthing transformer to get actual design ratio with single phase ap-
plication, the ratio measurement shall be made by applying line to neutral voltage (per phase) on
inter-star connected main winding and measuring the induced line to line voltage on correspond-
ing star connected secondary windings or vice versa.
Note : For ratio measurement with 3 phase application equal and balanced supply (w.r. to voltage and phase differ-
ence) shall be applied, otherwise ratio error will be high.
 SECTION M

Specifications for Furnace Transformers

 SECTION M
Specifications for Furnace Transformers

1.0 SCOPE

This section covers specifications for transformers having application to be used along with the
Furnaces. However, this does not purport to include all the necessary provisions of a contract.
For general requirements and tests, reference shall be made to other Sections ‘A’ and ‘BB’ of
the transformer manual.

2.0 GENERAL

Standards IS 2026 and IS 12977 to be followed for furnace transformers. Following are the
major application for the furnace transformers.

2.1 Melting Ferrous and Non Ferrous scraps.

2.2 Refining of steels and many other materials etc.

Furnace Transformers are described as below.

1. Arc Furnace Transformers which includes submergedarc furnace, Electric arc furnace
and Ladle refining arc furnace transformers.

2. Induction furnace Transformers.

Arc Furnace transformers are withlow secondary voltageswith very high secondary currentsand
areused for various process applications.Whereas Induction furnace transformers are having
medium & lowsecondary voltages.

Constructions of both furnace transformers aresimilar to power transformers to some extent

excluding arc furnace transformers which are dealing with very low secondary voltage with
higher currents. Here the secondary voltages are intentionally varied with current to melt and
boil the product mix for attaining defined chemical composition and characteristics. The variance
in voltage and current does depend on the quality of charge which is not predefined with fixed
chemical composition. Hence, to make the same Ferro alloys or produce the same steel you
have to selectively vary the KVA rating of the transformer alongwith the secondary voltage and
current which will ultimately vary from mother ore to mother ore as the ore made available is
various underground mines from various parts of the globe.

3.0 WINDING CONSTRUCTION

Arc furnace transformers based on the process optimization requirements have possibilities to
connect in Star and Delta configuration onprimary winding in order to get additional range of
secondary voltages. Star and Delta change overs is done using either external bushings or with
the help of star delta change over switch.

167
168 Specifications for Furnace Transformers

Secondary windings of Arc furnace transformers are having open delta construction. Closing to
Delta configuration is done within the furnace for such transformers.

In order to provide stability, higher rating Arc Furnace Transformers is often provided with
series reactor. Such reactors may be provided as in built or can be of separate unit.One of the
major purpose of providing the series reactor is also because of fast changing of impedance of
the molten bath in the crucible where the metal is both in solid-liquid state.

Fig. 1 Typical HVwinding connection of Arc Furnace Fig.2 Typical winding connections of Arc Furnace
Transformer having Star Delta Change over Transformer with separate Auto Transformer for tappings.
mechanism

Converter & inverter circuits are connected at the secondaryterminals of Induction furnace
transformers as the furnace panel needs to change the frequency of the molten metal bath
depending upon flux penetration and magnetic coupling required. Induction furnace Transformers
are mainly three winding transformers with secondary windings connected in Star and Delta or
in Star configuration. The number of secondary outputs will also depend on the number of
phases or pulse required in the melting system for more optimal power utilization and reduction
in system harmonics to a large extent.

Phase shifting is also provided for induction furnace transformers for larger furnacesto get
pulses of required numbers.

4.0 TAPPINGS AND TAP CHANGING

Tappings in the arc furnace transformers are provided on Primary windings in order to get
optimized process.

Depending upon the process and designrequirement either of the following tapping scheme is
adopted.
4.1 Direct Regulation. Tappings are provided on the main winding.

This is a variable flux voltage variation (VFVV) arrangement. This arrangement which consists
of taps at end of primary winding is used for low rating furnace transformers. The cost of OLTC
is minimum due to lower voltage and current values (the primary winding, may be of the order
 Specifications for Furnace Transformers 169

of 33 or 66 kV). In this arrangement the step voltage is variable throughout the range of voltage
regulation.

Fig. 3 Direct Regulation with Tappings provided on the Main winding.

4.2 Regulation with Auto Transformer

This arrangement is used mainly for larger furnace applications. In this arrangement separate
auto transformer is used for voltage regulation.This arrangement gives linear or equal steps
secondary voltage variation with tapping positions. The auto transformer and main transformer
may be housed either in common tank or in separate tanks.

For single phase arc furnace transformers, auto transformers are mounted within the same tank
of main transformer. Practice of providing separate 3 phase auto transformer for a bank of
3 single phase arc furnace transformers is also seen. This configuration is preferred beyond
12MVA requirement mostly to reduce the copper content of the external secondary bus bars of
the furnace system beyond the transformer till the electrodes. These transformers calls for very
high material content and hence it is heavy. Logistics always remains a question and moreover
these transformers are mounted at a height of 14 to 18 meters platform from the ground zero
level. To make the transformers lighter to handle such transformers are manufactured in single
phase units rather than 3 phase unit.

Fig. 4. Typical Schematic for Regulation with Auto Transformer.

4.3 Regulation with Auxiliary Booster Transformer

Such arrangement is used for medium and large rating furnace transformers to avoid constraints
related to OLTC current Rating. In this arrangement it is possible to get voltage variation in
170 Specifications for Furnace Transformers

equal steps throughout the full range of regulation. Main and Booster transformers are located in
the same tank, to minimize the length of connections between the secondary windings for both
the transformers in such arrangement. Since the Booster transformer is only for regulation, its
rating is much smaller than the main transformer rating.

Centre to centre distances and window heights of Booster and Main transformer are generally
kept same to facilitate connections between their secondary windings. In this arrangement
Secondary current of Main and Booster transformers are equal; the two winding sets are often
connected by their leads in a figure of eight which is known as the “eight-eight arrangement”,
thus avoiding extra connections between them.

Fig. 5. Typical Schematic for Regulation Fig. 6. Eight – Eight Arrangement for LV
with Auxiliary Booster Transformer. connection of Auxiliary Booster Transformer.

Since frequent tap changing is required for the process applications, Arc Furnace Transformers
are mainly provided with On Load Tap Changer.Since the number of tap changing per day of
continuous operation can go upto 250 operations a day, it is preferred to use Vacuum type OLTC
for this purpose. It is also a practice to use oil online filtration device to maintain oil quality in
the diverter chamber.

Induction Furnace Transformers are mainly provided with Off Circuit Tap Changers in case
the system voltage is stable. In case of unstable system voltage oil type OLTC is required
in the primary where there is no phase shifting done in the HV winding. In case phase
shifting is required to have higher pulse system then either LV phase shifting can be done
with OCTC or OLTC in primary winding. In case phase shifting is done in HV then it is
advised not to use OCTC or OLTC in the HV winding as the phase angle will get distorted
with change in tapping position with respect to nominal tap at which the phase difference
angle has been defined.

5.0 INSULATION LEVEL

Insulation level for the line terminals of shall correspond to as specified in IS 2026 (Part 3).
 Specifications for Furnace Transformers 171

6.0 LOSSES AND IMPEDANCE

In case of specific requirement of auto transformer the impedance of the auto transformer needs
to be kept little higher with sufficient hoop resistance to withstand short circuit current flowing
through it. Losses of the auto transformer need to be little higher. On addition of both these
attributes the auto transformer will have higher withstand-ability of high inrush current. This
will save the transformer from failing during switching operationof furnace system. There need
not be too much reduction in losses of the transformer that will unnecessarily give rise to cost
of transformer as the furnace system has higher losses compared to the transformer only in
the secondary bus bar path that carries power from the transformer secondary to the electrode
system. Standardization of losses might not work out feasible as KVA rating, secondary voltage
and current is always varying from rating to rating and application to application.

7.0 RATINGS

The MVA, LV voltage range and current are major factors in case the furnace is operating
in fixed pitch mode or variable pitch mode of the electrodes. The thermal delta (the physical
triangle formed in the molten bath) will decide the power density required to melt the charge.
However, manufacturer of induction furnace based on adopted converter& invertor circuits and
majorly the coil voltage required at the furnace crucible decides secondary voltage rating for
Induction furnace transformers.
8.0 TEMPERATURE RISE
For the purpose of standardization of maximum taemperature of oil and winding, the following
ambient temperatures are assumed.
Cooling Medium Air Water
Maximum Ambient Temeprature 50 30
Maximum Daily average ambient temperature 40 25
Maximum yearly weighted average ambient temperature 32 --

With the above ambient temepratures, temeprature rises are as given below.
Part Air Water
Windings (Measured by Hot Resistance) 55 60
Top Oil (Measured by Thermometer) 50 50

9.0 TESTS
IS 2026 is referred to for testing of Furnace Transformers.
9.1 Routine Tests:
9.1.1 Ratio Measurement Test
172 Specifications for Furnace Transformers

9.1.2 Check of voltage vector relationship and polarity.

9.1.3 Measurement of winding resistance.
9.1.4 Measurment of Insulation resistance.
9.1.5 Separate Source high voltage withstand test.
9.1.6 Induced over voltage withstand test.
9.1.7 Measurement of No Load Loss.
9.1.8 Measurement of Load Loss.
9.2 Type Tests
9.2.1 Temperature Rise Test
9.2.2 Impulse Test
Dynamic short circuit test is not conducted for furnace transformers. The same is demonstrated using IEC / IEEMA
guidelines and sophisticated software.
Higher time for disconnecting the secondary terminal shorting is expected during hot resistance measurement in
temperature rise test of Arc Furnace transformers, efforts should be made to minimize this duration.

10.0 FITTINGS AND ACCESSORIES

Unless otherwise specified within the contract, following minimum fittings and accessories are
to be provided with transformer.

10.1 Rating and Diagram Plate

10.2 Two Earthing terminals
10.3 Lifting Bollard
10.4 Jacking pads
10.5 Haulage Lugs
10.6 Pocket on tank cover for thermometer
10.7 Air Release device
10.8 Conservator with oil- filling hole, cap and drain valve
10.9 Magnetic type oil gauge with low oil level alarm contacts
10.10 Silicagel breather with oil seal.
10.11 Required number of pressure relief device capable of resealing after release of
pressure.
10.12 Valves
10.12.1 Drain valve.
10.12.2 Two filter valves on diagonally opposite ends - one at top and other at bottom.
10.12.3 Oil Sampling valve at bottom of main tank.
10.13 Valve schedule plate.
 Specifications for Furnace Transformers 173

10.14 Buchholz relay with alarm and trip contacts

10.15 One number shut-off valve (Size: 80 mm) on conservator side
10.16 Dial type oil temperature indicator.
10.17 Dial type winding temperature indicator for a two winding transformer.
10.18 Cover lifting lugs.
10.19 Weather proof Marshaling box for housing control equipment and terminal
connections.
10.20 Cooling accessories.
10.20.1 ONAN/OFAF cooling
Requisite number of radiators provided with:
Air release device on top
Drain and sampling device at bottom
Lifting lugs
10.20.2 OFWF or ODWF cooling
Oil/water heat exchangers with segregated oil and water headers
Oil pumps with shut-off valves on both sides.
Oil and Water flow indicator with alarm and trip contacts
Dial type thermometer.
Pressure gauge.
Differential pressure gauge with alarm contacts, operating when difference between oil
outlet pressure and water inlet pressure is less than 0.2 kg/cm2
Drain and sampling device on cooler pipe connection.
10.21 It is alwaysrecommended to provide Surge suppressors and RC Elements at the line
terminals of Furnace transformer at users end.
 SECTION N

Specifications for Rectifier Transformers

 SECTION N
Specifications for Rectifier Transformers

1.0 SCOPE

This section covers specifications for transformers having application to be used along with
the low voltage rectifier circuits. However, this does not purport to include all the necessary
provisions of a contract. For general requirements and tests, reference shall be made to Sections
‘A’ and ‘BB’of the transformer manual.

2.0 GENERAL

2.1 Standards IS 2026, IEC 61378 and IEC 146 to be followed for rectifier transformers.
Following are the major application of the rectifier transformers.
2.1.1 Electrolytic process for Aluminum, Zinc, Copper etc.
2.1.2 Chemical process of Caustic Soda, Zinc, Copper, Chlorine etc.
2.2 Rectifier Transformers are used with either of the following DC circuits.
2.2.1. Rectifier Bridge connection 6 Pulse or 12 pulse for medium to high DC voltages
2.2.2. Rectifier single-way inter-phase connection for low DC voltage levels & high DC
currents
2.2.3. Thyristor or diode rectifiers

Construction of rectifier transformer is decided based on the configuration of the DC circuit

scheme adopted.

The rectifier transformers have typically low voltages in the range of few hundreds only.

The Rectifier Transformers require wide range of voltage regulation on secondary side and
automatic constant current control. For voltage regulation, it is extremely difficult to have taps
on the secondary winding because of few turns in LV and high current value. The taps are
either provided on the primary winding, or a separate regulating transformer (autotransformer)
is used (feeding the primary of the main transformer) which can be accommodated in the same
tank. The required double-wound or auto-connected regulating transformer can, depending on
transport or site limitations, be built into the same tank as the rectifier transformer, or into a
separate tank.

For large rating rectifier transformers, the field due to high currents causes excessive stray
losses in structural parts made from magnetic steel. Hence, these parts are usually made of non-
magnetic steel.

Due to a large variety of applications, there are several influencing factors to consider:

• Voltage range and step voltage.

177
178 Manual on Transformers

• Double-tier: HV and LV windings in two levels, and Star and Delta connection to
achieve a 12-pulse reaction.
• Pulse numbers higher than 12: requires additional phase shifting windings.
• LV bushing arrangement: adapted to suit rectifier design and to limit structural heating.
Bushings /risersare typically mounted on the tank side wall.

3.0 WINDING CONSTRUCTION

Rectifier transformers are provided with two or multi windings based on DC circuit adopted. In
case of Bridge configuration, two windings connected either in Star or Delta is adopted. In case
of Configuration with inter phase transformer multi windings with secondary connected in Star
configuration is provided.

In both of the cases, Configuration of primary winding can either be star or delta and decided by
the rectifier manufacturer.

Fig. 1 Typical vector diagram of 12 pulse Scheme with Fig.2 Typical vector diagram of 6 pulse
Inter phase Transformer Bridge configuration.

(a) Windings

 HV winding: The HV windings of the rectifier transformer are usually disc type and
are connected in either star or delta or zigzag. These type of connection are used to get
the phase shift between the input and output voltages to increase the no of pulses of the
rectified DC output. More number of pulses of the DC output system reduce the ripples
there by improving the quality of DC output.
 LV winding: The secondary voltage of the rectifier transformer is very less and of the
order of a few volts. Thereby, the turns in the secondary winding are also very less. On
the other hand, current carried by these windings is very high. For this reason a special
winding called half & Sections is used. This resembles the disc winding to the extent
that each coil is wound in two disc accommodating the total number of turns. A number
 Specifications for Rectifier Transformers 179

of coils of this type are connected in parallel by bus-bars for sharing total current. The
advantage of this coil is that odd number of turns can be accommodated in two discs of
the coil without any loss of space, which cannot be done with the normal disc-winding
technique. This improves the space factor of the winding and insures compactness.
LV winding arrangements: adapted to minimize the winding hotspots and influence of
harmonics.
 Interleaving of LV windings
The two groups of coils of both the secondary are axially interleaved to ensure that the
impedance between the two secondary is minimum and the impedance of the secondary
with respect to the primary windings is same so that all the coils of both the secondary
share the current equally. The ends of the bus-bars are then connected in star or delta as
the case may be.
The bus bars are placed in go-no go arrangement in such a manner that the fluxes are
getting cancelled as a result there would be minimum reactance between bus-bars and
stray losses..
 Coil disposition
Since the secondary coils carry heavy currents and the coils are connected in parallel by
means of bus-bars, it is essential that the secondary coils are placed outermost for ease
of connection. Consequently, HV coil is placed concentrically over the core, over which
the LV coils are placed. Sometimes an electrostatic shield between coils is provided to
limit transferred surges.

(b) Voltage Regulation

 By OLTC/OCTC
In case of OLTC, the voltage variations are being achieved on line by changing OLTC
taps. The OLTC is generally used with Diode Type Rectifier Unit.
The OCTC tap-changers are generally used for the transformer coupled with Thyristor
rectifier. In this case the voltage variations are being achieved by change of firing angle
of the thyristor, which is not economical alway
 By Auto transformer
The diode rectifiers have a longer range and a higher number of smaller voltage steps
in the transformer. A multi-coarse-fine on-load tap changer (OLTC) or an OLTC/NLTC
combination is preferred, together with LV-side saturable reactors for the voltage fine-
tuning.
Electrolysis processes require wide regulation ranges, fast and tune voltage
regulation.
 The Wide regulation is carried out by a regulating transformer.
 The fast & tune regulation is carried out either by a set of saturable reactors.
Aluminium electrolysis Rectiformer requires wide range of secondary voltage variation
from 0% to 100% to start pot line from beginning. The whole range of regulation is
180 Manual on Transformers

split up into smaller ranges with a combination of OLTC (On load tap changer) +
Saturable reactor.

(c) Saturable Reactor core (Transductors)

When connected to a diode technology rectifier, Self-Saturable Reactors offer solutions

for fast & tune voltage regulation. These Saturable Reactors are placed in rectifier
transformer tank. Magnetic cores mounted on LV copper busbars carrying the main
current produces a voltage drop. The saturation level is controlled by a DC current
circuit permitting a controlled variation of voltage drop. In normal practice, there
will be two DC windings of Self-Saturable Reactors namely bias winding & control
winding. The control and bias windings are in the form of copper rod passing through
the ring core. This fine regulation is equivalent to 2 or 3 steps of the OLTC and discrete
voltage achieved. Ring type cores are being used.

(d) Interphase Transformers

Two or three rectifier systems may need to be paralleled, when the current rating
increases. The paralleling is done with the help of inter phase transformer which
absorbs at any instant the difference between the direct voltages of individual systems
so that there are no circulating current. Since the flux in the magnetic circuit of the
interphase transformer is alternating with 3 times the supply frequency i.e 150Hz, when
two systems are paralleled, the core losses in IPT are high. Hence, the operating flux
density in the interphase transformer is designed to be around 50 to 67% of the value
used for the conventional transformer. The ‘C’ type cores are used in IPT.

4.0 INSULATION LEVEL

Insulation level for the line terminals of shall correspond to as specified in IS 2026 (Part 3).

5.0 LOSSES AND IMPEDANCE

Unless otherwise specified, Losses and the Impedance of transformer are specified at the principal
tap. Principal tap is having maximum LV voltage with highest MVA. In case of transformer
having application of self Saturable reactor, values and measurement scheme of losses and
percentage impedance shall be agreed between purchaser and supplier.

Losses in inter phase transformer and Saturable reactors, if not measured shall be demonstrated
by calculations.

6.0 STANDARD RATINGS

There are no standard ratings of Rectifier Transformers. The rating is decided based on the
defineda pplications.
 Specifications for Rectifier Transformers 181

7.0 TEMPERATURE RISE

Rectifier Transformers are subjected to non linear loads having significant harmonic contents
during service conditions. Pattern of such harmonics shall be considered during limiting top oil
and winding rises. OFWF cooling is standardized for rectifier transformers. For the purpose of
standardization of maximum temperature of oil and winding, the following ambient temperatures
are assumed.

Cooling Medium Water

Maximum Ambient Temeprature 30
Maximum Daily average ambient temperature 25
Maximum yearly weighted average ambient temperature --

With the above ambient temepratures, temeprature rises are as given below.

Part Water
Windings (Measured by Hot Resistance) 60
Top Oil (Measured by Thermometer) 50

8.0 TESTS

IS 2026 is referred to for testing of Rectifier Transformers.

8.1 Routine Tests

8.1.1 Ratio Measurement Test
8.1.2 Check of voltage vector relationship and polarity.
8.1.3 Measurement of winding resistance
8.1.4 Measurment of Insulation resistance
8.1.5 Separate Source high voltage withstand test
8.1.6 Induced over voltage withstand test
8.1.7 Measurement of No Load Loss
8.1.8 Measurement of Load Loss, Calculation of Load Loss shall be as oer IEC 146.
8.2 Type Tests
8.2.1 Temperature Rise Test considering increased value of losses due to harmonics
8.2.2 Impulse Test

Dynamic short circuit test is not conducted for Rectifier transformers. The same is demonstrated using IEC / IEEMA
guidelines and sophisticated software.
Higher time for disconnecting the secondary terminal shorting is expected during hot resistance measurement in
temperature rise test of Rectifier transformers, efforts should be made to minimize this duration.
182 Manual on Transformers

9.0 FITTINGS AND ACCESSORIES

Unless otherwise specified within the contract, following minimum fittings and accessories are
to be provided with transformer.

9.1 Rating and Diagram Plate

9.2 Two Earthing terminals
9.3 Lifting Bollard
9.4 Jacking pads
9.5 Haulage Lugs
9.6 Pocket on tank cover for thermometer
9.7 Air Release device
9.8 Conservator with oil- filling hole, cap and drain valve
9.9 Magnetic type oil gauge with low oil level alarm contacts
9.10 Silicagel breather with oil seal.
9.11 Required number of pressure relief device capable of resealing after release of
pressure.
9.12 Valves
9.12.1 Drain valve.
9.12.2 Two filter valves on diagonally opposite ends - one at top and other at bottom.
9.12.3 Oil Sampling valve at bottom of main tank.
9.13 Valve schedule plate.
9.14 Buchholz relay with alarm and trip contacts
9.15 One number shut-off valve (Size: 80 mm) on conservator side
9.16 Dial type oil temperature indicator.
9.17 Dial type winding temperature indicator for a two winding transformer.
9.18 Cover lifting lugs.
9.19 Weather proof Marshaling box for housing control equipment and terminal
connections.
9.20 Cooling accessories.
OFWF or ODWF cooling
Oil/water heat exchangers with segregated oil and water headers
Oil pumps with shut-off valves on both sides.
Oil and Water flow indicator with alarm and trip contacts
Dial type thermometer.
Pressure gauge.
 Specifications for Rectifier Transformers 183

Differential pressure gauge with alarm contacts, operating when difference between oil
outlet pressure and water inlet pressure is less than 0.2 kg/cm2
Drain and sampling device on cooler pipe connection.
9.21 It is recommended to provide Surge suppressors and RC Elements at the line terminals
of Rectifier Transformer. Location of the same may be decided between purchaser and
manufacturer.
 SECTION O

Specifications for Electrostatic Precipitator

Transformers
 SECTION O
Specifications for Electrostatic Precipitator Transformers

1.0 Scope

This section covers specifications High voltage rectifier transformers (HVR) having application
for supplying power to Electrostatic Precipitator (ESP) used for cleaning the flue gases.
However, this does not purport to include all the necessary provisions of a contract. For general
requirements and tests, reference shall be made to Sections ‘A’ and ‘BB’ of the transformer
manual.

2.0 General

Since several other components are part of the transformer housed in the same tank, generally
Standard IS 2026, where ever applicable, is followed for HVR transformers.

HVR Transformer is used for thyristor controlled HV DC power supply to the high voltage fields
of Electrostatic Precipitator (ESP). An Electrostatic Precipitator (ESP) used in industries and
especially in power plants, is equipment which utilizes an intense electric field for extraction and
removal of suspended particles / dust from flue gases to clean the flue gases before discharging
the same into the atmosphere to avoid pollution.

3.0 Construction

The HVR Transformer is a single phase step up transformer fitted with various components as
HV Rectifier, HF Choke, HV Resistor column, and a linear reactor inside the same tank. The
single phase AC input supply of 415 V ± 10 % is fed to the transformer through a microprocessor
based electronic controller (EC). EC-HVR combined unit provides controlled HVDC supply to
the ESP electrodes. EC controls the input voltage of the HVR in-order to optimize the ESP
operation based on the HVR output current & voltage feedbacks.

The high voltage side output of the transformer is connected to Diode Bridge Rectifier for full
wave rectification to DC output up to 95 kVp and up to 1600 mA. The positive polarity of the
DC output is earthed during operation. The negative polarity of the transformer is taken out
through a bushing. This negative polarity output is connected to the ESP field coils.

The flue gases passing between the electrodes of ESP are subjected to an Intense Electric
Field. Continuous sparks take place across the electrodes during dust extraction from the Flue
gases, which shorts the HV output of the transformer to the Earth. An HVR transformer has
to withstand these momentary short circuits, in the form of sparks throughout its life. A linear
reactor is connected in the input of the transformer to increase the impedance and limit the short
circuit current in the event of short circuit.The supply to transformer is continuously switched
on and off by electronic controller for controlling spark and maximum dust collection.

The high frequency choke is connected to the output to provide high impedance to high frequency
currents. HV Resistor column is provided as potential divider for providing feedback of output
DC voltage to the electronic controller.

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188 Manual on Transformers

The transformer may be manufactured with a breather or may be made in hermetically sealed
construction without a breather.

The transformer tank is filled with Mineral transformer oil (IS-335) or Silicone transformer fluid
(IEC-60836) having high flash point based on the requirement.

4.0 Tappings Changing

The input voltage supplied to the HVR transformer is controlled through the electronic
controller for the required output voltage and current. Tappings are not required for the HVR
transformers.

5.0 Insulation Level

HV winding of the HVR transformer is tested for separate source withstand voltage at 10 kV
since the positive polarity of DC output is earthed at site during operation. However, separate
source withstand voltage for LV winding, induced over voltage withstand and Impulse voltage
withstand levels are as specified in IS 2026 (Part 3).

6.0 Losses and Impedance

Since the transformer experiences frequent short circuits during operation, the impedance
offered to the short circuit is kept high of the order of 25 to 35 % by providing a linear reactor
in the LV side of the transformer.

7.0 Standard Ratings

The voltage rating of the transformer is standardized with DC peak output voltage of 70 kVP
and 95 kVp. The DC output current rating of the transformer varies from 400 mA to 1600 mA
as per the requirement.

8.0 Temperature Rise

Temperature rises of winding and oil above ambient temperature of 50 °C are as given below:

Part Temperature Rise (°C)

Windings (Measured by Hot Resistance) 55

Top Oil (Measured by Thermometer) 50

9.0 Tests

IS 2026 in general is followed for testing of HVR Transformers, where ever applicable.
 Specifications for Electrostatic Precipitator Transformers 189

9.1 Routine Tests

9.1.1 Ratio Measurement Test1

9.1.2 Measurement of winding resistance1
9.1.3 Measurment of Insulation resistance
9.1.4 Separate Source high voltage withstand test2
9.1.5 Induced over voltage withstand test
9.1.6 Measurement of No Load Loss and current
9.1.7 Measurement of Load Loss and impedance

9.2 Type Tests:

9.2.1 Temperature Rise Test3

9.2.2 Impulse Test4
9.2.3 Spark Test (Short Circuit Test) 5
9.2.4 Functional Tests – Measurement of parameters pertaining to voltage and current
feedback signals to electronic controller, and check of different functional operational
requirement with the electronic controller.
1
Ratio and resistance of the transformer is measured during assembly of the transformer with other components, since
these tests are not possible after assembly and tanking due to connection of various other components,
2
HV winding of the HVR transformer is tested for separate source withstand voltage at 10 KV since the positive polarity
of DC output is earthed at site during operation
3
The temperature rise will be computed from the hot winding resistance of the LV winding since various components are
connected in series with the HV winding of the transformer.
4
Impulse test is be conducted on the transformer without linear reactor, Rectifiers, HF choke and Resistor column
5
Continuous sparks take place across the electrodes of ESP during dust extraction which shorts the HV output of the
transformer to the Earth. An HVR transformer has to withstand these momentary short circuits, throughout its life.
The short circuit test is conducted on the HVR transformer along with the electronic controller, by simulating this
site condition with a spark gap connected across the output. The gap is adjusted to get the required no. of sparks per
minute at required peak voltage which is the short circuit condition while the electronic controller controls the voltage
to quench the spark.

10.0 Fittings and Accessories

Unless otherwise specified within the contract, following minimum fittings and accessories are
to be provided with transformer.

10.1 Rating and Diagram Plate

10.2 Two Earthing terminals
10.3 Jacking pads
190 Manual on Transformers

10.4 Air Release plug

10.5 Conservator with oil- filling hole
10.6 Magnetic oil level indicator with low oil level alarm contacts
10.7 Silicagel breather
10.8 Pressure relief valve / vent
10.9 Drain plug
10.10 Valves – Two valves on diagonally opposite ends - one at top and other at bottom.
10.11 Buchholz relay with alarm and trip contacts
10.12 One number shut-off valve on conservator side
10.13 Dial type oil temperature indicator.
10.14 Weather proof Marshaling box for housing control equipment and terminal connections
(housing relays, feedback resistor, OTI etc. and the associated wiring).
 SECTION P

Specifications for Traction Transformers

 SECTION P
Specifications for Traction Transformers

1.0 Scope

This section covers specifications for transformers used on board rolling stock. However, this
does not purport to include all the necessary provisions of a contract. For general requirements,
loss capitalization and tests, reference shall be made to Sections ‘A’, ‘AA’ and ‘BB’ of the
transformer manual.

2.0 General

IEC-60310 is followed for traction transformers. Traction transformers are deployed to power
the main traction circuit as well as various auxiliaries circuits such as train air conditioning, train
pantry car, locomotive/EMU auxiliaries etc. Traction transformers are used in:

2.1 Electric locomotives

2.2 Electric multiple units (EMU)

Traction Transformers can be subdivided as:

l Fixed ratio transformers

l Transformers with HV taps
l Transformers with LV taps

Traction transformers are basically step down transformers – used to step down the overhead
catenary (OHE) voltage levels (typically 25 kV) to traction system levels (around 1000 V).

Traction transformers are generally forced cooled to save the precious equipment space.
Inhibited Mineral oil is generally used for the cooling of the transformers. However other types
of synthetic oils are also gaining popularity owing to high flash points – directly related to fire
safety.

Traction transformers are under slung mounted and should be suitable to withstand the shock/
vibrations experienced during traction service. The transformer base should be rigid enough to
avoid the damages due to the hitting by extraneous objects during service.

3.0 Winding Construction

Traction transformers are single phase transformers. Both shell type and core type configurations
are used. Windings are generally sandwich coils or concentric coils. The complete core-coil
assembly is finally fitted in horizontal position inside the tank. The core coil assembly needs
adequate strengthening and support - to sustain the shocks and vibrations experienced during
traction service.

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194 Manual on Transformers

4.0 Tappings

For traction power control, one or more of the windings may be equipped with tappings. Tappings
can be on the HV side or the LV side as per the system configuration.

5.0 Insulation Level

Insulation level for the primary winding and secondary windings shall be as per IEC-60310 or
as specified by the purchaser.

6.0 Losses and Impedance

Losses are normally not specified for traction transformers by the purchaser. For traction
transformer, generally the efficiency is specified at rated load. Losses are generally higher as
compared to the equivalent rating power transformers – in order to pack more power in the
limited space.

Impedance is specified by the system designer based on the traction controls.

7.0 Ratings

Traction transformers usually have several secondary windings e.g. traction, auxiliary, hotel
load etc. The rating of the transformer is specified in kVA which is individually specified for
each winding.

8.0 Temperature Rise

Limits of temperature rises shall be as per IEC-60310 or as specified by the purchaser.

9.0 Tests

IEC 60310 is followed for testing of traction transformers. List of applicable tests is as under:

9.1 Routine Tests

1. Measurement of winding resistance

2. Measurement of voltage Ratio
3. Measurement of No Load Loss & No-load current
4. Measurement of Impedance voltage
5. Measurement of load loss
6. Induced voltage withstand test
7. Separate Source voltage withstand test
 Specifications for Traction Transformers 195

9.2 Type Tests

1. Determination of total losses

2. Temperature Rise Test

3. Full wave impulse voltage withstand Test

4. Shock & vibration withstand test

9.3 Investigation tests:

1. Behaviour under short circuit conditions (optional)

10.0 Fittings and Accessories

Fittings and accessories shall as agreed mutually between the manufacturer and purchaser.
However guidance may be taken from other sections of the manual.
 SECTION Q

Specifications for Dry Type Transformers

 SECTION Q
Specifications for Dry Type Transformers
1.0 SCOPE

1.1 This section of the specification covers the different types of dry type transformers.
This section does not purport to include all the necessary provisions of a contract. For general
requirements, tests, erection, maintenance and commissioning, reference shall be made to
Sections ‘A’, ‘BB’&‘CC’ of the Manual.

1.2 It is not the intent to specify completely all details of design and construction of the
equipment. However, the equipment shall conform in all respect to high standard of design,
engineering and workmanship and be capable of performing in continuous commercial
operations.

2.0 STANDARDS

2.1 Except where specified otherwise herein, all material, equipment and construction shall
conform to Indian Electricity Act and rules and latest versions of Indian standards specified
below:
2.2 List of Standards

(a) IS-11171 : Dry type transformers

(b) IS - 2026 (Part-I) : Power transformers
- General
(c) IS - 2026(Part-II) : Power transformers
Temperature rise
(d) IS - 2026 (Part-Ill) : Insulation Levels, Dielectric Tests and
External Clearances in Air
(e) IS - 2026 (Part-IV) : Terminal markings,
tappings and connections.
(f) IS - 2026 (Part-V) : Ability to Withstand Short Circuit
(g) IS-12063 : Degree of protection
provided by enclosures
(h) IEC-60076-11 : Power transformers
Dry type transformers

3.0 SERVICE CONDITIONS

The transformer to be supplied against this specification shall be suitable for satisfactory
continuous operation under the climatic condition prevailing at site and to be specified by the
purchaser as per IS2026/ International Standard as under,

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200 Manual on Transformers

(i) Location : ....

(ii) Max ambient air temperature (Deg.C) : ....
(iii) Min. ambient air temperature (Deg.C) : ....
(iv) Max. average daily ambient air temperature (Deg.C): ....
(v) Max. yearly weighed average ambient temperature (Deg.C): ....
(vi) Max. altitude above mean sea level (m) : ....

4.0 TERMINOLOGY

4.1 Dry Type Transformer

A transformer in which mineral oil or any liquid is not employed either as a cooling or insulating
medium. Cooling will be by natural circulation of air or by forced air cooling. (AN or AN/AF
as per IS11171).

4.2 Dry Type Transformers are classified into following categories depending on the
insulation potting process:

(a) Vacuum Pressure Impregnated (VPI) Transformers have coils impregnated with polyester
varnish/resin under vacuum & pressure. These transformers are generally available upto
1800C (Insulation Class ‘H’). Some manufacturers also use silicon resin for impregnation.

(b) Cast Resin Transformers have coils encapsulated in epoxy resin by molding process.
Depending on the temperature class of resin used these transformers are available upto
1550C (Insulation class ‘F’) or 180°C (Insulation Class ‘H’).

5.0 STANDARD RATINGS FOR 3 PHASE TRANSFORMERS

Standard ratings of dry transformers with losses & impedances are recommended in Table 1

Table 1 : Standard ratings and losses of Dry type transformers.

Total Loss Total Loss Total Loss Total Loss
Rating %Z
at 50% load at rated load %Z at 50% load at rated load
kVA kV
kV * kV * kV * kV *
HV upto 22kV class/ LV upto 600V HV 33kv class/LV upto 600V
100 0.94 2.4 4 1.12 2.4 5
160 1.29 3.3 4 1.42 3.3 5
200 1.5 3.8 4 1.75 4 5
250 1.7 4.32 4 1.97 4.6 5
315 2 5.04 4 2.4 5.4 5
400 2.38 6.04 4 2.9 6.8 5
500 2.8 7.25 5 3.3 7.8 5
630 3.34 8.82 5 3.95 9.2 5
800 3.88 10.24 5 4.65 11.4 5
1000 4.5 12 5 5.3 12.8 5
1250 5.19 13.87 6 6.25 14.5 6
1600 6.32 16.8 6 7.5 18 6
2000 7.5 20 6 8.88 21.4 6
2500 9.25 24.75 6 10.75 26.5 6
 Specifications for Dry Type Transformers 201

Total Loss values given in above table are applicable for thermal classes,B,E & F and have
component of load loss at reference temperature according to clause 17 of IEC 60076-11.

An increase of 7% in above losses for thermal class H is allowed.

* Reference temperature for load losses = average winding temperature rise as given in column
2 of table 2 plus 30 deg C

Other higher ratings of dry type transformers upto 15 MVA having HV upto 33 kV and LV upto
11 kV are possible depending on the application for which they are required.

6.0 RATED FREQUENCY

The standard frequency shall be 50 Hz with a tolerance of ± 3 percent.

6.1 Operation other than the Rated Voltage and Frequency

6.1.1 Transformer built in accordance with this specification may be operated at its rated kVA
at any voltage within ± 10 percent of the rated voltage at that particular tap.

6.1.2 The transformer shall be capable of delivering rated current at a voltage equal to 105
percent of the rated voltage.

Note : The slight temperature rise increase which would correspond to the 5 percent over voltage
due to high no load loss is disregarded.
6.1.3 A transformer for two or more limits of voltage or frequency or both shall give its rated
kVA under all the rated conditions of voltage or frequency or both; provided an increase in
voltage is not accompanied by decrease in frequency.

7.0 ELECTRICAL CHARACTERISTICS AND PERFORMANCE

(a) Thermal classification of insulation and permissible temperature rises should confirm to
class ‘F or class ‘H’ as per relevant clause of IS 11171.
(b) Impedance voltage and short circuit performance against, thermal and dynamic
requirements arc applicable as per relevant clauses of IS 2026 & IS 11171.

7.1 Core

The core shall be stacked type generally of high grade cold rolled grain oriented silicone steel
lamination having low loss and good grain properties coated with carlite. The stacked lamination
will be bolted or tied with belts firmly to prevent vibration or noise. The complete design of core
must ensure permanency of the core losses with continuous working of transformers. Cruciform
core with Mitred/ step lap joints are used to reduce the core losses and magnetizing current.

7.2 Windings

The low voltage and high voltage windings can be made of Copper, Foil/ insulated rectangular
202 Manual on Transformers

strips. Aluminium foils/conductors can also be used. However, losses recommended in Table 1
Note: The Low Voltage (<600V) windings of cast resin transformer can be with no casting in mold if insulation , pre
impregnated with heat activated epoxy resin, is used.
7.3 Insulating Material

The insulating material shall conform to the thermal class of Insulation specified.
Table-2: Winding Temperature Rise Limits

Insulation system Average winding temperature

temperature (°C) rise limits at rated current K
105 (A) 50
120 (E) 65
130 (B) 70
155(F) 90
180(H) 115
200 125
220 140

7.4 Protective Housing for Dry Type Transformer

Dry type transformer shall be provided with suitable protective sheet steel housing, if required
by the site conditions with minimum IP 43 degree of protection for the enclosure for outdoor and
IP20 for indoor transformers. The housing shall have ventilation louvers/ opening provided with
wire mesh screens and shall be supplied with suitable lifting lugs. Safety limit switches shall be
provided and wired in such a way that the incoming supply may be disconnected whenever any
one of the sides of the enclosures are opened with the transformer in energized condition.
The provision for suitable padlocking shall be provided on the doors of enclosure for safety.
7.5 Off-Circuit Links
The off-circuit tapping links shall be provided on the HV side with appropriate register plate
to show the link location. The links shall be provided with inspection window for viewing
purpose.
7.6 Insulators & Bushings
HV & LV insulators & Bushings shall be of epoxy mould type.
7.7 Termination
LV & HV termination shall be suitable for cable/ busduct termination as per the purchaser’s
specifications.
7.8 Transformer Fittings
Each transformer shall be fitted with following accessories :
(i) Inspection covers.
 Specifications for Dry Type Transformers 203

(ii) Off circuit links in the primary for voltage variations

(iii) Rating & diagram plates
(iv) Terminal marking plate
(v) Two nos. earthing terminals
(vi) Lifting lugs and haulage lugs / holes
(vii) Winding temperature detectors with solid state type temperature signaliser with digital
read out and requisite sets of remote signaling contacts for alarm and trip operation.
(viii) Under carriage with bi-directional rollers with locking and bolting devices. Suitable
arrangement for core and winding assembly to draw out the same.
(ix) Marshalling box complete with all instruments, accessories and fittings as required for the
transformer.
(x) Danger plate indicating “entry prohibited under energized condition” of the transformer.

8.0 INSULATION LEVELS

Rated lightning
Highest voltage for Rated short duration power impulse withstand
equipment Um frequency withstand voltage voltage kV (peak)
kV (rms) kV (rms)
List 1 List 2
< 1.1 3
3.6 10 20 40
7.2 20 40 60
12.0 28 60 75
17.5 38 75 95
24.0 50 95 125
36.0 70 145 170

Choice between List 1 and List 2 as per relevant clause of IS 11171 & IEC 60076 Part 11

9.0 EXTERNAL CLEARANCES

The following clearances are to be maintained in air between line to earth for the respective
voltage:

Highest voltage for Minimum external

equipment Um clearance between
kV (rms) line to earth mm
< 1.1 25
3.6 60
7.2 90
12.0 110
17.5 170
24.0 210
36.0 280
204 Manual on Transformers

10.0 TESTS AND TEST CERTIFICATES

The transformer shall be subjected to all the routine, type and special tests as per IS—11171 and
2026 / IEC 60076 as agreed upon between the purchaser and the manufacturer.

10.1 Routine Tests

The following shall constitute the routine tests:

(a) Measurement of winding resistance.

(b) Measurement of voltage ratio and check of voltage vector relationship.
(c) Measurement of Insulation Resistance.
(d) Measurement of impedance voltage (principal tapping), short circuit impedance and load
losses.
(e) Measurement of no-load losses and current.
(f) Separate source voltage withstand lest.
(g) Induced over-voltage withstand test.

10.2 Type Tests

The following shall constitute the typetests:

(a) Lightning impulse test

(b) Temperature rise test

10.3 Special Tests

The following tests may be carried out by mutual agreement between the purchaser and the
supplier:

(a) Short circuit withstand test

(b) Measurement of acoustic sound level
(c) Partial discharge measurement
(d) Mechanical tests: IP test on enclosure

11.0 SURFACE TREATMENT AND PAINTING

Surface treatment and painting shall be done as per Section A of this Manual.

12.0 PACKING, TRANSPORT, STORAGE AND INSTALLATION

12.1 Packing

• Dry type transformers with Enclosure need not be packed and can be dispatched only
wrapped with polythene sheet.
 Specifications for Dry Type Transformers 205

• Dry Type transformers without enclosures should be wrapped with polythene sheet and
packed in wooden crates.
• The Dry Type transformers should be dispatched fully assembled, unless until transport
restrictions do not permit.

12.2 Transport

To lift the transformer, all four lifting lugs must be loaded uniformly with equal length straps
of suitable length in order to avoid distortion to the top core clamping structure and system of
core and coil supports.

12.3 Storage

Dry transformers must be stored in a dry, well-ventilated room and covered with a plastic sheet.
After a long storage period at extreme low temperatures or after a lengthy period of being de-
energised in very humid surrounding, the transformers must be dried before putting back into
service. Drying can be achieved by warm air heaters or by industrial dehumidifiers.

12.4 Installation

• After packing materials and any other blocking means used during transport are removed,
the transformer should be cleaned and dusted-off, taking special care of the air cooling
ducts between the windings and between the low voltage coils and the magnetic core.
Once in final position ensure that the transformer is secured by blocking the rollers. The
installation location should be well ventilated.
• Suitable proper air circulation should be ensured around the transformer during operation
at all times.
• If the Dry Type transformer is required for outdoor installation, then the same shall be
specified by customer in initial specifications.
• Before the putting in service of the transformer, all electrical connections must be checked
(incl. the tapping link connections). A poor electrical connection willcause unnecessary
heating, resulting in possible damage to the transformer insulation.

13.0 TEMPERATURE RISE TEST

Temperature rise of dry type transformers can be conducted as per following methods which is
based on loading type:

(i) Direct Loading Method

This method is generally followed for small transformersdue to loading consideration.

In this method, one winding preferably the inner winding of the transformer is excited at
rated voltage with the other connected to a suitable load such that rated currents flow in
both windings.
206 Manual on Transformers

(ii) Back-To-Back Method

This method is appropriate when there are two similar transformers. Two transformers,
one of which is the transformer under test, are connected in parallel, and the inner winding
is excited at the rated voltage of the transformer under test. By means of different voltage
ratios or an injected voltage, therated current is made to flow in the transformer under
test until stabilization of the core and winding temperatures (refer Fig-1 below). The hot
resistance of the winding is measured and compared with cold resistance to calculate
average winding temperature rise.

Fig-1 (Back to Back Method)

A Voltage source at rated frequency for no-load losses
B Source for rated current at rated frequency for load losses
C Booster transformer
(iii) Simulated Load Method:

In this method, Temperature rise is established by combining the short-circuited test (load
loss) and the open circuit test (no-load loss) in two stage. In each stage, hot resistance of
the winding is measured and compared with cold resistance to calculate average winding
temperature rise. The final temperature rise is calculated by adding them together as per
IEC 60076-11.
Out of all the above three methods, the widely followed method is simulated loading method

Following procedure may be followed for temperature rise test:

1. Test procedure shall be followed as per IEC 60076-11.

2. Test should be carried out with/without enclosure as per user requirement.
3. Test shall be conducted at Minimum Tap.
 Specifications for Dry Type Transformers 207

4. For measurement of ambient temperature, atleast 4 nos. sensors shall be placed at each
side around the transformer at a level approximate half way up to cooling surface, at a
distance of 2 meters from the cooling surface.
5. For direct measurement of winding temperature through WTI, atleast 4 nos. RTD sensors
(Two in center limb & one in each outer phase) shall be placed as close as possible to the
innermost LV winding conductors at the top of the winding and for measurement of core
temperature, 1 no. RTD sensor shall be placed in the centre of top yoke.
6. Hot resistance of all winding (centre phase) shall be measured and their final winding
temperature rise shall be calculated inline with IEC 60076-11.
7. Accuracy of all the instruments used in testing should be equal to or better than 1 oC.
8. In critical Transformers temperature of core, winding, LV terminals/Busbar/Flange &
enclosure shall also be recorded using Laser Gun/Thermo vision camera immediately
after test.
 Vol. II
Application, Standard
Fittings and Accessories
 SECTION AA

Capitalization Formula for Transformer Losses

 SECTION AA
Capitalization Formula for Transformer Losses
A. Capitalization Formula for Power Transformers
1.0 The rate of capitalisation of transformer losses depends upon the rate of interest, rate of
electrical energy per kWh, life of transformer and average annual loss factor. The annual
loss factor takes into account the loading of the transformer during the year. In computing
the rate of capitalisation of ‘Iron losses’, ‘Load losses’ and ‘Auxiliary losses’, following
methodology is recommended :
(i) Rate of interest (r)
(ii) Rate of electrical energy (EC): It is the cost of energy per kWh at the ‘Bus’ to which the
transformer is to be connected. This has been taken as Rs. per kWh at 11 kV.
(iii) Life of the transformer (n): It is taken as 25 years.
(iv) The transformer may be considered in service (LF) for (365x24) 8760 hours in a year.
With modern techniques in design of Condition-monitoring etc, for calculation of losses
no downtime is considered.
(v) The cooling auxiliaries system has been considered in service for 40 percent of the time,
the transformer is in service.
(vi) Annual losses factor:
LS = 0.2LF+0.8(LF)2
where:
LS is the annual loss factor
LF is the annual load factor. This may be decided by the purchaser depending on the application
of transformer. However assuming annual load factor (LF) as 60 percent, annual loss factor (LS)
works out to 0.408.
(vii) Capitalisation Formula Suggested,
Capitalised Cost of Transformer = Initial Cost (IC) + Capitalised Cost of annual iron losses (Wi) +
Capitalised cost of annual Load losses (Wc) + Capitalised cost of annual auxiliary losses (Wp).

Note:
(i) Actual value can be worked out by the purchaser by considering appropriate values of r, EC, LF and LS.
(ii) For auto transformer, the load losses capitalisation shall consider the losses due to both HV and IV loaded
to their rating with tertiary unloaded unless otherwise required by the purchaser. For other three winding
transformers the loading combinations for capitalisation of losses shall be indicated by purchaser.

213
214 Manual on Transformers

B. Capitalization Formula for Shunt Reactor

As the losses of the shunt reactor cannot be separated in to Iron Loss and Copper Loss, It is
customary to guarantee the Total Losses of the shunt reactor. In such a case it is recommended
that the capitalization formula as applicable for Iron losses of the power transformers shall be
applied to the total losses of the Shunt Reactor.

C. Capitalization Formula for Distribution Transformers

For distribution transformers, the following illustrates the method for calculating the loading
factors for evaluation of loss capitalization to be specified by the purchaser. The values indicated
are typical values and the utility may adopt values different from those indicated in case the
rates of interest, cost of energy and the number of hours of operation are different from those
indicated in the example below. A life expectancy of less than 25 years is not recommended.

LOADING FACTOR FOR NO LOAD LOSS

A= H x Ec x [{(l+r)n -1} / r(l+r)n ]

Rate of Expected Number Cost of 1+r (1+r) n (l+r) n-l [{(l+r) n–l} A=loading
Interest in life of hours of energy to /r(l+r) n] factor per
n operation in the utility at kW
per unit
a year UkV level
r of iron loss
H Ec
0.08 25 8400 Ec 1.08 6.848475 5.84848 10.67477619 Rs. 89668iEc

LOADING FACTOR FOR COPPER LOSS LLF = 0.2*LF + 0.8 *LF*LF

1 1 1 = 0.3
B = A x LLF

Where
A = Loading factor in Rs. per kW of no load loss.
B = Loading factor in Rs. Per kW for load loss.
H = No. of hours, the transformer will remain charged in a year, i.e., no. of hours of
operation (taken as 8400 hrs.).
Ec = Cost of energy to the utility at 11 kV level.
r = Rate of interest per unit (Taken as 8%)
n = Expected life of the transformer (Taken as 25 years)
LLF = Loss load factor (where LLF=0.2 x Load factor + 0.8 x L.F.2)
LF = Load factor (taken as 0.5)
Ec = Cost of energy (in Rupees per unit at 11 kV feeder level).
Note: In case of non-availability of Ec (Energy cost per unit) at 11 kV feeder level, utility should consider the Bulk Rate
Tariff plus 5% as the cost of energy at 11 kV feeder level. Load factor considered for Bfactor is 0.5, higher load
factor may be considered for urban areas.
 SECTION BB

Test Requirements for Transformers

 SECTION BB
Test Requirements for Transformers
1.0 General

Test requirements, procedures and criteria for successful testing of transformers are defined in
national and international standards, i.e. IS 2026 and IEC Publication 60076

This Section describes specific requirements for performing tests specified in IEC Publication
60076, IS 2026 and other standards applicable to distribution, power and regulating transformers.
It is intended for use as a guide and reference for testing of transformers. The chapter covers
purpose, interpretation and explanation of specific conditions pertaining to the testing of
transformer and procedure for correction when ideal test conditions can not be achieved.

The main objectives of this manual are following:

• To ensure system needs are met

• To obtain technical uniformity
• To provide inputs for proper interpretation of test results
• To eliminate unsuccessful practices

2.0 Necessity of tests on transformer

When all manufacturing processes have been completed, tests are performed on transformer at
the manufacturer’s works to ensure the following purposes:

(1) To prove that the design meets the specified job requirements and to obtain transformer
characteristics.
(2) To check that the quality requirements have been met and that performance is within the
tolerance guaranteed.
Tests performed for the former purpose are referred to as Type Tests and that for the latter
purpose are referred to as Routine Tests (carried out on every unit manufactured). In addition to
the aforesaid two categories of tests, Special Tests may also be performed to obtain information
useful to the user during operation or maintenance of the transformer.

Transformer is important and vital equipment, it is therefore necessary to ensure its proper
performance throughout its service life. Also during transportation, installation and service
operation, the transformer may be exposed to conditions, which adversely affect its reliability
and useful life. It is therefore necessary to do the field testing to ensure good operating health
of transformers.

3.0 Tests

The general requirements and details of the various categories of tests (Routine Tests, Type Tests
and Special Tests) are in accordance with IEC Publication 60076 (latest edition). The Indian

217
218 Manual on Transformers

standard IS: 2026 is under revision and is expected to be revised in accordance with IEC. The
customer specific requirements are referred hereto as Additional Special tests and Mechanical
Tests.

The following tests are generally performed on the transformer which may also form part of the
customer acceptance:
(A) Factory Tests

• Routine Tests

1. Measurement of winding resistance

2. Measurement of voltage ratio, polarity and check of voltage vector relationship
3. Measurement of no-load loss and excitation current
4. Measurement of short-circuit impedance and load loss
5. Measurement of Insulation resistance
6. Tests on on-load tap-changers, where appropriate
7. Switching impulse withstand voltage test, transformer winding Um > 170 kV
8. Lightning impulse withstand voltage test, transformer winding Um > 72.5 kV
9. Separate-source withstand voltage test
10. Induced AC over voltage withstand test with partial discharge measurement
(The tests at sl. no.7, 8, 9 and 10 above are referred to as Dielectric Tests)
• Type Tests
11. Lightning impulse voltage withstand test, for Um ≤ 72.5 kV
12. Temperature rise test
• Special Tests

13. Lightning impulse test on neutral terminal

14. Long-duration induced AC voltage test (ACLD) transformer winding Um < 170 kV
15. Short-circuit withstand test
16. Measurement of zero-sequence impedances on three phase transformers
17. Measurement of acoustic sound level
18. Measurement of the harmonics of the no-load current
19. Measurement of the power taken by the fan and oil pump motors
• Additional Special Tests

20. Test with lightning impulse chopped on the tail

21. Magnetic circuit (Isolation) test
22. Determination of capacitances and dissipation factor between winding-to-earth and
 Test Requirements for Transformers 219

between windings.
23. Magnetic balance test on three-phase transformers
24. Determination of transient voltage transfer characteristics
25. Dissolved gas analysis (DGA) of oil filled in the transformer before and after temperature
rise test
26. Recurrent surge oscillographic (RSO) test
27. Determination of core hot spot temperature
28. Frequency response analysis (FRA) test
29. Measurement of magnetization current at low voltage
30. Functional tests on auxiliary equipments
31. Tests on oil filled in transformer
32. Dew point measurement before dispatch
Mechanical Tests

33. Oil pressure test on completely assembled transformer

34. Jacking test and Dye-penetration test
35. Pressure relief device test
(B) Recommended Field tests

1. Dew point measurement for large transformer filled with dry air or nitrogen filled
2. Winding resistance measurement
3. Vector group and polarity
4. Voltage ratio test
5. Measurement of magnetizing current
6. Magnetic balance test on three phase transformer
7. Magnetic circuit (Isolation) test
8. Measurement of short circuit impedance at low voltage
9. Insulation resistance measurement
10. Measurement of capacitance and dissipation factor on windings and Bushings of 72.5 kV
class and above.
11. Dissolved gas analysis (DGA) on transformers
12. Tests on oil filled in transformer as per IS 1866 / IEC 60422
13. Frequency response analysis (FRA) test
The dielectric tests (Test Nos. A.7 to A.12) may be routine, type or special tests depending upon
the voltage rating, specific customer requirements and referred standards.

The purpose, interpretation and explanation for specific conditions of the tests are briefly
described as below.
220 Manual on Transformers

The tests and their sequence shall be mutually agreed between the manufacturer and the user.

3.1 Measurement of Winding Resistance

3.1.1 General
Resistance measurement helps to determine the following:
(a) Calculation of the I2R losses.
(b) Calculation of winding temperature at the end of a temperature rise test.
(c) As a base for assessing possible damage in the field.
3.1.2 Determination of Cold Temperature

The resistance is measured at ambient (cold) temperature and then converted to resistance at 75 0C,
for all practical purpose of comparison with specified design values, previous results and diagnostics.
The cold temperature of the winding shall be determined as accurately as possible when measuring
the cold resistance. The following should be observed.

3.1.2.1 Transformer Windings Immersed in Insulating liquid

The temperature of the winding shall be assumed to be the same as the temperature of the
insulating liquid, provided:
(a) The windings have been under insulating liquid with no excitation and with no current in
the winding from three hours to eight hours (depending upon the size of the transformer)
before the cold resistance is measured.
(b) The temperature of the insulating liquid has stabilized, and the difference between top and
bottom temperature does not exceed 5 0C.
3.1.2.2 Transformer windings without insulating liquid

The temperature of the winding shall be recorded as the average of several thermometers or
thermocouples inserted between the coils, with care taken to see that their measuring points are
as nearly as possible in actual contact with the winding conductors. It should not be assumed
that the windings are at the same temperature as the surrounding air.
3.1.3 Resistance Measurement Methods

The resistance of each winding shall be measured by any one of the following methods. If
winding has tapping, then resistance shall be measured on at least principal, maximum and
minimum taps.
3.1.3.1 Voltmeter-Ammeter method

This method should be employed if the rated current of the transformer winding is one ampere
or more. The following steps are performed to conduct this test.

(a) Measurement is made with direct current, and simultaneous readings of current and
 Test Requirements for Transformers 221

voltage are taken.

(b) To minimize errors of observation:
(1) The measuring instruments shall have such ranges as will give reasonably large
deflection.
(2) The polarity of the core magnetization shall be kept constant during all resistance
readings.
(c) The voltmeter leads shall be independent of the current leads and shall be connected as
closely as possible to the terminals of the winding to be measured. This is to be avoid
including in the reading the resistance of current-carrying leads, their contacts and extra
length of leads.
(d) Readings shall not be taken until after the current and voltage have reached steady-state
values.
(e) Readings shall be taken with not less than four values of current when deflecting
instruments are used.
(f) The current used shall not exceed 15% of the rated current of the winding whose resistance
is to be measured. Larger values may cause inaccuracy by heating the winding and thereby
changing its temperature and resistance.
3.1.3.2 Bridge Method

Bridge methods or high-accuracy digital instrumentation are generally preferred because of their
accuracy and convenience. The current rating of the measuring instrument should not be very
low for large inductive objects. In case of delta connected windings of a large rating transformer,
the resistance meter should have adequate current rating.

For star connected windings with neutral brought out, the resistance shall be measured by two
methods

(1) Between line and neutral

(2) For small transformer with star connected windings, the resistance shall be measured
between phases (line to line), and then resistance of the individual windings shall be
determined by dividing the value by 2. This will rule out the effect of the resistance of
the neutral lead and bus bars which is significant in comparison to phase resistance of
small transformers. However, for the delta connected windings, measurements shall be
made between pairs of line terminals. In this case the resistance per winding will be 1.5
X measured resistance between the pair of line terminals. In case of open delta connected
winding, the resistance can be measured across all the three windings are in series and
also individual winding resistance can be measured.
Few precautions are to be carried out to minimize errors while performing the test as follows:

(a) Charged battery of sufficient capacity or at least 10 A shall be used with the bridge to
avoid errors due to drop in battery voltage during measurements.
(b) To reduce the high inductive effect, it is advisable to use a sufficiently high current to
222 Manual on Transformers

saturate the core. Therefore the measuring instruments shall have high ranges as well as
large deflection.
(c) The polarity of the core magnetization shall be kept same during all resistance readings. A
reversal in magnetization of the core can change the time constant and result in erroneous
readings.
(d) The voltmeter leads shall be independent of the current leads and shall be connected
as closely as possible to the terminals of the winding to be measured. This is to avoid
including in the reading the resistances of current-carrying leads and their contacts and of
extra lengths of leads.
(e) To protect the voltmeter from injury by off-scale deflections, the voltmeter should be
disconnected from the circuit before switching the current on or off. To protect the
personnel from inductive kick, the current should be switched off by a suitably insulated
switch.
(f) Readings shall not be taken until after the current and voltage have reached steady-state
values.
(g) The current used shall not exceed 15% of the rated current of the winding whose resistance
is to be measured. Larger values may cause inaccuracy due to heating of the winding and
thereby changing its temperature and resistance.
3.2 Measurement of Voltage Ratio, Polarity and Check of Voltage Vector Relationship
3.2.1 Ratio Test
3.2.1.1 General

The turn ratio of a transformer is the ratio of the number of turns in the high-voltage winding to
that in the low-voltage winding.

When the transformer has taps, the turn ratio shall be determined for all taps and for the full
winding.

The ratio tests shall be made at rated or lower voltage and the voltage shall be applied to the
winding with higher voltage rating.

In the case of three-phase transformers, when each phase is independent and accessible, single-
phase supply should be used; although, when convenient, three-phase supply may be used.

3.2.1.2 Tolerances for ratio

The tolerances for ratio shall be as specified in IS 2026 Part 1 and IEC 60076-1.

Ratio test methods

Various types of ratio test methods are possible. Out of those, Ratio Bridge method is most
commonly adopted. In this method, the turn ratio on each tapping between pairs of winding
shall be measured by a direct reading ratio meter. This method gives more accurate results as
 Test Requirements for Transformers 223

compared to other methods described in aforesaid standards.

The modern ratio bridge can also be used to test polarity, phase relation and phase sequence. More
accurate results can be obtained using a ratio bridge that provides phase-angle correction.

3.2.2 Polarity and Vector Group Verification

Polarity and phase-relation tests are of interest primarily because of their bearing on
paralleling or banking two or more transformers. Phase-relation tests are made to determine
angular displacement and relative phase sequence. Phase-relation or vector group
verification test is performed on a three phase transformer or on a bank of three single-
phase transformers.

The details of Additive and Subtractive polarity are given in IS: 2026-Part 1 and IEC 60076-1.

3.2.2.1 Polarity By Alternating-Voltage Test

For a single-phase transformer having a ratio of transformation of 30 to 1 or less, the polarity

test shall be done as follows. The line terminal of high voltage winding (1.1) shall be connected
to the adjacent line terminal low-voltage winding (2.1) as shown in Fig. 1

Fig.1 Polarity by alternating voltage test

Any convenient value of alternating voltage shall be applied to the full high-voltage winding and
readings shall be taken of the applied voltage and the voltage between the right-hand adjacent
high-voltage and low-voltage leads.

When the later reading is greater than the former, the polarity is additive.

When the later reading is less than the former (indicating the approximate difference in voltage
between that of the high-voltage and low-voltage windings), the polarity is subtractive.

3.2.2.2 Verification of Vector Group

The phasor diagram of any three-phase transformer that defines the angular displacement and
phase sequence can be verified by connecting the HV and LV leads together to excite the
224 Manual on Transformers

unit at a suitably low three-phase voltage, taking voltage measurements between the various
pairs of leads and then either plotting these values or comparing them for their relative order
of magnitude with the help of the corresponding phasor diagrams, e.g. as shown in Fig. 2
and 3. Typical check measurements are to be taken and their relative magnitudes are then
compared.
Example 1

CONNECT 1U TO 2U
MEASURE 1W-2V, 1W-2W, 1U-2W, 1V-2V,
1V-2W
VOLTAGE RELATION
1W-2V= 1W-2W
1W-2V< 1W-1U
1V-2V<1V-2W
1V-2V <1U-1W
Fig 2 : For HV-Delta / LV-Star Transformer
Example 2

Connect 1U to 2U
MEASURE 1W-2V, 1W-2W, 1U-2W, 1V-2V,
1V-2W
VOLTAGE RELATION
1W-2W = 1V-2W
1W-2V > 1V-2V
1U-N= (1U-2W)+(2W-N)
Yd11
Fig 3 : For HV-Star / LV-Delta Transformer

3.3 Measurement of No-load Loss and Excitation Current

3.3.1 General

No-load (excitation) losses are those losses that are incident to the excitation of the transformer.
No-load (excitation) losses include core loss, dielectric loss, conductor loss in the winding due
to excitation current, and conductor loss due to circulating current in parallel windings. These
losses change with the excitation voltage.

Excitation current (no-load current) is the current that flows in any winding used to excite the
transformer when all other windings are open-circuited. It is generally expressed in percent of
the rated current of the winding in which it is measured.
 Test Requirements for Transformers 225

3.3.2 No-load Loss Test

The purpose of the no-load loss test is to measure no-load losses at a specified excitation voltage
and a specified frequency. The no-load loss determination shall be based on a sine-wave voltage.
The average-voltage voltmeter method is the most accurate method for correcting the measured
no-load losses to a sine-wave basis and is recommended. This method employs two-parallel-
connected voltmeters; one is an average-responding (possibly rms calibrated) voltmeter; the
other is a true rms-responding voltmeter. The readings of both voltmeters are employed to
correct the no-load losses to a sine-wave basis, using equation given in paragraph for waveform
correction of no-load losses.

Test voltage will be 90%, 100%, 110%, guaranteed at 100% and for reference purpose at 90 and
110%

3.3.2.1 Connection Diagrams

Tests for the no-load loss determination of a single-phase transformer are carried out using
the schemes depicted in Figs. 4 & 5. Fig. 4 shows the necessary equipment and connections
for the case where instrument transformers are not required. When instrument transformers
are required, which is the general case, the equipment and connections shown in Fig. 5 apply.
If necessary, correction for losses in connected measuring instruments may be made by
disconnecting the transformer under test and noting the wattmeter reading at the specified test
circuit voltage. These losses represent the losses of the connected instruments (and voltage
transformer, if used). They may be subtracted from the earlier wattmeter reading to obtain the
no-load loss of the transformer under test.

Tests for the no-load loss determination of a three-phase transformer shall be carried out by
using the three wattmeter method. Figure 6 is schematic representation of the equipment and
connections necessary for conducting no-load loss measurements of a three-phase transformer
when instrument transformers are necessary.

Nowadays, digital power analysers or power meters are available for determination of losses
(both no-load and load). Selection of these power analysers shall be based on the desired
accuracy at low power factors

Fig 4 : Connections for no-load loss test of a single-phase transformer

without instrument transformers
226 Manual on Transformers

without instrument transformers

Fig : 5 - Connections for no-load loss test of a single-phase transformer

with instrument transformers

Note : Source neutral

should be available
for Y-Y connected
Note : Voltmeters should
transformers when no
be connected Line-to-Neutral
delta winding is
for Y-connected winding
present to provide
or Line-to-Line for
return path from
delta-connected winding
transformer neutral Fig : 6 - Three phase transformer connections for no-load loss and excitation
current tests using three-wattmeter method

3.3.2.2 Voltage and frequency for no-load loss test

The operating and performance characteristics of a transformer are based upon rated voltage
and rated frequency, unless otherwise specified. Therefore, the no-load loss test is conducted
with rated voltage impressed across the transformer terminals, using a voltage source at
a frequency equal to the rated frequency of the transformer under test, unless otherwise
specified.

For the determination of the no-load losses of a single-phase transformer or a three-phase

transformer, the frequency of the test source should be within ± 0.5% of the rated frequency
of the transformer under test. If the excitation frequency is beyond the specified tolerance,
then the test voltage shall be adjusted to maintain the V/f ratio corresponding to the ratio
of rated voltage and rated frequency. The voltage shall be adjusted to the specified value as
indicated by the average-voltage voltmeter. Simultaneous values of rms voltage, rms current,
electrical power and the average voltmeter readings shall be recorded. For a three-phase
transformer the average of the three voltmeter readings shall be the desired nominal value
of the voltage.

The most difficult cases, both with regard to voltage wave shape distortion and power
measurements usually arise when testing large single-phase transformers.
 Test Requirements for Transformers 227

3.3.2.3 Instrument error at low power factor

At low power factors, judicious selection of measurement method and test system components
is essential for accurate and repeatable test results. The phase-angle errors in the instrument
transformers, measuring instruments, bridge networks and accessories affect the loss test
results. Procedures for correcting the losses for meeting phase-angle errors are described in IEC
Publication 60076-8

3.3.2.4 Correction of no-load losses

The eddy current component of the no-load loss varies with the square of the rms value of
excitation voltage and is substantially independent of the voltage waveform. When the test
voltage is held at the specified value as read on the average-voltage voltmeter, the actual rms
value of the test voltage may not be equal to the specified value. The no-load losses of the
transformer corrected to a sine-wave basis shall be determined from the measured value by
means of the following equation:

The above equation is valid only for voltage with moderate waveform distortion. If waveform
distortion in the test voltage causes the magnitude of the correction to be greater than 5%, then
the test voltage waveform must be improved for an adequate determination of the no-load losses
and currents. For large single phase transformers, it is expected that the difference between rms
voltages and average voltage will be greater than 5%, which should be accepted in view of test
voltage source limitation.

The new generation of power analysers are equipped with software for automatic calculation of
corrected losses based on the input data of voltages and power.

3.3.3 Measurement of Excitation (no-load) Current

The excitation (no-load) current of a transformer is the current that maintains the rated magnetic
flux excitation in the core of the transformer. The excitation current is usually expressed in per
unit or in percent of the rated line current of the winding in which it is measured. Measurement
of excitation current is usually carried out in conjunction with the tests for no-load losses. RMS
current is recorded simultaneously during the test for no-load losses using the average-voltage
voltmeter method. This value is used in calculating the per unit or percent excitation current.
228 Manual on Transformers

For a three-phase transformer, the excitation current is calculated by taking the average of the
magnitude of the three line currents. The tolerance for no-load current should be as per IS 2026
Part -1

3.4 Measurement of Short-circuit Impedance andLoad Loss

3.4.1 General

The load losses of a transformer are those losses incident to a specified load carried by the
transformer. Load losses include I2R loss in the windings due to load current and stray losses
due to eddy currents induced by leakage flux in the windings, core clamps, magnetic shield,
tank walls and other conducting parts. Stray losses may also be caused by circulating currents in
parallel windings or strands. Load losses are measured by applying a short circuit across either
the high voltage winding or the low voltage winding and applying sufficient voltage across the
other winding to cause a specified current to flow in the windings. The power loss within the
transformer under these conditions equals the load losses of the transformer at the temperature
of test for the specified load current.

The impedance voltage of a transformer between a pair of windings is the voltage required to
circulate rated current through one of two specified windings when the other winding is short
circuited, with the windings connected as for rated voltage operation. Impedance voltage is
usually expressed in per unit or percent of the rated voltage of the winding across which the
voltage is applied and measured.

The impedance voltage is measured during the load loss test by measuring the voltage required
to circulate test current in the windings. The measured voltage is the impedance voltage at
the test frequency and the power loss dissipated within the transformer is equal to the load
losses at the temperature of test and at rated load. The impedance voltage is corrected to the
rated frequency and the load losses are corrected to a reference temperature using the formulas
specified in this standard.

3.4.2 Factors Affecting the Values of Load Losses and ImpedanceVoltage

The magnitude of the load losses and the impedance voltage will vary depending on the
positions of tap changers, if any in various windings. These changes are due to the changes in
the magnitudes of load currents and associated leakage-flux linkages as well as being due to
changes in stray flux and accompanying stray losses.

3.4.2.1 Temperature

Load losses are also a function of temperature. The I2R component of the load losses
increases with temperature, while the stray loss component decreases with temperature.
Procedures for correcting the load losses to the standard reference temperature are described
in 3.5.5.
 Test Requirements for Transformers 229

3.4.2.2 Instrument error at low power factor

At low power factors, judicious selection of measurement method and test system components
is essential for accurate and repeatable test results. The phase-angle errors in the instrument
transformers, measuring instruments, bridge networks and accessories affect the load loss test
results. Procedures for correcting the load losses for meeting phase-angle errors are described
in IEC Publication 60076-8
3.4.3 Methods for Measuring Load Losses and Impedance Voltage
Test Conditions
To determine the load losses and impedance voltage with sufficient accuracy, the following
conditions shall be met.
1. The temperature of the insulating liquid has stabilized and the difference between top and
bottom oil temperatures does not exceed 5 0C.
2. The temperature of the windings shall be taken immediately either before or after the
load losses and impedance voltage test in a manner similar to that described in 3.1.1. The
average shall be taken as the winding temperature for computation of losses.
3. The conductors used to short-circuit the low voltage, high current winding of a transformer
shall have a cross-sectional area greater than the corresponding transformer winding leads.
4. The test current shall be at least 50 % of the rated current of the winding across which the
voltage is applied.
5. The measurement of losses shall be done at the earliest after excitation of the transformer
to the test current to avoid heating of the winding resulting in increase in resistance.
3.4.3.1. Wattmeter-voltmeter-ammeter method for load loss and impedance voltage test

The connection and apparatus needed for the determination of the load losses and impedance
voltage of a single-phase transformer are shown in Figures 7 and 8. Figure 8 applies when the
instrument transformers are required, which is the general case.
For three phase transformers, three-phase power measurement utilizing two wattmeter is
possible but can result in very large errors at low power factors encountered in load loss tests of
transformers. It is recommended that the two-wattmeter method should not be used for loss tests
on three-phase transformers of ratings preferably above 20 MVA, 66 kV class.
For three phase transformers, Figure 9 shows the apparatus and connections using the three-
wattmeter method.

Fig 7 : Basic circuit for load loss and impedance measurement

230 Manual on Transformers

Fig 8 : Single-Phase transformer connection for load loss and

impedance tests with instrument tranformers

Fig 9 : Three phase transformer connection for load loss and

impedance voltage tests using three- wattmeter method

3.4.3.2 Measurement with Power Analyser

Nowadays, digital power analysers or power meters are available for determination of load
losses. Selection of these power analysers shall be based on the desired accuracy at low power
factors.

The new generation of power analysers are equipped with software for automatic calculation of
corrected losses based on the input data of voltage, current, power, frequency and temperature.
3.4.4 Test Procedure
3.4.4.1 Two-winding transformers and auto transformers

Load loss and impedance voltage tests are carried out using the connections and apparatus
shown in figure 8 for single-phase transformers and figure 9 for three-phase transformers.

With one winding short-circuited, a voltage of sufficient magnitude is applied to the other
winding and adjusted to circulate test current in the excited winding. Simultaneous readings
of wattmeter, voltmeter and ammeter are taken. If necessary, the corrections for the losses in
external connections and connected measuring instruments should be made.
 Test Requirements for Transformers 231

The procedure for testing three-phase transformers is very similar, except that all connections
and measurements are three-phase instead of single-phase and a balanced three-phase source
of power is used for the test. If the three line currents cannot be balanced, their average rms
value should correspond to the desired value, at which time simultaneous reading of wattmeters,
voltmeters and ammeters should be recorded.
Single phase and three-phase auto transformers may be tested with internal connections unchanged.
The test is made using the auto transformer connection. The input (or output) terminals are
shorted and voltage is applied to the other terminals. The voltage is adjusted to cause test current
to flow in the test circuit as shown in Figure10. Simultaneous readings of wattmeters, voltmeters
and ammeters are recorded for determination of load losses and impedance voltage.

Fig 10 : Connection for impedance loss and impedance-voltage

tests of an auto-transformer

For the purpose of measuring load losses and impedance voltage, the series and common
windings of auto transformers may be treated as separate windings, one short circuited,
the other excited. In this situation, where the transformer is connected in the two-winding
connection for the test, the current held must be the test current of the excited winding, which
may or may not be the same as rated line current. The load loss watts and applied volt-amperes
will be same, whether series and common windings are treated as separate windings in the
two-winding connection or are connected in the auto-transformer connection, so long as rated
winding current atleast 50 percent is held in the first case and rated line current atleast 50
percent in the second case.

3.4.4.2 Three winding transformers

For a three winding transformer, which may be either single phase or three phase, three sets of
impedance measurements are made between pairs of windings, following the same procedure
as for two winding transformers. Measurement of the impedances Z12, Z23 and Z31 are obtained
between windings 1, 2 & 3.

If the kVA capacities of the different windings are not alike, the current held for the
impedance test should correspond to the capacity of the lower rated winding of the pair
of the windings under test. However, all of these data when converted into percentage
form should be based on the same output kVA, preferably that of the primary winding. An
equivalent three-winding impedance network as shown in Figure 11 can be derived from
the following equations:
232 Manual on Transformers

Fig 11 : Equivalent three-winding impedance network

Where

Z12, Z23 and Z31 are the measured impedance values between pairs of windings, as indicated all
expressed on the same kVA base.

These equations involve complex numbers, but they may be used for the resistance (in-phase)
component or the reactance (quadrature) component of the impedance voltage or of the
impedance volt-amperes.

The treatment of the individual load losses for temperature corrections, etc., is the same as for
two-winding, single phase transformers.

The total load losses of the three winding transformer is the sum of the losses in the branches of
the equivalent circuit of Figure 11 for any specific terminal load conditions.

3.4.5 Calculation of Load Losses and Impedance Voltage

Load loss measurements vary with temperature and in general must be corrected to a reference
temperature. In addition, load loss measurement values must be corrected for metering phase
angle error. Impedance voltage measurement to vary with frequency and the values must be
corrected for rated frequency.

• Temperature correction of load losses

Both I2R losses and stray losses of transformer vary with temperature. The I2R losses, Pr(Tm),
of a transformer are calculated from the ohmic resistance measurements (connected to the
temperature, Tm, at which the measurement of the load losses and impedance voltage was
done) and the current that were used in the impedance measurement. These I2r losses subtracted
 Test Requirements for Transformers 233

from the measured load loss watts P(Tm), give the stray losses, Ps(Tm), of the transformer at the
temperature at which the load loss test was made.

Ps (Tm) = P(Tm) – Pr(Tm)

Where

Ps(Tm) is the calculated stray losses (watts) at temperature Tm.

P(Tm) is the transformer load losses (watts), corrected in accordance with phase angle errors in
wattmeter at temperature Tm.

Pr (Tm) is the calculated I2R loss (watts) at temperature Tm

The I2R component of load losses increases with temperature. The stray loss component
diminishes with temperature. Therefore, when it is desirable to convert the load losses from the
temperature at which it is measured, Tm, to another temperature, T, the two components of the
load losses are corrected separately.

Thus,

Then
P (T) = Pr (T) + Ps (T)
Where
Pr (T) = I2R loss (watts) at temperature T, 0C
Ps (T) = stray losses (watts) at temperature T, 0C
P (T) = Transformer load losses (watts) corrected to temperature T, 0C
Tk = 234.5 0C (copper) » 235 0C
Tk = 225 0C (aluminium)
• Calculation for impedance

The impedance shall be measured at rated frequency by applying an approximately sinusoidal

supply to one winding, with the terminal of other winding short circuited, and with possible
other winding open circuited. The supplied current should be equal to the relevant rated current.
However, in case of limitation in the rating of supply source the current should not be less than
the 50% of the rated current. Due to fluctuation in load the supply frequency may not be always
234 Manual on Transformers

be the rated frequency. Then frequency correction should be applied to calculate the actual
impedance at rated frequency as following.

The formula for calculating the percentage impedance with current and frequency correction is
Vtest I rated fr
Z (%)= X X X 100
Vrated I test ft
Where

Vtest = Test voltage

Vrated = Rated voltage
Itest = Test current
Irated = Rated current
ft = Test frequency
fr = Rated frequency
3.5 Measurement of Insulation Resistance

Insulation resistance tests are made to determine the insulation resistance from individual
winding to ground or between individual windings. The insulation resistance in such tests
is commonly measured in mega-ohms, or may be calculated from measurements of applied
voltage and leakage current.
Note
(1) The insulation resistance of electrical apparatus is subjected to wide variation in design, temperature, dryness,
and cleanliness of the parts. When the insulation resistance falls below prescribed values, it can, in most cases
of good design and where no defect exists, be brought up to that required standard by cleaning and drying the
apparatus. The insulation resistance, therefore, may offer a useful indication as to whether the apparatus is in
suitable condition for application of dielectric tests.
(2) Under no conditions, test should be made while the transformer is under vacuum.

• Instrumentation
Insulation resistance may be measured using the following equipment:

(a) A variable-voltage dc power supply with means to measure voltage and current
(generally in micro-amperes or milli-amperes)
(b) A mega-ohmmeter
Mega-ohmmeters are commonly available with nominal voltages of 500 V, 1000 V, 2500 V, and
5000 V; dc or in multiples of 1000 V upto 10,000 V.

• Voltage to be applied

The dc voltage applied for measuring insulation resistance to ground shall not exceed a value
 Test Requirements for Transformers 235

equal to the half of the rated voltage of the winding or 5 kV whichever is lower.

• Procedure

Insulation resistance tests shall be made with all circuits of equal voltage above ground
connected together. Circuits or groups of circuits of different voltages above ground shall be
tested separately. All external insulating parts of the transformer shall be cleaned thoroughly to
remove dust, moisture etc. before the test.

• Examples:

(a) High voltage to low voltage and ground, low voltage to high voltage and ground.
(b) Voltage should be increased in increments of usually one kilovolt and held for one
minute while the current is read.
(c) The test should be disconnected immediately in the event the current begin to
increase without stabilizing.
(d) After the test has been completed, all terminals should be grounded for a period of
time sufficient to allow any trapped charges to decay to a negligible value.
• Polarisation Index (PI)

The purpose of polarisation index test is to determine if equipment is suitable for operation or
even for an overvoltage test. The polarisation index is a ratio of insulation resistance value at the
end of 10 min test to that at the end of 1 min test at a constant voltage.

The total current that is developed when applying a steady state dc voltage is composed of three
components:

(1) Charging current due to the capacitance of the insulation being measured. This
current falls off from maximum to zero very rapidly.
(2) Absorption current due to molecular charge shifting in the insulation. The transient
current decays to zero more slowly.
(3) Leakage current which is the true conduction current of the insulation. It has a
component due to the surface leakage because of the surface contamination.
The advantage of PI is that all of the variables that can affect a single IR reading, such as
temperature and humidity, are essentially the same for both the 1 min and 10 min readings. Since
leakage current increases at a faster rate with moisture present than does absorption current, the
IR readings will not increase as fast with insulation in poor condition as with insulation in good
condition. After 10 min the leakage current becomes constant and effects of charging current
and absorption current die down.

Acceptable PI value for power transformer shall be better than 1.5. For distribution transformer
it should be at least 1.3.
236 Manual on Transformers

• Interpretation of Results
Insulation resistance may vary with applied voltage and temperature any comparison must be
made with measurements at the same voltage.

The significance of values of insulation resistance tests generally requires some interpretation,
depending on the design and the dryness and cleanliness of the insulation involved. When a user
decides to make insulation resistance test, it is recommended that insulation resistance values be
measured periodically (during maintenance shutdown) and that these periodic values be plotted.
Substantial variations in the plotted values of insulation resistance should be investigated for cause.

3.6 Tests on On-load Tap-Changers

3.6.1 Operation Test

With the tap-changer fully assembled on the transformer the following sequence of operations
shall be performed without failure:

(a) With the transformer un-energised, eight complete cycles of operations (a cycle of
operation goes from one end of the tapping range to the other, and back again).
(b) With the transformer un-energised, and with the auxiliary voltage reduced to 85% of its
rated value, one complete cycle of operation.
(c) With the transformer energized at rated voltage and frequency at no load, one
complete cycle of operation
(d) With one winding short circuited and, as far as practicable, two rated current according
to IEC 60076-1 in the winding, 10 tap-change operations across the range of two steps
on each side from where a coarse or reversing changeover selector operates, or otherwise
from the middle tapping.
3.6.2 Auxiliary Circuits Insulation Test

After the tap changer is assembled on the transformer, a power frequency tests according to IEC
60076-1 shall be applied to the auxiliary circuits as specified in IEC 60076-3.

3.7 Dielectric Tests

The purpose of dielectric tests is to demonstrate that the transformer has been designed and
constructed to withstand the specified insulation levels. The insulation requirements for
the transformers and the corresponding dielectric tests are given in IS 2026 Part-3 and IEC
Publication 60076-3 with reference to specific windings and their terminals. For oil immersed
transformers, the requirements apply to the internal insulation only.

The dielectric tests shall generally be made at the manufacturer premises with the transformers
approximately at ambient temperature.

Transformers, including bushings and terminal compartments when necessary to verify

air clearances, shall be assembled prior to making dielectric tests, but assembly of items,
 Test Requirements for Transformers 237

such as radiators and cabinets, which do not affect dielectric tests is not necessary. Bushing
shall, unless otherwise authorised by the purchaser, be those to be supplied with the
transformer.

If a transformer fails to meet its test requirements and the fault is in a bushing, it is permissible to
replace this bushing temporarily with another bushing and continue the tests on the transformer to
completion without delay. A particular case arises for tests with partial discharge measurements,
where certain types of commonly used high-voltage bushings create difficulty because of their
relatively high level of partial discharge in the dielectric. When such bushings are specified for
the transformer, it is permitted to exchange them for bushings of a partial discharge free type
during the testing of transformer.

Test levels and other test parameters shall be as per IEC Publication 60076-3 and the corresponding
IS 2026 Part-3.

It is recommended to measure voltage at the high voltage terminal of its transformer. The
measuring system shall be in accordance with IEC Publication 60071-2.

In conducting low frequency tests for transformers of 100 kVA and less to be tested at 50 kV
or less, it is permissible to depend on the ratio of testing transformer to indicate the proper test
voltage.

3.7.1 Rules for Some ParticularTransformers

In transformers where uniformly insulated windings having different Um values are connected
together within the transformer, the separate source AC withstand test voltages shall be
determined by the insulation of the common neutral and its assigned Um.

In transformers which have one or more non uniformly insulated windings, the test voltages for
the induced withstand voltage test, and for the switching impulse test, are determined by the
winding with highest Um value, and the windings with lower Um values may not receive their
appropriate test voltages.

During switching impulse tests, the voltages developed across different windings are
approximately proportional to the ratio of turns. Rated switching impulse withstand voltages
shall only be assigned to the winding with the highest Um. Test stresses in other windings are
also proportional to the ratio of numbers of turns and are adjusted by selecting appropriate
tappings to come as close as possible to the assigned value.

3.7.2 Insulation Requirements and DielectricTests

The basic rules for insulation requirements and dielectric tests for different categories of
windings are described in Table 1(Refer IEC Publication 60076-3)
238 Manual on Transformers

Category of Highest voltage for Tests

winding equipment Um
kV Lightning Switching Long Short Separate
impulse impulse duration duration source AC
(LI) (SI) AC(ACLD) AC(ACSD)
Uniform Um ≤ 72.5 Type Not Not Routine Routine
applicable applicable
Uniform and 72.5 < Um ≤ 170 Routine Not Special Routine Routine
non-uniform applicable
insulation
170 < Um < 300 Routine Routine* Routine Special* Routine
Um ≥ 300 Routine Routine Routine Special Routine
* If ACSD test is specified, the SI test is not required.

The standard dielectric requirements are verified by dielectric tests. They shall, where applicable
and not otherwise agreed upon, be performed in the sequence as given below.
(1) Switching impulse test (SI) for the line terminal
(2) Lightning impulse test (LI) for the line terminals
(3) Lightning impulse test (LI) for neutral terminal
(4) Separate source AC withstand voltage test (applied potential test)
(5) Short-duration induced AC withstand voltage test (ACSD)
(6) Long-duration induced AC voltage test (ACLD)

3.7.3 Switching Impulse withstand Voltage Test, Transformer Winding Um > 300 kV

This test is intended to verify the switching impulse withstand strength of the line terminals and
its connected windings to earth and other windings, the withstand strength between phases and
along the winding under test.
The impulses are applied either directly from the impulse voltage source to a line terminal of
the winding under test, or to a lower voltage winding so that the test voltage is inductively
transferred to the winding under test.

The detailed test procedures and specific test requirements are addressed in IEC Publication
60076-3.
• Switching impulse waves
Polarity
The polarity of test voltage shall be negative because this reduces the risk of erratic external
flashovers in the test circuit.
Wave shape
The voltage impulse shall have a virtual front time of at least 100 μs, a time above 90% of the
specified amplitude of at least 200 μs, and a total duration from the virtual origin to the first zero
passage of at least 500 μs but preferably 1000 μs.
 Test Requirements for Transformers 239

• Test sequence and records

The test sequence shall consists of one impulse of a voltage between 50% and 75 % of the full test
voltage and three subsequent impulses of full voltage. If the oscillographic or digital recording
should fail, that application shall be disregarded and a further application made. Oscillographic
or digital records shall be obtained of at least the impulse wave-shape on the line terminal under
test and preferably the neutral current.
• Test connections

During the test the transformer shall be in a no-load condition. Windings not used for the test
shall be solidly earthed at one point but not short-circuited. For a single phase transformer, the
neutral terminal of the tested winding shall be solidly earthed.

A three-phase winding shall be tested phase by phase with the neutral terminal earthed and
with the transformer so connected that a voltage of opposite polarity and about half amplitude
appears on the two remaining line terminals which may be connected together.

To limit the voltage of opposite polarity to approximately 50% of the applied level, it is
recommended to connect high ohmic damping resistors (10 kΩ to 20 kΩ) to earth at the non
tested phase terminals.
• Failure detection

The test is successful if there is no sudden collapse of voltage or discontinuity of the neutral
current if recorded on the oscillographic or digital records.
Additional observation during the test (abnormal sound effect etc.) may be used to confirm the
oscillographic records, but they do not constitute evidence in themselves.
3.7.4 Lightning Impulse withstand Voltage Test
This test is intended to verify the impulse withstand strength of the transformer under test. This
test shall only be made on windings that have terminals brought out through the transformer
tank or cover.
When non-linear elements or surge diverters are installed for the limitation of transferred over
voltage transients, the evaluation of test records may be different compared to the normal
impulse test. These non-linear protective devices connected across the windings may cause
difference between the reduced full wave and the full-wave impulse oscillograms. To prove that
these differences are indeed caused by operation of these devices, this should be demonstrated
by making two or more reduced full-wave tests at different voltage levels to show the trend in
their operation.

The detailed test procedure and specific test requirements are addressed in IEC 60076-3.

• Impulse wave

The test impulse shall be a full standard lightning impulse: 1.2 µs ± 30% / 50 µs ± 20 %.
240 Manual on Transformers

But in some cases this standard impulse shape cannot reasonably be obtained, because of low
winding inductance or high capacitance to earth. In such cases wider tolerance may be accepted
by the agreement between purchaser and customer. It is recommended to use IEC Publication
60722 as a guide for non-standard wave shapes.

• Test sequence

The test sequence shall consists of one impulse of a voltage between 50% to 75% of full test
voltage, and three subsequent impulses at full voltage. If, during any of these applications,
an external flashover in the circuit or across a bushing spark gap should occur, or if the
oscillographic recording should fail on any of the specified measuring channels, that application
shall be disregarded and a further application made.
• Test Connections

• During test on line terminals

The impulse test sequence is applied to each of the line terminals of the tested winding in
succession. In the case of a three phase transformer, the other line terminals of the winding
shall be earthed directly or through a low impedance, not exceeding the surge impedance of the
connected line. If the winding has neutral terminal, it shall be earthed directly or through a low
impedance such as a current measuring shunt.

In the case of separate-winding transformer, terminals of windings not under test are earthed
directly or through impedances, so that in all circumstances, the voltage appearing at the
terminals is limited to not more than 75% of their rated lightning impulse withstand voltage for
star connected windings, and 50% for delta- connected windings.

In case of auto transformer, when testing the line terminal of the high voltage winding the non-
tested line terminal shall be earthed through resistors not exceeding 400 Ω to get the impulse
waveform as needed.

• Impulse test on a neutral terminal

Impulse withstand capability of neutral may be verified by :

(a) Indirect application:

Test impulses are applied to any one of line terminals or to all three line terminals
connected together. The neutral is connected to earth through an impedance or is left
open. Then standard lightning impulse is applied to the line terminal which shall not
exceed 75% of the rated LI withstand voltage of the line terminal.
(b) Direct application:
Test impulse corresponding to the rated withstand voltage of the neutral is applied directly
to the neutral with all line terminals earthed. In this case, however a longer duration of
front time is allowed, upto 13µs.
 Test Requirements for Transformers 241

• Records of test
The oscillographic or digital records obtained during calibrations and tests shall clearly show the
applied voltage impulse shape (front time, time to half value and amplitude). The oscillograms
of the current flowing to earth from the tested winding shall also be recorded.

• Test sequence

The test sequence shall consist of one impulse of a voltage between 50% to 75% of full test
voltage, and three subsequent impulses at full voltage. If, during any of these applications,
an external flashover in the circuit or across a bushing spark gap should occur, or if the
oscillographic recording should fail on any of the specified measuring channels, that application
shall be disregarded and a further application made.

Failure detection

• Grounded current oscillograms

In this method of failure detection, the impulse current in the grounded end of the winding tested
is measured by means of an oscilloscope or by a suitable digital transient recorder connected
across a suitable shunt inserted between the normally grounded end of the winding and ground.
Any differences in the wave shape between the reduced full-wave and final full-wave detected
by comparison of the two current oscillograms, may be indication of failure or deviations due to
no injurious causes. They should be fully investigated and explained by a new reduced wave and
full-wave test. Examples of probable causes of different wave shapes are operation of protective
devices, core saturation, conditions in the test circuit external to the transformer.

The ground current method of detection is not suitable for use with chopped-wave tests.

• Other methods of failure detection

Voltage Oscillograms: Any unexplained difference between the reduced full-wave and final
full-wave detected by comparison of the two voltage oscillograms, or any such differences
observed by comparing the chopped-waves to each other and to the full-wave up to the time
of flashover, are indications of failure.

Noise: Unusual noise within the transformer at the instant of applying impulse is an indication
of trouble. Such noise should be investigated.

Measurement: Measurement of voltage and current induced in another winding may also be
used for failure detection.

3.7.5 Separate Source Voltage withstand Test

• Duration, frequency and connections

A normal power frequency, such as 50 Hz, shall be used and the duration of the test shall be one
minute.
242 Manual on Transformers

The winding being tested shall have all its parts joined together and connected to the terminal
of the testing transformer.

All other terminals and parts (including core and tank) shall be connected to ground and to the
other terminal of the testing transformer.
• Application of voltage for Separate Source Withstand test
The test shall be commenced at a voltage not greater than one-third of the full value and be
brought up gradually to full value in not more than 15 s. After being held for the specified time
of 60 seconds, it should be reduced (in not more than 5s) to one third or less of the maximum
value and the circuit opened.

• Failure detection
Careful attention should be started given for evidence of possible failure that could include items,
such as an indication of smoke and bubbles rising in the oil, an audible sound such as a thump, or
a sudden increase in test circuit current. Any such indication should be carefully investigated by
observation, by repeating the test, or by other test to determine if a failure has occurred.

3.7.6 Induced AC voltage withstand tests with partial discharge measurement

ACSD test is intended to verify the AC withstand strength of each line terminal and its connected
winding(s) to earth and other windings, the withstand strength between phases and along the
winding(s) under test

As per IS 2026 Part 3 and IEC Pub. 60076-3, the test is normally performed with partial
discharge measurement (Method 2) for transformers with highest voltage winding of ≥
300 kV. For transformer with highest voltage winding of < 300 kV, the test is performed
without partial discharge measurement (Method 1). However, with the latest revision of
IEC 60076-3, the methods for induced over-voltage withstand test are reformed as AC
short duration test (ACSD) and AC long duration test (ACLD).

ACSD test is intended to verify the AC withstand strength of each line terminal and its connected
winding(s) to earth and other windings, the withstand strength between phases and along the
winding(s) under test.

For Um >72.5 kV, the test is normally performed with partial discharge measurements to verify
partial discharge free operation of the transformer under operating condition. However, the
requirements for partial discharge measurement during the ACSD test may be omitted. This
shall be clearly stated at the enquiry and order stages.

ACLD test is always performed with the measurement of partial discharge during the whole
application of test. This is test is not a design proving test, but a quality control test and is
intended to cover temporary over voltages and continuous service stress. It verifies PD free
operation of the transformers under operating conditions.
 Test Requirements for Transformers 243

An alternating voltage shall be applied to the terminals of one winding of the transformer. The
voltage shall be as nearly as possible sinusoidal and its frequency is sufficiently above the rated
frequency to avoid excessive magnetizing current during the test.
The test voltage is the peak value of voltage divided by √2 .The test time at full test voltage shall
be 60 sec for test frequency up to and including twice the rated frequency. For frequency above
twice the rated frequency the time duration of test shall be:
Rated frequency ,but not less than 15 sec
120 X
Test frequency
Table below shows the different conditions of induced AC voltage test as defined in IEC
publication 60076-3. The time duration for the application of test voltage with respect to earth
is shown in Figure 12
Table 2 :Induced AC Voltage test
Type of Type of winding Highest Test voltage level Test Remarks
test voltage of Duration
equipment (Refer Fig
Um 12)
Uniformly insulated ≤ 72.5 kV As per Table 2 of IEC 60 sec No PD measurement
60076-3

> 72.5 kV U1= from Table D.1 of C= 120 x PD level should be

IEC 60076-3 Rated Freq. ≤ 300 pC at level U2
U2= 1.3 Um/√3 Test freq.
AC Short D=5 min
duration
(ACSD) Non-uniformly insulated >72.5 kV Phase to U1=from C= 120 x PD level
earth test Table Rated Freq. should be
D.2 of Test freq. ≤ 500 pC at level U2
IEC
60076-3
U2=1.5 D=5 min
Um/√3
Phase to U1=from PD level should be
phase test Table ≤ 300 pC at level U2
D.2 of IEC
60076-3
U2= 1.3
Um/√3
Delta 72.5<Um U1= 1.7 Um/√3 D=30 min PD level should be
connected ≤ 245 kV U2= 1.5 Um/√3 C= 120 x ≤ 500 pC at level U2
HV Rated Freq.
Test freq.
Star 72.5<Um U1= 1.7 Um/√3 D=30 min PD level should be
Uniformly connected <300 kV U2= 1.5 Um/√3 C= 120 x ≤ 500 pC at level U2
AC Long and non- HV Rated Freq.
Duration uniformly Test freq.
(ACLD) insulated
≥ 300 kV U1= 1.7 Um/√3 D=60 min
U2= 1.5 Um/√3 C= 120 x
Rated Freq.
Test freq.
244 Manual on Transformers

Fig.12: Time sequence for the application of test voltage with respect to earth

Where

Um = Highest voltage for equipment

U1 = Test voltage

U2 = Partial discharge evaluation level

The detailed procedure and specific test requirements are addressed in IEC-60076-3

3.7.7 Switching ImpulseVoltage withstand Test, Transformer Winding Um < 300 kV

Refer to the clause no 3.7.3 of this Section

3.7.8 Lightning Impulse Voltage withstand Test, Transformer Winding Um < 300 kV

Refer to the clause no 3.7.4 of this Section

3.7.9 Long-duration Induced AC Voltage test (ACLD), TransformerWinding Um < 170 kV

The test procedure is same as clause 3.7.6 of this Section

3.8 Temperature Rise Test

Temperature rise test is performed to prove that temperature rise comply to limits specified in
standards and to derive thermal characteristics for the transformer.

The test is carried out supplying full load losses for sufficient time to ensure that the temperature
rise of the winding and oil reach steady state values.

The transformer shall be assembled completely with its cooling equipment. It is desirable
to put the specified conservator with the transformers, if available. Alternatively, temporary
conservator of approximately same capacity can be used for the purpose of the test.
 Test Requirements for Transformers 245

The top oil temperature is measured by a thermometer in a pocket at the top of the transformer
tank, and this is used to verify that steady conditions have been reached. Final winding
temperatures cannot be measured directly.

The transformers shall be tested in the combination of connections and taps that give the highest
winding temperature rises as determined by the manufacturer and reviewed by the purchaser’s
representative when available. This will generally involve those connections and taps resulting
in the highest losses.

All temperature rise test shall be made under normal (or equivalent to normal) conditions of the
means of cooling.

The temperature–rise test shall be made in a room that is free from drafts as practicable and
equipped with its protective device.

• Cooling air temperature

Precautions should be taken to minimise variations of cooling air temperature specially when
the steady state is approached. Rapid variation of reading should be prevented by providing at
least three sensors, and average of their readings shall be used for evaluation. The sensors shall
be distributed around the tank 1m to 2m away from the tank or cooling surface and protected
from direct radiation.

• Cooling water temperature

The temperature is measured at the intake of the cooler. Readings of temperature and rate of
water flow should be taken at regular interval.

Test Method

• Short Circuit Method

During this test the transformer is subjected to the calculated total losses, previously obtained by
two separate determination of losses, namely load loss at reference temperature and no load loss.

The purpose of this test is

- to establish the top oil temperature rise in steady-state condition with dissipation of total losses
- to establish the average winding temperature rise at rated current and with the top oil
temperature rise as determined above.
This is achieved in two steps:
(a) Total loss injection

First the top oil and average oil temperature rises are established when the transformer is
subjected to a test voltage such that the measured power is equal to the total losses of the
246 Manual on Transformers

transformer. The test current will be above rated current to the extent necessary for producing
an additional amount of loss equal to the no-load losses, and winding temperature rise will be
correspondingly elevated.

The oil temperature and cooling medium temperature are monitored, and the test is continued
until a steady- state oil temperature rise is established.

The test may be terminated when the rate of change of top oil temperature rise has fallen below
1oC per hour and has remained there for a period of 3 hour.

(b) Rated current injection

When the top oil temperature rise has been established, the test shall immediately continued
with the test current reduced to the rated current for the winding combination connected.
This condition is maintained for 1 h, with continuous observation of oil and cooling medium
temperatures.

At the end of one hour, the resistance of windings are measured with suitable method.

During the hour with rated current the oil temperature falls. The measured values of winding
temperature shall therefore be raised by the same amount as the average oil temperature rise has
fallen from the correct value. The corrected winding temperature value minus the cooling medium
temperature at the end of the total losses injection period is the average temperature rise.

By the agreement, the two steps of the test may be combined in one single application of the
power at a level between load loss and the total loss. The temperature- rise figures for the top
oil and for the windings shall then be determined using the correction rules. The power injected
during the test shall however be at least 80% of the total loss figure.

(c) Determination of average winding temperature

The average winding temperature is determined via measurement of winding resistance.

A reference measurement (R1,θ1) of all winding resistances is made with the transformer at
ambient temperature, in a steady condition. When the resistance R2 at different temperature (θ2)
is measured this yields the temperature value

R2
θ2 = R1(235+θ1) - 235
Copper:

R2
Aluminum
: 02= Rl ( 225+ θ1) - 235
The external cooling medium temperature at the time of shutdown is θa
The winding temp. rise is then, finally :
∆θw =θ2-θa
 Test Requirements for Transformers 247

(d) Determination of winding temperature before shutdown

Immediately after disconnection of test power supply and removal of short circuit connection
the resistance of winding is measured with a suitable measuring circuit. The winding has large
electrical time constant therefore accurate reading obtained only after a certain time delay. The
resistance of the winding varies with time as the winding cools down. It shall be measured for a
sufficient time to permit the extrapolation back to instant of shutdown.

The detailed procedure to determine the resistance at the instance of shutdown is accordance
with IEC-60076-2.

(e) Corrections

If the specified values of power or current have not been obtained during the test, the result shall
be corrected according to the following relation. They are valid within a range of +20% from
target value of power and +10% from target value of current.
The oil temperature rise above ambient during the test is multiplied by :
X

 Total losses 
 Test losses
X= 0.8 for distribution transformers

X= 0.9 for larger transformers with ON cooling

X= 1.0 for transformers with OF or OD cooling

The average winding temperature rise above average oil temperature during the test is multiplied by:
Y

 Rated Current 
 Test losses
Y=1.6 for ON and OF cooled transformers

Y= 2.0 for OD cooled transformers

3.9 Short Circuit WithstandTest

This test identifies the requirement for power transformer to sustain without damage the effects
of over current originated by external short-circuit. The test demonstrates the thermal ability and
dynamic effects of power transformer to withstand the rated short-circuit forces. The detailed
procedures describing the magnitude of current, test duration, no. of tests and evaluation criteria
shall be as per IEC 60076-5.

3.10 Measurement of zero–phase–sequence impedances on 3-phase transformers

• Zero–phase–sequence impedance tests of three–phase transformers
248 Manual on Transformers

The zero–phase–sequence impedance characteristics of three–phase transformers depend upon

the winding connections, and in some cases, upon the core construction. Zero–phase–sequence
impedance tests apply only to transformers having one or more windings with a physical
neutral brought out for external connection. In all tests, one such winding shall be excited at
rated frequency between the neutral and the three line terminals connected together. External
connection of other windings shall be as described in succeeding paragraphs for various
transformer connections. Transformers with connections other than as described in succeeding
paragraphs shall be tested as determined by those responsible for design and application.

The excitation voltage and current shall be established as follows:

If no delta connection is present on the transformer, the applied voltage should not exceed 30%
of the rated line–to–neutral voltage of the winding being energized, nor should the phase current
exceed its rated value. If a delta connection is present, the applied voltage should be such that
the rated phase current of any delta winding is not exceeded. The percent excitation voltage at
which the tests are made shall be shown on the test report. The time duration of the test shall be
such that the thermal limits of any of the transformer parts are not exceeded.

Single–phase measurements of excitation voltage, total current, and power shall be similar to
those described in for load loss measurements. The zero–sequence impedance in percent on kVA
base of excited winding for the test connection is:

E
Z (%)=300 E I
Ir 
 r
Where
E = measured excitation voltage
Er = rated phase–to–neutral voltage of excited winding
I = measured total input current flowing in the three parallel–connected phases
Ir = rated current per phase of the excited winding
A zero-sequence test shall be made on the winding with the available neutral. A single–phase
voltage shall be applied between the three shorted line terminal and neutral. The external
terminals of all other windings may be open–circuited or shorted and grounded.

The zero-sequence impedance is dependent upon the physical disposition of the windings and
the magnetic parts and measurement of different windings may not therefore agree.

3.11 Measurement of Acoustic Sound Level

This test shall be done in accordance with the clauses given in NEMA TR1 and IEC-60076-10.
The guidelines of testing method is given in IEC 60076-10-1

Audible sound from transformer originates principally in the transformer core and is transmitted,
 Test Requirements for Transformers 249

either through the dielectric fluid or the structural support, to other solid surfaces from which it
is radiated as airborne sound. The audible sound also contains the noise emitted by any dielectric
fluid mechanical cooling system.

Measurement should be made in an environment having an ambient sound pressure level at least
five decibels below the combined sound pressure level of the transformer and the ambient sound
pressure level.

The transformer shall be located so that no acoustically reflecting surface is within 3 m of the
measuring microphone, other than the floor or ground.

The transformer shall be connected and energised at rated voltage and rated frequency,
and shall be at no load with the tap changer on principal tap. Pumps and fans shall be
operated as appropriate for the rating being tested. Sound measurements shall begin after the
transformer being tested is energised and steady- state sound level conditions are established.
Measurements may be made immediately on the transformers that have been in continuous
operation.

The rated voltage shall be measured line-line for ∆ connected windings and line-neutral for Y
connected windings. The voltage shall be measured with a voltmeter responsive to the average
value of the voltage but scaled to read the rms value of a sinusoidal wave having the same average
value. The voltmeter should be connected between the terminals of the energized windings.

The reference sound-producing surface is a vertical surface that follows the contour of a taut
string stretched around periphery of the transformer or integral enclosure (Fig 12). The contour
shall include radiators, coolers, tubes, switch compartments, and terminal chambers, but exclude
bushing and minor extensions.

The measurement shall be done with the microphone, which shall be calibrated as recommended
by the sound level meter manufacturer before and after measurement. The first microphone
locations shall coincide with the main drain valve. The number of microphone position is not
less than 4. The microphone shall be located on the measurement surface spaced 0.3 m from
the reference sound- producing surface. When fans are in operation, the microphone shall be
located 2 m from any portion of radiators and coolers. For transformers having an overall tank or
enclosure height of les than 2.4 m, measurements shall be made at half height. For transformers
having an overall tank height of 2.4 m or more, measurements shall be made at one-third and at
two-thirds height.

The sound power rating of the transformer is determined using the following five steps:
(a) Measure ambient sound pressure level
(b) Measure combined ambient and transformer sound pressure levels
(c) Compute ambient corrected sound pressure levels
(d) Compute average sound pressure levels
(e) Calculate sound power levels
250 Manual on Transformers

The detailed calculation is done in accordance with the ANSI/IEEEC57.12.90.

The average sound level of transformers should not exceed the values given in table 0-2 through
0-4 of NEMA TR1 when measured at the factory in accordance with the conditions outlined in
ANSI/IEEEC57.12.90.

Fig. 13 Microphone location for measuring audible sound from transformers

3.12 Measurement of the Harmonics of the No-load Current

The harmonics of the no–load current in all the phases are measured by means of harmonic analyzer
and the magnitude of the harmonics is expressed as a percentage of the fundamental component.
3.13 Measurement of Power taken by the Fans and Oil Pump Motors

The measurement shall be done by suitable instruments at rated voltage.

3.14 Test with Lightning Impulse Chopped onTail

This test is a special test and should be used for special applications on the line terminals of a
winding. When this test is performed it shall be combined with the full lightning impulse test.
The peak value of the chopped impulse shall be 1.1 times the amplitude of the full impulse.

Usually the same settings of the impulse generator and measuring equipment are used, and only
the chopping gap instrument is added. The standard chopped lightning impulse shall have a time
to chopping between 2 µs and 6 µs.

The triggered type chopping gap should be used with adjustable timing, although a plain rod-rod
gap is allowed. The chopping circuit should be so arranged that the amount of over swing to
opposite polarity of the recorded impulse will be limited to not more than 30% of the amplitude
of the chopped impulse. For this purpose, it is permitted to put a resistance in service with the
chopping gap.
The test is combined with the full impulse test in a single sequence. The order of application is :
 Test Requirements for Transformers 251

one reduced level impulse

one full level impulse
one or more reduced level chopped impulse(s)
two full level chopped impulses
two full level impulses
The same type of measuring channels and oscillographic or digital records are specified as for
the full-wave impulse test.

The detection of faults during chopped impulse test depends essentially on a comparison of the
oscillographic or digital records of full level and reduced level chopped impulses. The neutral
current record presents a superposition of transient phenomena due to the front of the original
impulse and from the chopping. Account should therefore be taken of the possible variations, of
the chopping time delay.

The recordings of successive full impulse tests at full level constitute a supplementary criterion of
a fault, but they do not constitute in themselves a quality criterion for the chopped impulse test.

3.15 Magnetic Circuit (Isolation ) Test

This test is done to detect the presence of inadvertent ground if exists.
This test is done with help of megger or by AC supply. During this test other terminals should
be in open circuit position. This test is done by applying the voltage alternate between the core
clamp to end frame, core clamp to tank and between end frame to tank. The value of test voltage
is varying according the customer requirement and electrical specification. The duration of test
voltage application is 60 seconds.

Alternatively the test is performed with the help of megger. In which the value of insulation
resistance is measured between two terminals. This test shall be conducted in accordance with
IS-2026 Part 1.

The tests will be successful if the terminals withstand the required AC voltage for test duration.
The values of the insulation resistance in mega-ohm (MΩ) should as follows;

Test voltage : 2.5 kV

New equipment : > 10 MΩ
Service aged equipment : > 1 MΩ
Insulation deterioration : < 1 MΩ
Destructive circulating current : < 100 KΩ
252 Manual on Transformers

3.16 Determination of Capacitance and Dissipation Factor Between Winding to Earth

and between Windings
Capacitance and tan delta are usually determined for winding to earth and between windings by
bridge measuring technique, such as Schering Bridge.
The test specimen shall have the following requirements:
All windings immersed in insulating liquid in case of liquid filled transformer.
All winding short-circuited.
All bushings are in place.
The applied voltage for measuring capacitance and tan delta shall not exceed half of the low
frequency test voltage, for any part of the winding or 10 kV whichever is lower.
This test may be performed with or without guard for the circuit combination as shown below.
Method 1 Method II
Test without guard Test with guard
Two winding Two winding
HV to LV and ground HV to LV and ground
LV to HV and ground LV to HV and ground
HV and LV to ground HV and LV to ground
LV to ground, Guard on HV
Three winding Three winding
HV to IV, LV and ground HV to LV and ground, guard on IV
IV to HV, LV and ground HV to ground, guard on LV & IV
LV to IV, HV and ground LV to IV & ground, guard on HV
HV and IV to LV and ground LV to ground, guard on HV & IV
IIV and LV to IV and ground IV to HV & ground, guard on LV
IV and LV to HV and ground IV to ground, guard on HV & LV
IIV, IV and LV to ground HV &LV to IV & ground
HV & IV to LV & ground

• Temperature correction factors

The temperature correction factors for the insulation power factor depend upon the insulating
material, their structure, moisture, etc. Values of correction factor ‘K’ listed in the below table
are typical and satisfactory for practical purpose for use as given in equation

Test temperature T, 0C Correction Factor ‘K’

10 0.80
15 0.90
20 1.00
25 1.12
30 1.25
35 1.40
40 1.55
45 1.75
50 1.95
55 2.18
60 2.42
65 2.70
70 3.00
 Test Requirements for Transformers 253

FP20 = Fpt /K
Where,
FP20 is the power factor corrected to 20 0C
Fpt is the power factor measured at T
T is the test temperature 0C
K is the correction factor as per table above
Insulation temperature may be considered to be that of the average liquid temperature. When
insulation power factor is measured at a relatively high temperature and the corrected values
are unusually high, the transformer should be allowed to cool and the measurements should be
repeated at or near 20 0C

3.17 Magnetic Balance Test on 3-phase Transformers

This test is conducted only in three phase transformers to check the imbalance in the magnetic
circuit. In this test, no winding terminal should be grounded; otherwise results would be erratic
and confusing.

• Evaluation criteria

The voltage induced in the center phase shall be 50% to 90% of the applied voltage on the outer
phases. However, when the center phase is excited then the voltage induced in the outer phases
shall be 30 to 70% of the applied voltage.

Zero voltage or very negligible voltage induced in the other two windings should be
investigated.

The purpose of this test basically is to ensure that there is no inter turn fault in the winding which
is generally reflected in high excitation current in faulty winding.

3.18 Determination of Transient Voltage Transfer Characteristics

When the low-voltage winding cannot be subjected to lightning over voltage from the low
voltage system, this winding may, by agreement between supplier and purchaser, be impulse
tested with surges transferred from high voltage winding.

This method is also used when the design is such that an impulse directly applied to
the low voltage winding could result in unrealistic stressing of higher voltage windings,
particularly when there is a large tapping winding physically adjacent to the low voltage
winding.

With the transferred surge method, the tests on the low voltage winding are carried out by
applying the impulse to the adjacent high voltage winding. The line terminals of the low
voltage winding is connected to earth through resistance of such value that the amplitude of the
254 Manual on Transformers

transferred impulse voltage between line terminals and earth, or between different line terminal
or across a phase winding, will be as high as possible but not exceeding the rated impulse
withstand voltage. The magnitude of the applied impulses shall not exceed the impulse level of
the winding to which the impulses are applied.

The details of the procedure shall be same as the lightning impulse test on line terminal of HV
winding.

3.19 Dissolved Gas Analysis (DGA) of Oil Filled in the Transformer

• Introduction

For many years the method of analyzing gasses dissolved in the oil has been used as a tool in
transformer diagnostics in order to detect incipient faults, to supervise suspect transformers, to
test a hypothesis or explanation for the probable reasons of failures or disturbances which have
already occurred and to ensure that new transformers are healthy.

The evaluation criteria with dissolve gas analysis is based on the fact that during its lifetime the
transformer generates decomposition gasses–essential from the organic insulation – under the
influence of various stresses– both normal and abnormal.

The gasses that are of interest for the DGA analysis are the following;

- H2 Hydrogen
- CH4 Methane
- C2 H4 ethylene
- C2H6 Ethane
- C2H2 acetylene
- (C3H6 propene )– not always measure
- (C3H8 propane ) – not always measure
- CO carbon monoxide
- CO2 carbon dioxide
- O2 oxygen
- N2 Nitrogen
- TCG total combustible gas content (= H2 + CH4 + C2H4 + C2H6 + C2H2 + CO)
All these gases except oxygen and nitrogen may be formed during the degradation of the
insulation. The amount and the relative distribution of these depend on the type and severity of
the degradation and stress.

Around the world and during the years several different schemes have been proposed as
evaluation scheme for the DGA. The most commonly known schemes are the one proposed by
Rogers and the scheme laid down in IEC publication 60599
 Test Requirements for Transformers 255

• Procedure
The DGA procedure consists of essential four steps:

- Sampling of oil from the transformer

- Analysis of these gases from oil
- Analysis of the extracted gas mixture in a gas chromatography, GC.
- Interpretation of the analysis according to an evaluation scheme.
Sampling, extraction and analysis procedures are given in IEC publication 60599

• Interpretation

There are several different approaches how to explain and interpret the analyzed gas composition
and to diagnose the condition of the transformer. The well known DGA analysis techniques are

- Identification of the key gas, The key gas identify a particular problem, e.g., H2 indicates
a PD
- Determination of rations between gasses, normally between gas levels.
- Determination of rates of increase (“production rates”), in ppm / day or ml gas/day
The most common known schemes are the one proposed by Rogers forming the basis for the
ANSI method and the scheme laid down in IEC Publication 60599. Both these methods are
using ratios gas concentrations.

This scheme can also be used to understand the evaluation – scheme based on ratios.

For instance, the IEC method uses 3 ratios, C2H2/ C2H4, CH4/ H2, C2H4/ C2H6

CH4/H2 is used to discriminate between a thermal fault and an electric fault. C2H2/C2H4 indicates
the presence of a strong discharge of very severe electric problem and C2H4/ C2H6 is an indication
of the oil temperature.

3.20 Recurrent Surge Oscillographic (RSO) Test

This test is generally performed at pre-stage of transformer manufacturing after completion of

terminal gear.

The insulation of a transformer must be proportioned to the surge voltages, which will appear
at the various points throughout the windings. The surge voltage distribution in the winding is
independent of the magnitude of the applied voltage and that the same results may be obtained
by applying a reduced surge voltage, of the order of a few hundred volts.

This test is conducted with a recurrent surge generator, which consists of a capacitor charged
to a suitable voltage and discharged by means of a thyratron into a circuit which is designed to
generate the required low-voltage surge of the standard wave shape. The charge and discharge
sequence is repeated fifty times per second. The output voltage from the recurrent surge
256 Manual on Transformers

generator is applied to the terminal of the transformer being tested, in a similar manner to
that in which a high voltage impulse test would be conducted. The surge voltage appearing
at any point of the winding can be measured and displayed on the screen of the cathode-ray
oscilloscope. The time base is arranged so that it is synchronized with the recurrent discharge
of the capacitor. By this means it is possible to obtain a standing picture on the screen of the
applied voltage and of the voltage appearing at the points along the winding, together with a
time calibration wave.

The test provides information on impulse distribution along the winding and transferred surge
voltages on the other windings.

3.21 Determination of Core Hot Spot Temperature

This test is done to check uniform distribution of flux on every point on the core & to determine
the core hot spot temperature.

This test is done by exciting the core with suitable voltage, which is the voltage per turn is
multiplied with the wound turn around the core.

The required voltage is applied to transformer and note down the reading of temperature at the
different point on the core using thermo vision camera or laser temperature scanner. The reading
of the temperature should not vary too much from point to point.

If the temperature is varying from one point to other then the flux is not distributed uniformly
around the core. Scan the point around the core where the highest temperature occurs. This is
the hot spot temperature of the core.

3.22 Frequency Response Analysis (FRA)

Frequency response analysis (FRA) test is conducted on transformers & reactors to determine
the frequency response of windings. The reference frequency responses obtained during
laboratory testing serve as ‘fingerprints’ to monitor the condition of the transformer or reactor
during service.
The frequency response of an electrical winding is obtained by application of sweep frequency
(sinusoidal). The winding will have a characteristic frequency response for the applied signal
at different frequencies. The response is uniquely determined by the winding arrangement
involved and any winding movement or other fault will modify the frequency response due
to changes in inductances and capacitances. The sweep frequency voltage is applied through
network analyzers. The frequency response of the winding is determined between the frequency
ranges of 10 Hz to 2 MHz.

The FRA test is performed on one winding of the electrical equipment at a time. The
transformer / reactor shall be electrically isolated from any other electrical connections or systems,
including earth connections during FRA test. The two end terminals of each winding shall be
made available for measuring the frequency response across the winding.
 Test Requirements for Transformers 257

# For star connected winding, the response shall be measured across the terminal &
neutral.
# For delta connected winding, the response shall be measured across two line terminals &
in case of open-delta, across individual winding.
# For auto connected winding, the response of series & common windings shall be measured
separately.
For a transformer, it is normal practice to earth one end of every winding that is not being tested,
leave the other open end. Alternatively, all other windings may be left unconnected from each
other and from earth. In every case, the termination of each winding for each test should be
recorded.
The frequency response of the winding is determined by plotting the ratio of the output from the
winding to the input at atleast following frequency ranges.

* 10 Hz to 2 kHz
* 100 Hz to 20 kHz
* 1 kHz to 200 kHz
* 10 kHz to 2 MHz
Alternatively frequency ranges specified by the customer can be selected. The test is normally
conducted at maximum, mean and minimum taps, in case of windings having tapping. While
making measurements at mean tap, care should taken to move the tap from higher voltage
taps, for proper comparison of FRA results of different phases of same transformer or different
transformers.
The FRA results is analyzed for
- Changes in response of the winding
- Difference between the FRA records of different phases of the same transformer.
FRA test is primarily a condition assessment test and can be used in conjunction with other
diagnostic tests for detailed analysis and interpretation of the transformer.

3.23 Measurement of Magnetization Current at Low Voltage

This test is performed at 415 V, 3-phase (neutral un-grounded) for three phase transformer and
230 V 1-phase for single phase transformer. This test is performed to locate defect in magnetic
core structure, failures in turn insulation or problem in tap changers.

The acceptance criteria for the results of exciting current measurement should be based on the
comparison with the previous site test results or factory test results. The general pattern is two
similar high readings on the outer phases and one lower reading on the center phase connected in
star, in case of three phase transformers. An agreement to within 25% of the measured exciting
current with the previous test is usually considered satisfactory. If the measured exciting current
value is 50% higher than the value measured during pre-commissioning checks, then the winding
needs further analysis.
258 Manual on Transformers

3.24 Functional Tests on Auxiliary Equipments

Acceptance test for Oil (OTI) and winding (WTI) temperature indicator
A. Routine test

1. OTI (Range 20º-140º C)

(i) Each completely assembled instrument shall be tested for accuracy over the complete
range i.e. at 40º, 60º, 80º, 100º & 120 º C by keeping the bulb in the hot oil bath
continuously stirred. The accuracy of indication shall be ±1.5 % full scale deflection
(FSD).
2. WTI ( Range 30º - 150º C)

(i) Each completely assembled instrument shall be tested by injecting the current to its
heater coil. Oil bath shall be maintained at 60 0C, Total temperature and temperature
rise shall be recorded for 0, 2, 3 and 4 amperes current. The accuracy of the indication
i.e. oil bath temperature measured by standard. Thermometer plus rise in temperature
due to injection of current in heating coil i.e. total temperature indicated by WTI
shall be within ± 1.5 % FSD. Error allowed shall be 1.5 / 100 x 150 = ± 2.25 0C
Max.
(ii) In case of repeater, both WTI and repeater shall be tested together by injecting the
current as mentioned in 2(I). Accuracy of the repeater readings shall be within ± 1.5
FSD i.e. ± 1.5 0C considering WTI readings as the reference temperature.
• High Voltage Test on Insulation test of auxiliary wiring

Unless otherwise specified the wiring for auxiliary power and control circuitry shall be subjected
to a one minute power frequency withstand test of 2 kV r.m.s. to earth. Motors and other
apparatus for auxiliary equipment shall fulfill insulation requirements according to the relevant
IEC standard (which are generally lower than the value specified for the wiring alone, and which
may sometimes make it necessary to disconnect them in order to test the circuits)

B. Type tests (one instrument of each lot / batch)

Switch setting and operations: Switches shall be able to set between 50–140 0C and their
operation shall be within ± 2.5% of pointer indication unless otherwise specified on purchase
order. Switch setting will be done as below:

OTI: Alarm (S1) – 95 0C

Trip (S2) – 100 0C
WTI: Alarm (S1) – 115 0C
Trip (S2) – 125 0C
Fan start (S3) – 85 0C
Pump start (S4) – 95 0C
 Test Requirements for Transformers 259

Switch differential

Each switch shall have adjustable differential (difference between make and break temperature)
of 6 0C to 90 0C and will be set for 6 ± 1 0C differential.

Switch Rating

5 Ampere, continuous 250 V, AC or DC for make or break.

3.25 Tests on Oil Filled in Transformer

Following test on the oil filled in the transformer shall be necessary performed before conducting
electrical test to ensure proper oil impregnation of the insulation system.

3.25.1 Dielectric Strength

The voltage at which the oil breaks down when subjected to an AC electric field with continuously
increasing voltage contained in the specified apparatus is called dielectric strength. The voltage
is expressed in kV.

The dielectric strength of oil is determined by the two methods. First method utilizes spherical
capped electrode in the test cell, which is recommended primarily for filtered, degassed and
dehydrated oil prior to and during filling of electrical power equipment rated above 230
kV and above. The second method utilizes flat electrodes and recommended for all other
apparatus.

The detailed test procedure is in accordance with IS 6792.

The acceptance value of oil for the different test voltage of transformer in general is recommended
as per the table given below.

3.25.2 Water Content

The recommended value of water content are given in table below

System voltage of transformer BDV kV Water content Tan delta at 90° C

kV ppm, max.
Above Upto and including
- 72.5 60 20 <0.05
72.5 245 65 15 <0.02
245 420 70 10 < 0.01
420 800 75 10 < 0.01

High water content accelerates the chemical deterioration of the insulating paper and is indicative
of the undesirable operating conditions or maintenance requiring correction.
260 Manual on Transformers

3.25.3 Dielectric Dissipation Factor (Tan delta at 900C)

This test covers the determination of the power factor of new and service aged oil. This test
is used to indicate the dielectric losses in the oil when used in an alternating electric field
and of the energy dissipated as heat. A low power factor indicates low dielectric losses. It
is useful as a means to ensure that sample integrity is maintained, and as an indication of
changes in quality resulting from contamination and deterioration in service or as a result
of handling.

This test is satisfactorily performed in the field, as well as in a laboratory environment.

The detailed test procedure and test equipment shall be in accordance with IS 6262.

Acceptable limit for the dielectric dissipation factor largely upon the type of apparatus and
application. The power factor limits given for oil are based upon the understanding that this is
an indicator test for contamination by excessive water or polar or ionic materials in the oil. High
level of dissipation factor (0.5 % at 25º C) is because of contaminants may collect in the areas
of high electrical stress and concentrate in the winding. Very high dissipation factor ( > 1.0% )
in oil may be caused by the presence of free water which could be hazardous to the operation
of a transformer.

3.25.4 Resistivity

The resistivity (specific resistance) in ohm-centimeters of a liquid is the ratio of the dc potential
gradient in volts per centimeter paralleling the current flow within the specimen, to the current
density in amperes per square centimeter at a given instant of time and under prescribed
conditions. This is numerically equal to the resistance between opposite faces of a centimetre
cube of liquid.

Resistivity measurements are made at many different temperatures. But for acceptance test, it
is generally done at a temperature of 90º C, while for routine testing, it is usually made at room
temperature or 90º C. The average electrical stress to which specimen is subjected to shall not
be less than 200 V/mm nor more than 1200 V/mm. the upper limit is set with the purpose of
avoiding possible ionization if higher stresses are permitted.

The detailed test procedure is as accordance with IS 6103.

Useful information can be obtained by measuring resistivity at both ambient and at higher
temperature such as 90º C. A satisfactory result at 90º C coupled with an unsatisfactory
value at lower temperature is an indication of the presence of water or degradation products
precipitated.

3.26 Measurement of vibration on transformer tank

The vibration measurement on the completely assembled transformer is done to ascertain the
safety of the transformer against any impending mechanical damage due to looseness of the
 Test Requirements for Transformers 261

component leading to high vibrations. The vibration in the transformer caused by the attraction
between the poles at the level of each air gap. Mechanical resonance may appear in the system
formed by the core packets, the yokes and the insulating spacers. Moreover, other components
not located in the magnetic circuit can also enter into resonance, particularly some parts of the
tank, which receive impulses transmitted through oil.

For conducting vibration measurements, the transformer is energized at rated voltage and the
rated frequency. A magnetic accelerometer is fixed at the location where measurement is intended.
The vibration signal from accelerometer is transmitted to a vibration meter which indicates the
vibration level in microns. For thorough checking of vibration pattern, the transformer tank
is marked into several small sections for measurement of the highest amplitude vibrations.
The measurement shall commence after allowing minimum 30 minutes stabilization time after
energizing the transformer at rated voltage.

There is no acceptable criterion for vibrated level on a transformer. However, one should look
for only appreciable increase in the load during the test period and subsequent readings taken at
periodic intervals at site.

3.27 Vacuum Test on Transformer Tank

Vacuum test is carried out to check out any permanent deflection of flat plate after the vacuum
has been released. This test is to be carried out at test figures specified on the tank drawing.
This test is carried out on only one tank of same work order until otherwise specified by
customer.

Tank and its temporary structure are connected as given in the drawing and connect the tank to
the vacuum pumping instrument. The tank shall be capable of withstanding an absolute pressure
as stated on the drawing for at least 60 minute. During and after vacuum test we should examine
all welds for cracks. In the event of repair work, vacuum test should be repeated.

Maximum temporary deflection during test and permanent deflection after test should be
measured. Permanent deflection should not exceed the value specified in the specification.

3.28 Oil Pressure Test on Completely Assembled Transformer

This test is done after completion of all electrical and temperature rise test. Transformer with
cooling bank, bushing and other accessories shall be tested for any oil leakage at high pressure
(normal pressure plus 35 kN per sq.m measured at the base of tank) and at room temperature as
specified by customer.

The procedure for conducting this test is as follows:

1. Conservator along with the protective relay shall be disconnected.

2. Calibrated pressure gauge shall be mounted at the bottom of the tank.
3. Bushings will remain mounted however conservator along with buchholz relay shall be
262 Manual on Transformers

isolated.
4. In welded cover type construction cooler bank, bushings shall be removed but all turrets
and cover pipe work shall remain.
5. Fill the oil completely and release all trapped air.
6. The specified pressure shall be maintained for the specified test duration as specified in
the test schedule or quality plan.
7. The test duration should be at least one hour unless otherwise specified.
• Criteria for oil pressure test
During the pressure test, there shall not be any leakage. If there is pressure drop during the test
either because of some trapped air inside the transformer or due to ambient
temperature variation, the pressure shall be raised to the specified level. The unit will be
considered to pass the test only if there is no visual oil leakage. Pressure drop shall be considered
as failure of the unit in the test.
3.29 Jacking Test and Dye-penetration Test
This test is done to check out the mechanical capability of jacking pads on bottom tank of
transformer.
The procedure for conducting the above test is as follows:
1. Bring the transformer on to rail track
2. The transformer should be filled with oil.
3. Place jack under jacking pads such that the C.L. of the jack ram coincides with the jack
points on jacking pads at appropriate height.
4. connect the jacks to hydraulic pump unit
5. Raise pressure of oil slowly so that the transformer is lifted gradually.
6. Continue lifting till, the flanges of the rollers are above the R/L and its possible to turn the
wheel.
7. The transformer must be held in the raised condition for 15 minutes.
8. Lower the transformer gradually after the expiry of time period by releasing oil pressure
in stages till the wheel again rest on the rails.
The transformer jacking pads should withstand this test without any deformation or any cracks.
The dye-penetration test is done simultaneously with jacking test to check out any welding
cracks in jacking pads. This is done by applying the dye paint to the welded joints of jacking
pads. If there is no leakage of dye at welding joints, then the welded joint is perfect.
3.30 Pressure Relief Device Test
The pressure relief device shall be subjected to rising pressure (pneumatically). The pressure
at which the device operates shall be noted. The operating pressure should be less than normal
pressure plus 35 kN/m2.
 Test Requirements for Transformers 263

(B) RECOMMEND FIELD TESTS

• INTRODUCTION
Transformer is important and vital equipment between generation station and the utility and
therefore necessary to ensure its proper performance through out its service life. During
transportation, installation and service operation, the transformer may be exposed to conditions,
which adversely affect its reliability and useful life.
Field-testing and condition monitoring are the techniques to ensure good operating health of
power transformers. Interpretations are also included to provide additional information on the
particular test and to provide guidance on acceptable criteria. There is not necessary any direct
relationship between field tests and factory tests.
Interpretation of measured results is usually based on a comparison with data obtained previously
on the same unit under similar condition. It should be noted that some times the results of several
types of tests should be interpreted together to diagnose a problem. Manufactures acceptance
criteria shall also be consulted.
B.1 Dew Point Measurement for Large Transformers Filled with dry air or nitrogen filled
Large rating transformers are transported to site from manufacturing works, without oil and
filled with dry air or nitrogen due to weight limitations. Positive gas pressure is generally
maintained at 0.175 kg/m2 during transportation and storage. As the insulation of transformer is
hygroscopic, it absorbs moisture from atmosphere if positive pressure of gas is not maintained.
After arrival of transformer at site it is necessary to check the gas pressure and if it is not
positive there is every possibility that moisture must have gone inside the transformer during
transportation. To ascertain this factor and to check the dryness of the insulation, dew point
measurement is carried out at site.
Dew point is the temperature at which the water vapours present in the gas filled in the transformer
begin to condense.
It will not be possible to define a limit of dew point of nitrogen gas as dew point depends on the
ambient temperature, pressure of the gas, moisture level of cellulose insulation etc.
The procedure and acceptance limits are given in Section CC of this manual.
• ELECTRICAL TESTS
B.2 Winding Resistance Measurement
Transformer winding resistances are measured at site in order to check for abnormalities due
to loose connections, broken strands of conductor, high contact resistance in tap changers, high
voltage leads and bushings.

The resistance is measured by two methods

(a) Voltmeter Ammeter method
264 Manual on Transformers

(b) Bridge method

The detailed test procedure of above methods is same as factory testing and is covered in section
A.3.1.2 of this manual. Precautions shall be taken during field testing as given below.
The test shall be conducted at all taps of the transformer winding and the measured value shall
be converted to 75 0C.
The acceptance criterion is usually agreement to within 5% of resistance measurements
made separately on different phases, under field condition. But, for large transformers it is
recommended to compare the resistance values with original data measured in the factory and
in case of large variation, connection tightness to be checked.
The current used for these measurements should not exceed 15% of the rated current in
order to avoid heating the winding thereby changing its resistance. However, the current
should not be too small, which may not be sufficient to avoid inductive effect, due to core
magnetization
The winding resistance shall be preferably done when the difference in the top and bottom
temperature of the winding (temperature of oil in steady-state condition) is equal to or less
than 5oC.
Winding resistance measurement shall be done only after measurement of magnetization current
(excitation current), magnetic balance & SFRA. The polarity of the core magnetization shall be
kept constant during all resistance measurement. A reversal in magnetization of the core can
change the time constant and result in erroneous readings.
B.3 Vector Group and Polarity
To determine the phase relationship and polarity of transformers
The procedure to find out vector group shall be general be same as defined in section
A3.2.2.2.
(a) Connect neutral point and LV phase with earth
(b) Join 1R1 of HV and 3B1 of tertiary
(c) Apply 415V, 3 phase supply to HV terminals
(d) Measure voltage across following terminals
1R1- 1Y1, 1Y1 – 1B1, 1B1 – 1R1, 3Y1 – 1B1, 3Y1 -1Y1, 3R1-N, 3Y1 – N, 1R1- N, 2R1 – N, 2Y1-N, 2B1-N

Example 1
Connect 1U to 2U
MEASURE 1W-2V, 1W-2W, 1U-2W, 1V-2V,
1V-2W
VOLTAGE RELATION
1W-2V= 1W-2W
1W-2V< 1U-1W
1V-2V<1V-2W
1V-2V <1U-1W
Fig 1 : For HV-Delta / LV-Star Transformer
 Test Requirements for Transformers 265

Example 2

Connect 1U to 2U
MEASURE 1W-2V, 1W-2W, 1U-2W, 1V-2V,
1V-2W
VOLTAGE RELATION
1W-2W = 1V-2W
1W-2U > 1V-2U
1U-N=1U-2W+2W-N
Yd11
Fig 2: For HV-Star / LV-Delta Transformer

The test shall be conducted with three phase supply and voltmeters.

By the measured voltage data it should ensure that the desired conditions of vector group and
polarity are fulfilled.

Ensure the isolation of transformer from high voltage and low voltage side with physical
inspection of open condition of the concerned isolators. In case tertiary is also connected, ensure
the isolation of the same prior to commencement of testing.

B.4 Voltage Ratio Test

To determine the turns ratio of transformers during commissioning and periodic interval decided
by the customer for preventive maintenance

The procedure shall be following

(a) Keep the terminals of IV and LV open.

(b) Apply 3 phase or single phase supply according to the transformer type on HV
terminals.

(c) Measure the voltage ratio of HV and IV.

(d) Repeat the steps for each tap position separately.

The test shall be conducted with three phase supply and voltmeters.

Results of the transformation turns/voltage ratio are absolute, and may be compared with the
specified values measured during factory testing. One should also consider the trend of voltage
ratio values with reference to the ratio values measured during the commissioning tests.

The voltage should be applied only in the high voltage winding in order to avoid unsafe
voltage.
266 Manual on Transformers

B.5 Measurement of Magnetizing Current

This test is performed to locate defect in the magnetic core structure, shifting of windings,
failure in turn to turn insulation or problems in tap changers. These conditions change the
effective reluctance of the magnetic circuit thus affecting the current required to establish flux
in the core.

The procedure is as follows:

(a) First of all keep the tap position in the lowest position and IV and LV terminals open.
(b) Apply 3 phase 415V supply on the line terminal for 3-phase transformers and 1-phase,
230 V supply on single phase transformer.
(c) Measure the voltage applied on each phase (Phase-Phase) on line terminals and current in
each phase of the line terminal.
(d) After completion of the above steps keep the tap positioning Normal position and repeat
the steps a to c.
(e) After completion of the above steps keep the tap positioning at Highest position and
repeat the steps a to c.
(f) Repeat the test with tap position in normal position.
The test shall be conducted with single phase or three phase supply according to test requirement,
voltmeter and multimeter.
The acceptance criteria for the results of exciting current measurement should be based on the
comparison with the previous site test results or factory test results. The general pattern is two
similar high readings on the outer phases and one lower reading on the center phase, in case of
three phase transformers connected in star. An agreement to within 30% of the measured exciting
current with the previous test is usually considered satisfactory. If the measured exciting current
value is 50 times higher than the value measured during pre-commissioning checks, then there
is likelihood of a fault in the winding which needs further analysis.

Care should be taken during exciting current measurement to avoid the effect of residual
magnetism in the transformer core. The residual magnetism results in the measurement of higher
than normal exciting current.

B.6 Magnetic balance test on 3-phase transformer

This test is conducted only on three phase transformer to check the imbalance in the magnetic
circuit.
The procedure for conducting test is as follows
(a) Keep the tap in nominal tap position
(b) Disconnect the transformer neutral from ground
(c) Apply single phase 230 V across one of the HV winding terminal and neutral then measure
voltage in other two HV terminals across neutral. Repeat the test for each of the three phases.
(d) Repeat the above test for IV winding also
 Test Requirements for Transformers 267

The test shall be conducted with 230 V single phase supply and voltmeter

The voltage induced in the center phase shall be 50 to 90% of the applied voltage. However,
when the center phase is excited then the voltage induced in the outer phases shall be 30 to 70%
of the applied voltage.

Zero voltage or very negligible voltage induced in the other two windings should be
investigated.

Disconnect transformer neutral from ground and no winding terminal should be grounded,
otherwise results would be erratic and confusing.

The purpose of this test basically to ensure that there is no inter turn fault in the winding which
is generally reflected in high excitation current in faulty winding.

B.7 Magnetic circuit (Isolation) test

This test should be performed prior to a unit being placed in-service or following modifications
to the transformer which could affect the integrity of its core insulation.

Refer clause 3.15 part A of this section for test procedures and acceptance criterion.

B.8 Measurement of short circuit impedance at low voltage

To find out the short circuit impedance of transformer the measurement is performed in single
phase mode. This test is performed for the combination of two winding. The one of the winding is
short circuited and voltage is applied to other winding. The voltage and current reading are noted.

The test shall be conducted with variac of 0-280 V, 10 A, precision RMS voltmeter and
ammeter.
The acceptable criteria should be the measured impedance voltage having agreement to within 3
percent of impedance specified in rating and diagram nameplate of the transformer. Variation in
impedance voltage of more than 3% should be considered significant and further investigated.

The conductors used for short-circuiting one of the transformer windings should have low
impedance (less than 1m-ohm) and short length. The contacts should be clean and tight.

B.9 Insulation resistance measurement

Insulation resistance test are made to determine the insulation resistance from individual winding
to ground or between individual windings. The insulation resistance in such tests is commonly
measured in mega-ohms, or may be calculated from measurements of applied voltage and
leakage current.
The test is conducted with the help of Mega-ohmmeter. IR is proportional to the leakage current
through/over the insulation after capacitive charging and absorption currents become negligible
268 Manual on Transformers

on application of DC voltage. Insulation resistance shall be measured after the intervals of 15

sec, 60 sec and 600 sec. The polarization index (PI) is defined as the ratio of IR values measured
at the intervals of 600 and 60 seconds respectively. Whereas, the dielectric absorption is the ratio
of IR values measured after 60 sec and 15 sec. IR is normally measured at 5 kV DC or lower
test voltage, but the test voltage should not exceed the rated power-frequency test voltage of
transformer windings.

Polarization Index (PI) is useful parameters for logistic interpretation of IR test results. This
ratio is independent of temperature and gives more reliable data for large power transformers. A
PI of more than 1.25 and dielectric absorption factor of more than 1.3 are considered satisfactory
for a transformer when the results of other low voltage tests are found in order. PI of less than
1 calls for immediate corrective action. For bushings, an IR value of above 10000 M-ohms is
considered satisfactory.

The IR value of transformer is dependent on various factors such as configuration of winding

insulation structures, transformer oil, atmosphere condition etc. therefore, present trend is to
monitor oil characteristics for judging the condition of dryness of the transformer and not to rely
solely on absolute values of IR. It may be note that no national/international standards specify
minimum insulation resistance values of transformers. The value of IR could be even zero under
heavy fog or humid conditions.

During IR measurement, we must ensure following conditions.

- Transformer is disconnected from other associated equipment

- Bushings are cleaned and free of moisture
- Transformer tank and core are properly grounded
- Both ends of winding under test are short-circuited.
B.10 Measurement of capacitance and dissipation factor

The insulation dissipation factor (tan delta) is the ratio of the resistive current to the capacitive
current flowing through the insulation on application of sinusoidal voltage under prescribed
condition. The capacitance values are relatively independent of temperature and prevailing
atmospheric conditions. Normally low dissipation factor is indicative of problem in insulation
structure and predictive aging of insulation.

The voltage to be applied shall not exceed half of the power frequency test voltage or 10 kV
whichever is lower. Detailed test procedure is concerned under this manual earlier.

The test is conducted with high voltage supply and Schering bridge

High dissipation factor is indicative of problem in insulation structure and predictive aging of
insulation. But, the comparative values of tests taken at periodic intervals are useful in identifying
potential problems rather than an absolute value of tan delta. The initial reference can be drawn
from the tan delta values measured during factory testing.
 Test Requirements for Transformers 269

The acceptance criterion to assess the probable condition of the insulation of the transformer
is no substantial variation in the measured values of tan delta (dissipation factor) at periodic
interval when compared with previous references. For bushings, the tan delta value shall not
exceed 0.7% during operation.
Environmental factors like variation in temperature, relative humidity, surrounding charged
objects etc. have great influence on measurement of dissipation factor. Care shall be taken to
control the above factors during measurements.

B.11 Dissolved gas analysis (DGA)

Dissolved gas analysis is a well-established condition-monitoring tool for power transformers.

The method is based on analyzing the types of gases dissolved in the transformer oil and their
production rates. The relative concentration of these gases depends upon the type and severity
(energy density) of fault.

The test procedure to conduct DGA test is accordance with the IS 9434.

The main gases formed as result of thermal and electrical faults in a transformer are Hydrogen
(H2), Methane (CH4), Ethane (C2H6), Ethylene (C2H4), Acetylene (C2H2), Carbon Monoxide
(CO) and Carbon dioxide (CO2). Whereas Acetylene is mainly associated with arcing at very
high temperature ranges, Ethylene is related with hot spots and medium temperature ranges.
Hydrogen is mainly result of ‘cold’ gas plasma of corona discharges. Carbon monoxide and
carbon dioxide are the result of thermal decomposition of cellulose material.

For proper interpretation of DGA results, it is essential to collect data at periodic intervals
during the service life of the transformer and the additional information regarding age of the
transformer, past history of failures, loading pattern, history of filtration etc.

B12. Tests on oil filled in transformer as per IS 1866

Refer clause 3.25 part A of this Section

4.0 METHOD OF DECLAIRING EFFICIENCY

4.1 The efficiency to be declared is the ratio of the output in kW to the sum of the output in
kW and the following losses :
(a) No load loss, which is considered to be constant at all loads; and
(b) Load loss, which varies with load.
The total loss, on load is the sum of (a) & (b).
5.0 CALCULATION OF INHERENT VOLTAGE REGULATION

5.1 Two Winding Transformers

5.1.1 The inherent voltage regulation from no-load to a load of any assumed value and power
factor may be computed from the impedance voltage and corresponding load loss measured
270 Manual on Transformers

with rated current in the winding as follows:

Let

I = rated current in winding excited;

E = rated voltage of winding excited;

ISC = current measured in winding excited;

EZsc = voltage measured across winding excited (impedance voltage);

PSC= watts measured across winding excited;

EXSC = reactance voltage= Ö[ E2zsc-(Psc/Isc)2]

P=PSc corrected to 75 dcg. C, and from current ISC to I;

Ex=EXSC X (I/ISC)

Er = P ;
I

EX%=100EX/E;

Er%=100Er/E;

= Ia/I ; and

Ia = current in winding in excited during the short circuit test corresponding to that obtained when
loading at the assumed load on the output side and with rated voltage on the input side.
5.1.2 For rated load at unity power factor, the percentage regulation is approximately equal to:

Er + (Ex%)
2

200

5.1.3 For rated load at any power factor cosФ, the percentage regulation is approximately
equal to:

Er% cos Ф + Ex% sin Ф + (Ex% cos Ф - Er% sin Ф)2

200

5.1.4 For any assumed load other than rated load and unity power factor, the percentage
regulation is approximately equal to:

n. Er + (n. Ex%)
2

200
 Test Requirements for Transformers 271

5.1.5 For any assumed load other than rated load and at any power factor cos Ф, the percentage
regulation is approximately equal to:

(n .Er% cosφ + n. Ex% sin φ)

+ (n .Ex%cos φ - n .Er% sin φ)2

200

5.1.6 The above formula are sufficiently accurate for transformers covered by this
specification.

5.2 Three Winding Transformers

5.2.1 The formula given in 2.1 for two-winding transformers can be applied to three-winding
transformers and their regulation calculated with an accuracy comparable to that of the data
available by assuming that the currents in the windings remain constant both in magnitude and
phase angle even though the output terminal voltage change, due to the regulation, from their
no-load values.

On a three-winding transformer the no-load voltage of a winding will change with current in the
other windings (even though it remains itself unloaded).

Therefore, the voltages regulation of a winding on a three-winding transformer is expressed

with reference to its no-load open-circuit terminal voltage when only one of the other
windings is supplied and the third winding is on no-load, that is the basic voltage for each
winding and any combination of loading is the line no-load voltage obtained from its turns
ratio.

For the frequent case of two output winding (W2 and W3) and one input winding (W1) the voltage
regulation is usually required for three loading conditions, namely:

Only W2 loaded,
Only W3 loaded, and
Both W2 and W3 loaded.
For each condition two separate figures should be quoted, that is the regulation of each output
winding W2 and W3 (whether carrying current or not) for constant voltage supplied to the
winding W1.
Note:The regulation between W2 and W3 relative to each other for this simple and frequent case is implicit in the values
(W1 to W2) and (W1 to W3) and nothing is gained by expressing it separately.

5.2.2 The data required are the impedance voltage and load losses derived by testing the
three windings in pairs and expressing the results on a basic KVA, which can conveniently
be the rated kVA of the smallest winding. It should be determined from the transformer as
built.
272 Manual on Transformers

From the data, an equivalent circuit 3 winding transformer is derived as shown below:

5.2.3 The equivalent circuit is derived as follows:

Let
a12 and b12 be respectively the percentage resistance and reactance voltages referred to the base
kVA and obtained on a test, short-circuiting either winding W1 or W2 and supplying the other,
with the third winding W3 on open-circuit:

a23 and b23 similarly apply to a test on the windings pair W2 and W3 (with W1 on open-circuit);

a31 and b31similarly apply to a test on the windings pair W3 and Wj(with W2on open-circuit);

d = the sum (a12 + a23 + a31); and

f = the sum (b12 + b23 + b3I)

Then the mathematical values to be inserted in the equivalent circuit are:

Arm W1a1 = d/2 - a23, and b1 = f/2 - b23

Ami W2a2 = d/2 - a31, and b2 = f/2 - b31

Arm W3a3 = d/2 - a12, and b3 = f/2 - b12

It is to be noted that some of these mathematical values may be negative or may even
be zero (depending on the actual physical relative arrangement of the windings on the
core).
 Test Requirements for Transformers 273

For the desired loading conditions the kVA operative in each arm of the equivalent circuit is
determined and the regulation of each arm is calculated separately. The regulation with respect to
the terminals of any pair of windings is the algebraic sum of the regulations of the corresponding
two arms of the equivalent circuit.

5.2.4 The detailed procedure to be followed in the case of two output windings and one supply
winding is as follows

(a) Determine the kVA in each winding corresponding to the loading being considered.
(b) For the output windings W2 and W3, this is the specified loading under consideration;
deduce n2 and n3, where n is the ratio of the actual loading to the base kVA used in the
equivalent circuit.
(c) For the input winding W1 kVA should be taken as the vectorial sum of the outputs from
W2 and W3 windings, and the corresponding power factor and quadrature factor (sin φ)
deduced from the in-phase and quadrature components.
5.2.5 When greater accuracy is required, an addition should made to the above vectorial sum
of the outputs as follows:

Add to the quadrature component, to obtain the effective input kVA to windings W1,

b2
(output kVA from winding W2) x 100 x n2

+ (output kVA from winding W3) x W x b3 xn

100

n for each arm being the ratio of the magnitude of the actual kVA loading of the winding to the
base kVA employed in determining the network.

A more accurate solution is obtained by adding the corresponding quantities (a x n x output

kVA) to the in-phase component of the vectorial sums of the outputs, but the difference is rarely
appreciable.

5.2.6 Apply the final formula of 2.1.5 separately to each arm of the network, taking separate
values of n for each arm as defined in 2.2.5.

5.2.7 To obtain the regulation between the input winding and either of the loaded windings,
add the separate regulations determined under 2.2.6 for the corresponding two arms, noting that
one of these may be negative. (Note that the summation is algebraic, but not vectorial).
Note: A positive value for the sum determined indicates a voltage drop from no-load to the loading considered while a
negative value for the sum indicates a voltage rise.

5.2.8 Repeat the operation described in 2.2.7 for the other loaded winding.
274 Manual on Transformers

5.2.8.1 The above procedure is applicable to auto-transformers if the equivalent circuit is based
on the effective impedances measured at the terminal of the auto-transformer.

5.2.8.2 In the case of input to two windings and load from one winding, the above procedure can
be applied if the division of loading between the two supplies is known.

5.2.8.3 Example of Application to a Three-Winding Transformer. Assume that:

W1 is a 66 kV primary winding,

W2 is a 33 kV output winding loaded at 2000 kVA having a power factor cos φ of 0.8
lagging, and

W3 is a 11 kV output winding loaded at 1000 kVA having a power factor cos φ of 0.6
lagging.

The following information is available, having been calculated from test data and is related to
a base kVA of 1000:

a12 = 0.26 b12 = 3.12

a23 = 0.33 b23=1.59

a31=0.32 b31=5.08

It can be deduced that

d = 0.91 and f = 9.79

If follows, therefore, that for

W1, a1 = 0.125 and b1 = +3.305

W2 ,a2= 0.135 and b2 = -0.185

W3 , a3 = 0.195 and b3 =+1.775

The effective full load input kVA to winding W1 is:

(a) with only output = 2000 kVA

winding W2loaded at power factor 0.8 lagging.

(b) With only output = 1000 kVA

winding W3 loaded at power factor 0.6 lagging.

(c) With only output = 2980 kVA

 Test Requirements for Transformers 275

windingW2and W3 loaded at power factor 0.74 lagging.

Applying the formula of 2.1.5 separately to each arm of the network we have for the regulation
of that arms alone:

W1 under condition (a) where n1 = 2.0 is + 4.30 per cent

W1 under condition (b) where n1 = 1.0 is + 2.74 per cent

W1 under condition (c) where n1 = 2.98 is + 7.15 per cent

W2 under condition where n2 = 2.0 is - 0.005 per cent

W3 under condition where n3 = 1.0 is +1.54 per cent

Therefore, the total transformer regulation is:

For condition (a) - with output winding W2 fully loaded and W3 unloaded:

At terminals W2 - 4.30 - 0.005 = 4.295 per cent

At terminals W3 = 4.30 + 0 = 4.30 per cent

For condition (b) - with output winding W2 unloaded and W3 fully loaded:

At terminals W2= 2.74 + 0 = 2.74 per cent

At terminals W3= 2.74 + 1.54 = 4.28 per cent

For condition (c) - with both output windings W2 and W3 loaded:

At terminals W2= 7.15 - 0.005 = 7.145 per cent

At terminals W3= 7.15 + 1.54 = 8.69 per cent

 SECTION CC

Guidelines for Erection, Commissioning and

Maintenance
 SECTION CC
Guidelines for Erection, Commissioning and Maintenance
As the continuity of supply is of paramount importance in modern power systems, it is necessary
to take all possible precautions during erection and commissioning of the transformers followed
by regular preventive maintenance. This section covers erection, commissioning and maintenance
of Power and Distribution Transformers.

1.0 PACKING AND DISPATCH

1.1 After testing each transformer it shall be dispatched from the works ready for reassembly
of external components which are dismantled for facilitating transportation. According to
the transport facilities available and weight/ height restriction for the route, transformers are
transported either by rail, road or sea depending on the size of transformer. Power transformers
should be dispatched with external fittings dismantled and packed separately. However
distribution transformers can be transported in fully assembled condition.

1.2 Transformer tank is filled with oil or pure dry nitrogen/ air depending upon the transport
weight limitations. Dry air should be preferred due to safety of personnel entering inside the
Transformer. If nitrogen is used, the information shall be stenciled on the tank prominently. In
case the tank is filled with oil, sufficient space is left above the oil to take care of the expansion
of oil. This space is filled with pure dry air/nitrogen gas under atmospheric pressure. In case the
tank is filled with inert gas/nitrogen a positive pressure according to the manufacturer’s standard
practice and dew point of -50 deg C or better shall be maintained. The temperature, pressure
and dew point at the time of gas filling (reading taken after stabilization) shall be painted on the
transformer tank. External gas cylinders should be provided to make up any gas leakage during
transit for transformers having rating 50 MVA and above and voltage rating 132 kV and above.

1.3 Transformer shall be accompanied by escort decided by the manufacturers or the

customers as per the agreement. For large rating transformers of above 100 MVA the digital
impact recorders may be provided during shipment from transformer manufacturer’s works to
site. Provision of SMS alert needs to be provided during transportation and in case of any major
impact, SMS alert shall be sent to representatives of manufacturers and respective utilities. If
required by utility, GPS may also be installed on Transformers to locate the exact position during
transportation. Manufacturer shall specify the limiting values to the purchaser in advance. The
impact recorder is required to be sent back to the manufacturer for their analysis. Joint analysis
of impact recorder may also be carried out at trailer itself after receipt at site to check any
movement outside specified limit during transportation. Manufacturer shall send the analysis
report of impact recorder back to user / utility for their record. Interpretation of impact recorder
may be carried out as per standard DIN EN 13011. In case the impact recorder indicates some
serious shock during shipment, the core and coil will have to be subjected to thorough inspection
before erection. Higher impacts may also be verified with SFRA results comparison of factory
and site.

279
280 Manual on Transformers

Note:
(i) Impact recorders are attached to the main body of the transformer during transportation to monitor the
shock and impact, which the transformer may be subjected to during transportation. The impact recorder
is a electronic or mechanical recording accelerometer whose main feature is its ability to record shock and
impact from three directions axial, lateral and longitudinal.
(ii) Check at factory that impact recorders have sufficient paper, battery life and memory capacity for the
expected duration of transport.
(iii) Mount the impact recorder as low as possible near the transformer centerline. Always keep the impact
recorder axis aligned with the transformer major axis. This provides the best possible recorder data (Refer
DIN EN 13011).
(iv) For transformers with a N2 gas/ dry air pressure of 0.3 PSI, the acceptable limits of dew point shall be as
under: (Source: Courtesy BHEL, Bhopal)

Temperature of insulation Maximum Temperature of insulation in °C Maximum

in °F permissible dew point permissible
in °F dew point in °C
0 -78 -17.77 -61.11
5 -74 -15.0 -58.88
10 -70 -12.22 -56.66
15 -66 -9.44 -54.44
20 -62 -6.66 -52.22
25 -58 -3.33 -49.99
30 -53 -1.11 -47.22
35 -48 +1.66 -44.44
40 -44 +4.44 -42.22
45 -40 +7.44 -39.39
50 -35 +9.99 -37.22
55 -31 12.77 -34.99
60 -27 15.55 -32.77
65 -22 18.33 -29.99
70 -18 23.11 -27.77
75 -14 23.88 -25.55
80 -10 26.66 -23.33
85 -6 29.44 -21.11
90 -1 32.22 -18.33
95 +3 34.99 -16.11
100 +7 37.75 -13.88
110 +16 43.33 -8.88
120 +25 48.88 -3.88
130 +33 54.44 +0.55
140 +44 59.99 +5.55
 Guidelines for Erection, Commissioning and Maintenance 281

1.4 All external fitting such as Conservator, Buchholz relay, Dehydrating Breather, Turrets,
Bushings, Explosion Vent/ Pressure Relief Devices (PRDs), OLTC - Driving Mechanism and
Motor Operated Mechanism (MOM) Boxes, Marshalling Kiosks, Radiators, Rollers, Cooling
Fans, Pumps, Gasket etc., which are liable to damage in transit, shall be removed and packed
separately. All openings created on the tank by the removal of components arc blanked with
identifiable blanking plates & suitable gaskets. All openings on the fittings removed are also
closed with blanking plates & suitable gaskets.

1.5 When any internal parts like tap changers, etc., are removed for transportation, they are
dispatched in tanks filled with oil/inert gas or suitable measures taken so that they do not absorb
moisture.

• All fragile parts such as temperature indicators, oil level gauges, etc., shall be carefully
packed to avoid breakage in transit.

• All blanking plates, tank valve guards, etc., used exclusively for transport is to be
preserved in safe custody by the purchaser for future use.

1.6 Rail Transport

1.6.1 Transformers may be transported by rail / road trailers depending on size of transformer,
destination, delivery time and the route limitations. In case of transformers where the weight and
dimensions of the main body exceed limits, special well wagons are employed. Detached parts
are packed/crated and normally dispatched along with the main body of the unit, so that all the
parts are received at the destination station with the unit.

1.6.2 Loading

1.6.2.1 Most of the transformer manufacturers have their own railway siding and transformers
are loaded at their works using their cranes. In cases where separate siding facilities are not
available, road tractor-trailers are used for the transport from works to loading railway stations.
Mobile cranes and railway cranes are also used for loading the units into the wagons. In the
absence of any crane facility, the transformers are unloaded from the trailers near the railway
track into a platform of adequate height built up of wooden sleepers. Jacks and pull lifts chain
pulley block of adequate capacity are used to slide the transformer over a pair of rails placed on
the sleeper platform bridging the trailer width in full. To prevent the trailer from toppling when
the transformer is moved to the platform the stage end of the trailer is supported by a sleeper
pack. From the platform the transformer is slid onto the wagon taking care to have the rails for
the full width of wagon. The rails are greased for easy movement. The rollers of the transformer
are removed before leaving the works. While providing a sleeper stage it should slightly be at a
higher level to allow for the increase in height of the trailer while the load is released due to the
springs getting relaxed.

1.6.3 Lifting and Jacking

16.3.1 Transformers should be lifted by jacking at the jacking pads provided for the purpose
and simultaneous use should be made of all such lugs or lifting bollards in order to avoid any
unbalance in lifting. Before lifting the complete transformer it should be ensured that all cover
282 Manual on Transformers

bolts arc tightened. Apart from the main lifting points designed to take the total weight of the
unit, the transformer has subsidiary lifting points suitable for particular components only. Care
must be taken to distinguish between them. It is advisable to use a spreader between slings so
that the lift on the hooks is in the vertical direction. The slinging angle is not to exceed 60°. Safe
loads of wire ropes and the multiplying factors to be used corresponding to the lifting angles are
furnished in Fig. 1. Gunnies are used on the slings to avoid metal contact and consequent damage
to the slings.

Sale load of wire ropes Multiplying factor for different lifting angles

Dia. of wire rope (mm) Safe load (Kg) Lifting angles Multiplying factor

8 600 0 1
12 1,300 20 1.015
16 2,300 40 1.065
20 3,500 60 1.155
24 5,000
28 7,000
32 9,000
36 11,000
40 14,000
44 17,000
56 24,500
64 33,500
70 40,000

1.6.3.2 Where it is necessary to use jacks for lifting, only the Jacking pads provided for the

Lifting angle

Slinging angle

Fig. 1 Correct method of slinging