Annex (A)

Technical Specifications for

Distribution Transformers
 PART 1: GENERAL

1. Scope

This specification covers the design, manufacturing, testing, supply, delivery and
performance requirements of three phase outdoor type distribution transformers
for use in the electricity distribution networks of Iraq.

2. Standards

The equipment shall comply with the latest editions and amendments of the
international standards listed below as a minimum.

IEC International Electrotechnical Commission:

 IEC 60071: Insulation co-ordination

 IEC 60076: Power transformers
 IEC 60137: Bushing for alternating voltages above 1,000V
 IEC 60156: Method for the determination of the electric strength of
insulting oils
 IEC 60296: Specification for unused mineral insulating oils for
transformer and switchgear
 IEC 60354: Loading guide for oil-immersed power transformers
 IEC 60437: Radio interference test on high-voltage insulators
 IEC 60551: Determination of transformer and reactor sound levels
 IEC 60616: Terminal and tapping markings for power transformers
 IEC 60722: Guide to the lightning impulse and switching impulse
testing of power transformers and reactors

ISO International Organization for Standardization:

 ISO 1459: Metallic coatings - Protection against Corrosion by Hot

Dip Galvanising - Guiding Principles
 ISO 1460: Metallic coatings - Hot dip galvanized coatings on ferrous
materials. Gravimetric determination of the mass per unit
area
 ISO 2178: Non-magnetic coatings on magnetic substrates -
Measurements of coating thickness - Magnetic method
 ISO 9000: Quality management and quality assurance standards -
Guidelines for selection and use
CENELEC/CEN Harmonized European Standards:

 HD 428: Distribution Transformers

 ASTM American Society for Testing and Materials:

 D 202: Methods of sampling and testing untreated paper used for

electrical insulation.

Where any provision of this specification differs from those of the standards listed
above, the provision of this specification shall apply. In case of conflict, the order
of precedence shall be:

 This specification
 IEC standards
 ISO standards
 Other standards

Equipment confirming to alternative standards may be accepted provided it is

demonstrated that they give a degree of quality and performance equivalent or
better than that of the reference standards. Acceptability of any alternative standard
is at the discretion of the Employer.

3. Service Conditions

Transformers will be installed outdoors, at ambient conditions given below.

3.1 Outdoor

Item Description
Altitude above sea level: Up to 1,000m above sea-level
Ambient Temperature:
Maximum outdoor - shade +55 °C for 6 hours a day
Minimum outdoor -10 °C
Maximum outdoor daily average +40 °C
Maximum outdoor yearly average +30 °C
Maximum ground at depth 1 m +35 C
Maximum Black Body (black objects in direct sun) +80 C
Relative Humidity:
Maximum 92 %
Minimum 12 %
Yearly Average 44 %
Maximum wind velocity: 140 kilometre per hour
Rainfall per year:
Maximum 500 mm
Minimum 50 mm
Maximum in one day 65 mm
Yearly Average 150 mm
Subject to sand storms and
Atmosphere:
wind blown dust
Average number of days per year of dust storms 30
Average number of days per year of thunder storms 15
4. System Conditions

The network design information is as follows;

Voltage
Description
11 kV 400 V
Nominal Voltage 11 kV 400/230 V
Highest System Voltage 12 kV 416 V
Number of Phases 3 3
Frequency 50 Hz 50 Hz
Neutral Point See Note below Directly Earthed
3 Phase Short Circuit Level 25 kA 10 kA
Duration of Short Circuit 1 sec -
Insulation Levels:
Impulse 75 kV -
Power Frequency 1 min 28 kV 3 kV

Note: The 11 kV networks are normally operated with the neutral point earthed
through a resistor to limit earth fault current. However, the 11 kV networks
may also be operated with the neutral isolated from earth during abnormal
conditions. The unearthed 11 kV equipment shall be suitable for continuous
operation with an earth fault on one phase and shall be designed to withstand
the over voltage that may occur due to arcing to earth.

5. Inspection, Testing and Quality Assurance

5.1 Inspection

The Contractor shall submit a detailed program covering the design,

manufacture and testing of the Distribution Transformers within one month of
receipt of the contract award. Reports shall subsequently be submitted at
intervals, outlining progress.

The Employer or its nominated entity shall have free entry at all times, while
work on the contract is being performed, to all parts of the manufacturer’s
works which concern the processing of the work. The manufacturer shall afford
the Employer without charge, all reasonable facilities to verify that the
equipment being furnished is in accordance with this specification.

5.2 Testing

The equipment shall have been type tested and successfully passed all type tests
referred to in Part 2 “Technical”, and in the most recent editions of the standards
referenced in Clause 2. Certificates of type tests already carried out shall be
submitted with the bid for evaluation.

Fresh type tests shall be carried out if required by the Employer at an

independent certified/accredited testing laboratory and witnessed by the
Employer or some other representative acceptable to the Employer. If the
Employer wishes to witness tests, then the Contractor shall give the Employer
a minimum of one-month notice that the equipment/material is ready for
 testing. If the Employer does not indicate an intention to participate in the
testing, the manufacturer shall carry out the tests and the Contractor shall
furnish the results thereof to the Employer for review and acceptance. Cost of
type tests shall be included in the Price Schedule.

All routine tests required by the relevant standards shall be carried out even
though they are not listed in this specification, at the expense of the Contractor
and these tests shall be carried out at the manufacturer’s works. The Contractor
shall submit full details of the proposed methods of testing, including
connection diagrams to the Employer for approval, at least one month before
testing.

The Contractor shall submit to the Employer five signed copies of the test
certificates, giving results of the prescribed tests. Equipment shall not be
dispatched until the Employer has received the test certificates and the
Contractor has been informed that they are acceptable. The Employer
reserves the right to reject any item of the equipment if the test results do not
comply with the values specified or with the data given in the Schedule of
Technical Data.

5.3 Quality Assurance

The manufacturer must operate a quality assurance system that complies with
ISO 9000. The Contractor shall provide current certification showing the
manufacturers’ compliance with ISO 9000 or equivalent national standard. The
certificate must have been issued by an independent, accredited issuing
authority.

6. Spare Parts

Not required.

7. Packing, Shipping and Hazardous Substances

7.1 Packing

All equipment, including accessories, shall be packed and securely clamped

against movement in robust, non-returnable packing cases to ensure safe transit
from the manufacturer's works to the agreed point of delivery. The base of the
packing case shall be strong enough to carry the weight of the transformer and be
large enough so that no part of the transformer and accessories such as pipes,
valves, etc extends beyond the edge of the pallet.

Transformers shall be supplied filled with oil. The weight and volume of oil in the
transformer shall be clearly stated.

All the spare parts shall be packed for long storage.

Internal surfaces of equipment and accessories shall be sealed off by means of

gaskets and blanking off plates. Equipment and surfaces liable to deterioration due
 to condensation shall be protected by packs of silica gel or other approved
desiccant.

Each transformer shall have 2 suitable plywood labels tied to it on adjacent sides.
Each label shall contain the following information indelibly marked on it:

 Individual serial number

 Employer’s name
 Contract number
 Contractor's name
 Manufacturer’s name
 Description of contents
 Country of origin
 Case measurements
 Gross and net weights in kilograms
 All necessary slinging and stacking instructions

The label and ties shall be fixed such that no damage or abrasion is caused to the
paintwork.

Each transformer shall contain a fully detailed packing list in a sealed waterproof
envelope robustly attached to it. Five (5) copies of each packing list shall be sent
to the Employer prior to dispatching the equipment.

7.2 Hazardous Substances

The Contractor shall submit safety data sheets for all hazardous substances used
with the equipment. These substances shall be classified in accordance with the
European Union SI 426.

If such substances are not used in with the equipment, the Contractor shall give
an assurance that there are no substances classified as hazardous in the
equipment supplied.

8. Submittals Required by Employer after Contract Award

The Contractor shall submit a detailed programme covering the manufacture,

testing and delivery of the materials and equipment.
 PART 2: TECHNICAL

9. General

This specification covers the design, manufacturing, testing, supply, delivery and
performance requirements of three phase, 50 Hz, 11/0.416 kV distribution power
transformers with accessories.

All transformers shall have separate primary and secondary windings and be
hermetically sealed, oil immersed with natural oil and air cooling (ONAN).

The design of the tank, fittings, bushings, etc. shall be such that it will not be
necessary to keep the transformer energized to prevent deterioration as the
transformers may be held in reserve, outdoors, for many years.

10. Technical Requirements

Description Requirement
Rated Voltage HV 11 kV
LV 416 V
Frequency 50 Hz
Number of Phases 3
Power ratings 100kVA, 250 kVA, 400 kVA and 630 kVA
Type Oil immersed, hermetically sealed (bolted type)
Standard IEC 60076
Cooling Self-cooled (ONAN)
Voltage Variation Off-load tap changer with 5 positions in the HV winding
giving + 2 x 2.5 %.
Windings Copper only
Core Grain orientated silicon steel, step-lap mitered joints
HV and LV Bushings Outdoor type
Vector Group Dyn11

10.1 Rated Power

The continuous rating of the distribution Transformers shall be 100kVA, 250

kVA, 400 kVA and 630 kVA.

Each Transformer shall be capable of supplying its rated power being the product
of rated voltage and rated current on the line side winding (at center tap) expressed
in kVA, as defined in IEC 60076-1.
The transformer shall also be capable of delivering rated current at an applied
voltage equal to 105% of the rated voltage.

- Likewise, each transformer shall be capable of supplying its rated power

continuously under ambient temperature conditions without the temperature
rise of the top oil exceeding 50 C and without the temperature rise of the
windings as measured by resistance exceeding 55 C.

10.2 Overload Capacity

The transformer shall be capable of operating in accordance with the loading

guidelines of IEC 60354 without exceeding the normal daily use of life and
without the transformer winding hot spot temperature exceeding 140 C.

The Contractor shall submit calculations demonstrating that above requirements

are met. These calculations shall disregard the effect of winding thermal capacity.

Importance is attached to overload capacity. Transformers incapable of meeting

the overload performance specified will not be considered.

10.3 Impedance Voltage

The guaranteed value of impedance measured at 75 C and center tap shall be 4%

for the transformers of 100kVA, 250 kVA and 400 kVA capacities and 6% for the
distribution transformers of 630 kVA capacity and it shall be subject to the
tolerance specified in IEC 60076.

The resistance component of impedance measured at 75 C on the center tap shall

not exceed 25 % for all kVA ratings

10.4 Short Circuit Performance

The transformer shall be capable of withstanding the thermal and dynamic effects
of short circuits. System short circuit level and the withstanding duration are given
in table “system conditions” in section 3.2.

The short circuit characteristics shall be as follows;

 The X/R ratio shall conform to HD 398 / HD 428

 The initial winding hot spot temperature shall be 98 C
 The final winding hot spot temperature shall be 250 C

The ability to withstand the thermal and dynamic effects of a short circuit shall be
demonstrated in accordance with IEC 60076 and IEC 60354. Calculations / test
certificates shall be submitted for approval.
 10.5 Flux Density

The flux density at any point of the magnetic circuit when the transformer is
connected on the centre tap and operating at normal voltage and frequency shall
not exceed 1.65 Tesla. Saturation must not occur at 10 % over voltage.

10.6 Noise Level

The average noise level of the transformers shall not exceed the values given in
IEC 60551. The measurements shall be carried out in accordance with the above
standard at a distance of 300 mm from the envelope of the transformer.

10.7 Tap Changing

Characteristics

Each transformer shall be fitted with 5 taps with ± 2x2.5% voltage variation. Tap
changing and the tap changing mechanism shall have the following characteristics:

 Tap changing shall be carried out with the transformer off-load. An

externally operated self-positioning tapping switch shall be provided.
 Provision shall be made for locking the tap switch handle with a padlock
having a 6 mm diameter hasp.
 Tap changer handles shall be fitted with gasketed covers, so that sealing
of the transformer under normal conditions is independent of the switch
shaft gland.

11. Materials and Construction

11.1 Core and Coils

The HV and LV windings shall be made of high conductivity copper. Copper foil
may be used for the LV winding.

The windings shall be uniformly insulated and the LV neutral point shall be
insulated for full voltage. The insulation material of windings and connections
shall be high quality, free from insulation softening, shrinking or collapsing during
service. Moreover none of the material used shall disintegrate, carbonize or
become brittle under the action of hot oil, under all load conditions.

The core shall be manufactured from non-aging, grain-orientated silicon steel of

high permeability with step-lap mitered joints.

The core and coil assembly shall have the core and coils rigidly connected to the
tank and suitable closed lugs shall be provided for removing the core and coil
assembly from the tank.

11.2 Bushings and Terminals

All bushings shall be so designed that there will be no excessive stressing of
any parts due to temperature changes and adequate means shall be provided to
accommodate conductor expansion. Insulation levels for bushings shall be at
least equal to those specified for the windings.

The Bushings shall be so installed that they are easy to be checked and removed
without removing the tank cover and the pipe work.

The creepage distances for the bushings and the insulators shall not be less than
25 mm/kV for maximum phase to phase system voltage.

Both HV and LV Bushings shall be complete with Brass terminals suitable for
terminating Copper conductors as details given below:

 HV: outdoor bushings with clamp for terminating 50-95 mm2 Copper
Conductor
 LV: outdoor bushings with terminals suitable for terminating copper cables
as specified below.
100 kVA – 1x1C 95 mm2
250 kVA – 2x1C 95 mm2
400 kVA – 3x1C 150 mm2
630 kVA – 4x1C 150 mm2
The HV and LV bushings shall be:

 Easily replaceable and cemented in bushings are not acceptable.

 Sufficiently robust to withstand normal transport hazards.

The HV bushings shall be labeled in accordance with IEC 60076. Letters shall be
at least 12 mm high. The means of marking shall be either:

 Engraved metal plate or etched anodized aluminium. Identification by

adhesive stickers is not acceptable.
 If labeling is to be carried out on the tank, it is preferred that one plate be used
rather than individual markings for each phase, in order to prevent incorrect
phase markings.

11.3 Earthing Terminals

All transformers shall be provided with a main earthing terminal of stainless steel
welded to the tank and be fitted with a stainless steel M12 bolt, nut, spring washer
and a lock washer.

11.4 Tank Fabrication

The transformer tank shall be of rigid construction, shall not leak and shall be
designed so that the completed transformer can be lifted and transported without
permanent deformation or oil leakage. The Contractor shall state what method of
leak testing is used.

The tank shall be fabricated of mild steel or stainless steel. If stainless steel is used
it shall not discolour or corrode; a minimum grade 304 L is required.

The minimum thickness of the steel tank shall be 3 mm for mild steel and an
equivalent thickness for stainless steel such that its mechanical strength shall be
the same as that of the 3 mm thick mild steel tank. Thickness below the minimum
value will be considered only in exceptional cases, such as where special
protective finishes are used. The Contractor shall provide full information about
any such special finish, including any field experience.

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 or dust deposits can build up.

The top cover shall be of the bolted type and fitted with neoprene bonded cork
seals suitable for temperature as stipulated in this specification. Surfaces at
gasketed joints shall be such that an even face is presented to the gasket, thereby
eliminating the necessity for the gasket to take up surface irregularities.

The cooling surfaces may be oil filled fins or radiators. Only larger faces of the
transformer shall be used to attach cooling surfaces.

All pipes and radiators, which are welded to the tank wall, shall be welded
externally.

100kVA, 250 kVA and 400 kVA transformers shall be pole mounted and 630 kVA
transformers shall be wheel mounted. Skids shall be aligned at right angles to the
line of the HV bushings.

11.5 Surface Treatment

The transformer tank, radiators and accessories should be adequately protected

against corrosion and the Contractor shall submit details of the proposed method
of protection.

All surfaces shall be thoroughly cleaned of rust, scale, grease and dirt and other
foreign matter and all imperfections shall be removed by means of approved
methods.

The transformer tank and its steel attachments shall be hot dip galvanized or
metallized, followed by painting. The painting system used should be proven and
documented.

The outside of the tank shall be painted Gray.

The inside of the tank shall be painted with an approved oil resisting varnish so
that the oil cannot come into contact with the tank metal at any time.
 11.6 Tank Fittings and
Attachments

The following fittings and attachments shall be provided in all transformers:

 Tap changer (off-circuit with pad lockable switch)

 HV bushing assembly
 LV bushings assembly
 Oil filling and drain valves
 Main earthing terminal
 Lifting eyes pulling eyes and jacking pads
 Stainless steel engraved rating and connection plate in both Arabic and
English languages
 Pressure relief valve
 Protecting irons
 Oil level indicator
 Terminal marking

11.7 Transformer Assembly

The core and winding shall be dried in a vacuum drying oven. The heating and
vacuum drying cycle shall be approved by the Employer. The tank, complete
with core and windings, shall be filled with oil under a vacuum.

11.8 Transformer Oil

The transformers shall be supplied filled with class 1 mineral oil conforming to
IEC 60296. The Contractor shall submit a detailed specification for the type of oil
proposed. The oil shall not contain polychlorinated biphenyls (PCB). The
Employer may require evidence that the oil is not contaminated by PCB. If an anti
oxidant is recommended, its use shall be subject to the Employer's approval.

12. Transformer Losses

The Contractor shall state the guaranteed losses. No positive tolerance is allowable
on the guaranteed values. Transformers supplied with losses exceeding the
guaranteed values will be rejected.

The Contractor shall also state the value of guaranteed magnetizing current,
subject to the tolerance specified in IEC 60076.

12.1 Loss Evaluation

The admissible tolerances for component and total losses of transformer after
testing shall be according to IEC 60076.

The Employer may at its sole discretion reject any transformer with Copper losses
or Iron losses exceeding the relevant tolerances.
 For the purpose of evaluation the transformer shall be evaluated according to the
total price plus the capitalized value of losses. The formula to be used in evaluation
will be:

Capitalized Cost = $T + (Fe x $5,000) + (Cu x $1,200) Where,

$T = The total cost of the transformer as tendered.

Fe = No load loss in kW
Cu = Load loss in kW at full rated load and maximum operating
temperature.

13. Tests

The tests listed hereinafter shall be carried out in accordance with provisions in
the referenced standards in the specification.

13.1 Routine Tests

Routine tests shall be carried out on all transformers and the tests shall be
conducted in accordance with IEC 60076 /other standards as applicable.

The following routine measurements and tests shall be carried out:

 Measurement of winding resistance

 Measurement of voltage ratio and check of polarity and vector group
 Measurement of impedance voltages
 Measurement of load losses
 Measurement of no load losses and no load current, including
measurement of harmonics
 Induced overvoltage withstand test
 Separate source voltage-withstand tests on HV and LV windings
 Bushing routine tests
 Oil leakage test
 Relief Device test
 Dielectric Routine Tests
 Galvanizing tests.

13.2 Type Tests

Following shall be regarded as type tests:

 Temperature Rise Test. This test shall be carried out on the tap
having maximum losses
 Short Circuit Withstand test
 Measurement of zero-sequence Impedances
 Impulse Voltage Test and Power Frequency Test
  Acoustic Sound Level Measurement
 Tank Vacuum Test
 Measurement of Harmonic Level in no load condition
 Oil Analysis
13.3 Galvanizing Tests

Galvanizing tests shall be carried out on transformer tanks prior to painting. Those
shall be routine tests, which shall be part of the routine tests documentation and
shall not be charged to the Employer. Testing shall be in accordance with ISO
1460 and is summarized as follows.

The following tests, measurements or inspections shall be carried out on each of

the selected samples:

 Visual inspection
 Thickness of galvanizing coat
 Uniformity of galvanizing coat

In the event of disagreement or dispute over the results of the above tests a coating
mass test shall be carried out. The result of this test shall be definite and binding.

14. Label and Rating Plates

Labels, name plates, markings and instructions shall be clear and indelible and
in the English language. A weatherproof rating plate shall be provided in
accordance with IEC 60076 and showing the following items, indelibly marked:

- Type of transformer
- Specification to which standard it was manufactured
- Manufacturer’s name
- Serial number
- Year of manufacturer
- Number of phases
- Rated power
- Rated frequency
- Rated voltage
- Rated currents
- Vector group
- Percentage impedance voltage at rated current
- Type of cooling
- Continuous ambient temperature at which ratings apply
- Top oil temperature rise at rated load
- Total weight
- Volume of oil
- Weight of core and windings
- Table of primary voltages at the 5 tapping positions
 - Connection diagram
- Employer’s name

SCHEDULES TO BE COMPLETED BY THE BIDDERS

Technical Data Schedule

The following Technical Schedule shall be filled out for the transformer rating.

Technical Data Schedule for 630 kVA Distribution Transformer

# Description Unit Data

1 International standards transformer complies with -
2 Nominal frequency Hz
3 Rated Power kVA
4 Nominal primary voltage kV
5 Nominal secondary voltage V
6 Rated primary voltage kV
7 Rated secondary voltage V
8 Type of cooling -
9 Vector group -
10 Number of steps ± steps
Tap changing
Tapping range ±%
11 Current kA
Rated short circuit current
12 and withstanding duration Duration s
13 Impedance measured at 75 C and center tap %
14 X/R ratio -
C
25 % overload
minutes
15 Duration of overload
C
50% overload
minutes
16 Design maximum outdoor temperature C
17 Design continuous ambient temperature C
18 Average winding temperature rise C
Maximum average temperature rise C
Thermal Characteristics
Maximum hot spot temperature rise C
Hot-spot to top-oil temperature gradient C
19 Magnetic flux density Tesla
20 Core Losses W
21 Winding losses W
22 No load current A
23 Regulation: full load, PF=1 %
# Description Unit Data
full load, PF=0.85 %
24 Manufacturer
Type and grade
Silicon steel Operating flux density Tesla
Losses kW/kg at operating flux density kW/kg
Manufacturer’s data sheet supplied Yes/No

# Description Unit Data

25 Manufacturer/Supplier and type
Conductor for HV winding Conductor Material
Shape and cross sectional area
26 Manufacturer/Supplier and type
Conductor for LV winding Conductor Material
Shape and cross sectional area
27 Manufacturer/Supplier
HV Bushing Type and grade
Bushing catalogue number
28 Manufacturer/Supplier
LV Bushing Type and grade
Bushing catalogue number
29 Bushing basic impulse
HV Bushing kV
level
30 HV Bushing kV
Bushing power frequency
withstand voltage LV Bushing kV
31 Type and metal used in HV terminal
Terminals Type and metal used in LV terminal
Type of metal used in Earth terminal
32 Minimum phase to phase clearance mm
33 Minimum phase to earth clearance mm
34 Spring and lock washers included Yes/No
35 Manufacturer/supplier
Type
Tap changer
Catalogue details attached Yes/No
Manufacturers data sheet attached Yes/No
36 Can tap changer switch be locked Yes/No
37 Tank material
Tank Fabrication Thickness of the metal sheet
Painting method details attached Yes/No
38 Tank Dimensions Width mm
 Height mm
Depth mm
39 Weight of core and windings kg
Weight of tank kg
Transformer weights Weight of oil at 20 C kg
Total weight of transformer, ready for kg
service
Shipping weight of transformer kg

Signature: ___________________ Company Seal