BUREAU OF INDIAN STANDARDS OFFICE ORDER. Subject: Preparation of Product Manuals by RO/BOs by Custodian BOs

Transcription

1 BIS/DGO( 428 )/ January 2015 BUREAU OF INDIAN STANDARDS OFFICE ORDER Subject: Preparation of Product Manuals by RO/BOs by Custodian BOs Attention of RO/BOs is drawn towards Cl.10.1 of DGO(404) whereupon it was informed that the structure of Product Manual was under consideration. The structure of Product Manual has now been approved by Competent Authority and is available at Annexure-A. The format is to be used by custodian BOs in preparing the Product Manuals. A typical Product Manual based on the structure of the format approved by the Competent Authority for Transformers as per IS 1180 (Part 1) has been drafted by CMD-II and enclosed at Annexure-B for perusal and guidance of RO/BOs (the same however needs to be modified by the Custodian BO and approval sought as per the office order). It has further been decided that all Product Manuals (under preparation/already prepared) shall be restructured using format given under Annexure-A and finalized after following the procedure given in DGO(404). The responsibility for preparation of Product Manual for new products under certification shall be done as per DGO(404). As and when the software is made operational by ITS, necessary inputs should be done in the software by the Custodian BOs. All Product Manuals for existing products under Certification Marks scheme are to be hosted on Intranet/Website latest by 30 June The responsibility adhering to the deadline shall lie with custodian BO and this should be monitored by PCO of the Region. RO is requested to forward the BO-wise list of IO assigned the responsibility of preparation of product Manual by 20 Jan Any difficulty encountered shall be brought to the notice of concerned DDGR. A compliance report in this regard shall be sent to CMD-II by the concerned PCO(ROs) on 01 July This is for information and necessary action by all concerned. This issues with the approval of Competent Authority Sd/ Ref.:CMD-II(L)/7 (V.K. Diundi ) Sc.F & Head Circulated to all Custodian BOs Copy to : 1. All DDGRs 2. PCO(RO)s 3. ITS - for hosting on Intranet and for preparation of software for preparation of Product Manual.

2 PRODUCT MANUAL (First Version) TITLE: IS NO: No. of Amendments: Custodian BO: Date of Issue: BUREAU OF INDIAN STANDARDS MANAK BHAWAN, 9, BAHADUR SHAH ZAFAR MARG, NEW DELHI

3 DISCLAIMER The use of Standard Mark is governed by the provisions of the Bureau of Indian Standards Act, 1986 and the Rules and Regulations made thereunder. The details of conditions under which the licence for the use of the Standard Mark may be granted to manufactures or producers may be obtained from the Bureau of Indian Standards. This Product Manual document is provided for informational purposes and should be used for reference purposes only. The document may be used by prospective applicants desirous of obtaining BIS certification licence. This Product Manual shall also be used as reference material by all Regional / Branch Offices & licensees to ensure coherence of practice and transparency in operation of BIS certification licence.

4 1. Title of the latest Indian Standard, IS Number & Total number of Amendments TITLE: IS NO: No. of Amendments:

5 2. LIST OF REFERRED STANDARDS IS No. Title

6 3. INTRODUCTION Objective: This Product Manual on Indian Standard IS 1180 (Pt1): Outdoor Type Oil Immersed Distribution Transformers Up to And Including KVA, 33KV provides all important information / elements needed for grant of a product certification licence and its continued operation and can be used by prospective applicants desirous of obtaining BIS certification licence. This Product Manual shall also be used as reference material by all Regional / Branch Offices to ensure coherence of practice and transparency. This will also help in having a uniform and transparent approach in processing of application for grant of licence and its operation The Product Manual will serve as an important guide for all stakeholders including licensees & applicant desirous of obtaining BIS Certification licence. General : A brief description of the Indian Standard applicable for the product and other provisions of relevance shall be indicated.. Important provisions which are of significance shall also be provided..

7 4. REQUIREMENTS OF THE STANDARD 4.1 Grade /Class/ Rating/ Variety/ Size as per Standard Grade Class Rating Variety Size Any other 4.2 Clause Wise Requirements Clause wise Requirements for Type/ Grade/ Variety Sl.N Clause No. o. RAW MATERIALS Raw Material Test Method (Clause/Reference) Critical/ Non Critical Remarks GENERAL Tests ROUTINE TESTS TYPE TESTS SPECIAL TESTS / ADDITIONAL TESTS/ OPTIONAL TESTS / MUTUALLY AGREED TEST Critical/non-critical to be decided for operation of BIS licence, irrespective of whether the Critical/non-critical parameters are defined in product standards or not.

8 4.2.2 Add on provisions for more type/grade/variety/ etc, if required Hygienic Conditions (applicable to food products) In case of food industries the hygienic conditions required as per the relevant clause of the standard to be to be maintained by the firm shall be given. 5. GROUPING GUIDELINES Group Remark 2 Sl no Grade / variety Type/Class Rating Size Justification 3 as per Standard 1 as per Standard 1 as per Standard 1 as per Standard 1 1 Group1 2.. Group Note : 1. All Type/Grade / Class / Rating / variety as per Standard has to be covered 2. Any specific instruction (if any) shall be given in remark column e.g relaxation for covering less stringent grade/variety / Size / thickness if more stringent grade / variety / higher / lower size / thickness is drawn. 3. Justification shall be given for grouping the types/grades / Class / Rating / variety / sizes 4. Intention shall be to draw less number of sample and cover maximum numbers of grade / variety / size based on criteria of most stringiest. 5. Grade/Size/Class/variety other than specified in standards or non standard size (e.g- which may be supplied as per mutual agreement between manufacturer and purchaser) shall not be endorsed in licence and hence shall not form part of grouping guideline. 6. SCOPE OF THE LICENCE A description of what should be in a typical licence document shall also be clearly spelt out. Specimen contents of a typical licence documents shall be given. Details of the scope of licence to be indicated, mentioning that Licence shall be granted with the following scope: Name of the Product Type Class Grade Sizes Any other aspect required as per the Standard As per IS-----

9 7. Infrastructure for Production 7.1 Description of Plant & Machinery A typical list of manufacturing machinery and equipment is given below for guidance as a minimum requirement. Alternative machinery may be used based on advancement of technology by various manufacturers which may be built into this manual from time to time". PROCESS 1 Sl No Description of Machinery Capacity Remarks PROCESS 2 Sl No Description of Machinery Capacity Remarks PROCESS Sl No Description of Machinery Capacity Remarks

10 7.2 Manufacturing Process A brief write-up of a typical manufacturing process indicating the involvement of machineries and its utility in the process, in-process controls exercised at various stages, etc to be provided. 7.3 Manufacturing Process Flow Chart A flow diagram for manufacturing process to be provided

11 8. Infrastructure for Testing Complete test facility for all the requirements covered under Routine Tests shall be available with the firm. For other tests, test report of conformity from BIS recognized/group-2 category of laboratories as per the frequency of STI shall be produced by the licensee to BIS (where in-house test facilities are not available for these tests and relaxation as given by BIS). A typical list of test equipment is given below for guidance as a minimum requirement. Alternative test equipment may be used based on advancement of technology which may be built into this manual from time to time based on revision / amendment in Indian Standard. Requirement Clause of Standard Frequency per Control Unit Importance of test requirement Test Equipment Least Count & Range Frequency of Calibration Approx Cost of test equipment In-house arrangement Or Outside Laboratory General Requirements Routine Test

12 Type Test Special Tests / Additional Tests/ Optional Tests / Mutually Agreed Test

13 9. CONTROL UNIT : The control unit shall be defined depending upon the type of process. This shall be suitably defined for level of controls to be exercised for the production.

14 10. TEST RECORDS TO BE MAINTAINED BY FIRM Format I Class / Type Group / Rating/ Size Important Parameters Date of manufacture Control Unit Quantity Under the Control Unit Quantity marked with Standard Mark Parameter x1 Parameter x2 Parameter x3 Parameter x4 Parameter x5 Parameter x6 Parameter x7 Parameter x8 Parameter xn Frequency Frequency Frequency Frequency Frequency Frequency Frequency Frequency Frequency Test result Test result Test result Test result Test result Test result Test result Test result Test result Other Parameters Date of manufacture Control Unit Quantity Under the Control Unit Quantity marked with Standard Mark Parameter x1 Parameter x2 Parameter x3 Parameter x4 Frequency Frequency Frequency Frequency Test result Test result Test result Test result

15 Format 2 S.No Batch No & Date of Manufacture Total Quantity Manufactured under the Control Unit Total Quantity Marked under the Control Unit Quantity found Non conforming Segregation / Disposal of Non Conforming product Dispatch details Bill No Date Name and address of the consignee(s) Quantity (with Batch No.) Dispatched with Standard Mark Balance in stock Format 3 RAW MATERIAL (Outside testing) Sl No Date of receipt Name of the Raw Material Source In case ISI marked raw material -No of the corresponding IS Number & Licence No In case Testing done from Outside Laboratory Name of Lab Sample sent On TR No & date In case Non ISI raw material & accompanied by Test Certificate- Test Certificate No & Date Results Remarks

16 Format 4 RAW MATERIAL (In house Testing) Sl No Date of receipt Name of the Raw Material Source Test Results of In house Testing Remarks Date of Testing IS No Clause Result

17 11. MARKING AND LABELLING REQUIREMENTS Marking & labeling shall be defined as per the requirement of standard and Scheme of Testing & Inspection. 12. PRODUCT SAMPLE SIZE AND TEST REQUEST Quantity of sample Qty of sample required for testing to be indicated. Manner of packing (to avoid contamination/ damage during transit) Details to be Indicated in test Request 1. Size / Class / Grade/ Rating 2. Keeping Quality, Shelf life, Type of killing etc.. 3. Declaration / manufacturer specified value 4. Drawings 5. Special Test/Optional Test (if any) or any any other requirement required to be tested Instruction to Lab Any specific instruction or information to lab regarding testing of sample may be given here Manner of sealing Instruction for re removing / defacing label and/or manufacturer's identification Mechanism for dealing with the remnants of sample to be indicated- In case sample is required to be returned back to certified body/ applicant, the same shall be indicated RAW MATERIAL SAMPLE SIZE AND TEST REQUEST Quantity of sample Qty of sample required for testing to be indicated. Manner of packing (to avoid contamination/ damage during transit) Details to be Indicated in test Request 1. Size / Class / Grade/ Rating 2. Keeping Quality, Shelf life, Type of killing etc..

18 3. Declaration / manufacturer specified value 4. Drawings 5. Special Test/Optional Test (if any) or any any other requirement required to be tested Instruction to Lab Any specific instruction or information to lab regarding testing of sample may be given here Manner of sealing Instruction for re removing / defacing label and/or manufacturer's identification Mechanism for dealing with the remnants of sample to be indicated- In case sample is required to be returned back to certified body/ applicant, the same shall be indicated

19 13. PRODUCT SPECIFIC GUIDELINES (If any) Product specific guidelines if issued shall be provided under this item 14. GUIDELINES FOR ASCERTAINING CONFORMITY OF PRODUCT AT THE TIME OF GRANT OF LICENCE 15. GUIDELINES FOR ASCERTAINING CONFORMITY OF PRODUCT BY WAY OF INDPENDENT TESTING DURING OPERATION OF LICENCE GENERAL Clause Requirement Periodicity of testing the requirement in Independent Testing ROUTINE TEST Clause Requirement TYPE TESTS: To be carried out at the first instance and whenever there is any change in design Clause Requirement SPECIAL TEST (If applicable, as agreed between purchaser and manufacturer) 16. GUIDELINES FOR OPERATION OF LICENCE IN CASE LICENCE BEING OPERATED BASED ON FACTORY TESTING 17. GUIDELINES TO ENSURE CONFORMITY OF RAW MATERIAL DURING GRANT OF LICENCE 18. GUIDELINES TO ENSURE CONFORMITY OF RAW MATERIAL DURING OPERATION OF LICENCE In cases where licences are being operated based on factory testing only, guidelines to be provided.

20 19 MARKING FEE # Unit Unit rate Marking Fee (Minimum) Large scale Marking Fee (Minimum) Small scale MF Rates effective from 20. TEST REPORT 20.1 TEST(S) TO BE CARRIED OUT DURING REGULAR SURVEILLANCE All requirements as far possible to be tested during regular surveillance is to be indicated TEST(S) TO BE CARRIED OUT DURING ROM VISIT All requirements as far possible and requirements which has failed TEST REPORT PERFORMA (To be linked with test report format of T &C) 21. SCHEME OF TESTING & INSPECTION

21 PRODUCT MANUAL (First Vesion) TITLE: OUTDOOR TYPE OIL IMMERSED DISTRIBUTION TRANSFORMERS UPTO AND INCLUDING 2500 KVA, 33KV SPECIFICATION - (PART 1) MINERAL OIL IMMERSED IS NO: 1180 (Part 1):2014 No. of Amendments: NIL Custodian BO: Date of Issue: BUREAU OF INDIAN STANDARDS MANAK BHAWAN, 9, BAHADUR SHAH ZAFAR MARG, NEW DELHI

22 DISCLAIMER The use of Standard Mark is governed by the provisions of the Bureau of Indian Standards Act, 1986 and the Rules and Regulations made thereunder. The details of conditions under which the licence for the use of the Standard Mark may be granted to manufactures or producers may be obtained from the Bureau of Indian Standards. This Product Manual document is provided for informational purposes and should be used for reference purposes only. The document may be used by prospective applicants desirous of obtaining BIS certification licence. This Product Manual shall also be used as reference material by all Regional / Branch Offices & licensees to ensure coherence of practice and transparency in operation of BIS certification licence.

23 1. Title of the latest Indian Standard, IS Number & Total number of Amendments TITLE: Outdoor Type Oil Immersed Distribution Transformers upto and including 2500 KVa, 33Kv Specification - (Part 1) Mineral Oil Immersed IS NO: 1180 (Part 1):2014 No. of Amendments: NIL

24 2. LIST OF REFERRED STANDARDS IS No. 191: 2007 Copper 335 : 1993 New insulating oils 554 : 1999 Pipe Threads Where Pressure-Tight Joints are Made on the Threads - Dimensions, Tolerances and Designation 1576 : 1992 Solid pressboard for electrical purpose 1608 : 2005 Mechanical testing of metals tensile Testing 1747 : 1972 Nitrogen 1885 (Part 38) : 1993 Electrotechnical vocabulary: Part 38 Power transformers and reactors 1897 : 2008 Copper strip for electrical purpose Title 2026 Power transformers : (Part 1) : 2011 General (Part 2) : 2010 Temperature rise (Part 3) : 2009 Insulation levels, dielectric tests and external clearances in air (Part 5) : 2011 Ability to withstand short circuit (Part 8) : 2009 Application guide (Part 10) : 2009 Determination of sound levels 2099 : 1986 Bushings for alternative voltages above volts 3024 : 2006 Grain oriented electrical steel sheets and strips 3347 Dimensions for porcelain transformer bushings for use in lightly Polluted Atmospheres (Part 1/Sec 1) : 1979 (Part 1/Sec 2) : 1979 (Part 2/Sec 1) : 1979 (Part 2/Sec 2) : 1979 (Part 3/Sec 1) : 1988 (Part 3/Sec 2) : 1988 Part 1: Up to and including 1 kv: Section 1 Porcelain parts Part 1: Up to and including 1 kv: Section 2 Metal parts 3.6 kv Bushings : Section 1 Porcelain parts 3.6 kv Bushings: Section 2 Metal parts 17.5 kv Bushings: Section 1 Porcelain parts 17.5 kv Bushings: Section 2 Metal parts (Part 4/Sec 1) : kv Bushings: Section1 Porcelain parts (Part 4/Sec 2) : kv Bushings: Section 2 Metal parts (Part 5/Sec 1) : kv Bushings: Section 1 Porcelain parts (Part 5/Sec 2) : kv Bushings: Section 2 Metal parts 3639 : 1966 Fittings and accessories for power transformers 4253 (Part 2) : 2008 Cork composition sheet- Part 2 Cork and Rubber 6162 Paper-covered aluminum conductors Round conductors (Part 1) : (Part 2) : 1971 Rectangular conductors 7404(Part1) : 1991 Paper covered copper conductors: Part 1 Round conductors

25 7421 : 1988 Porcelain bushings for alternating voltages up to and including 1000 V 8999 : 2003 Pipe Threads where Pressure-Tight Joints are Made on the Threads - Verification by Means of Limit Gauges 9335 (Part 1) : 1979 Cellulosic papers for electrical purposes:definitions and general requirements (Part 2) : 1998 Methods of test (Part 3/Sec 1) : 1984 Specifications for individual materials, Section 1 General purposes electrical paper (Part 3/ Sec 3) : 1984 Specifications for individual materials, Section 3 Crepe paper (Part 3/ Sec 5) :1985 Specifications for individual materials, Section 5 Special papers : 1984 Specification for rubber gaskets : 1988 Continuously cast and rolled electrolytic copper wire rods for electrical Conductors 13730(Part 0/Sec 3) : 2012 Specification for particular types of winding wires: General requirements Section 3: Enameled round copper wire ( Part 17) : 1996 Polyvinyl acetal enameled rectangular copper wire, Class 105 (Part 27) : 1996 Paper covered rectangular copper wire : 2013 Insulating liquids - Specification for unused synthetic organic esters for electrical purposes

26 3. INTRODUCTION Objective: This Product Manual on Indian Standard IS 1180 (Pt1): Outdoor Type Oil Immersed Distribution Transformers Up to And Including KVA, 33KV provides all important information / elements needed for grant of a product certification licence and its continued operation and can be used by prospective applicants desirous of obtaining BIS certification licence. This Product Manual shall also be used as reference material by all Regional / Branch Offices to ensure coherence of practice and transparency. This will also help in having a uniform and transparent approach in processing of application for grant of licence and its operation The Product Manual will serve as an important guide for all stakeholders including licensees & applicant desirous of obtaining BIS Certification licence. General : Transformers are the crucial and key power system equipments in the electricity distribution network. The reduction in total load loss and constant no-load electrical loss assume importance, considering the fact that total number of distribution transformers in the electricity network is quite large and these equipments are constantly under operation. Apart from this energy conservation aspect, another critical facet is the reliability of the equipment in ensuring uninterrupted power supply. Thus, the longevity of the distribution transformer is quite an important attribute to realise the goal of having a reliable power system network. Distribution Transformer Industry in the country has progressed a lot over the years. In view of the importance of conservation of energy, minimum energy performance standards for distribution transformers right up to 2500 KVA 3 phase ratings as well as single phase high voltage distribution transformers up to 25 kva has been specified in certain regulation. Indian Standard IS 1180 (Pt1): Outdoor Type Oil Immersed Distribution Transformers Up to And Including KVA, 33KV Specification specifies the requirements and tests which include standard loss levels of mineral oil immersed, natural air-cooled, outdoor type, and double wound distribution transformers for use in power distribution systems with nominal system voltages up to and including 33 kv and of following types and ratings: a) Three phase ratings up to and including 200 KVA both non-sealed type and sealed type. b) Three phase ratings higher than 200 KVA, up to and including KVA both nonsealed type and sealed type. c) Single phase ratings up to and including 25 KVA sealed type.

27 This standard recommends multiple rating with regard to Energy Efficiency that is, three energy efficiency levels: level 1, level 2 and level 3 of transformers based on the maximum total loss. It is expected that transformers shall conform to at least energy efficiency level 1. In due course of time with improvements in technology and materials, higher levels of energy efficient transformers shall be progressively used..

28 4. REQUIREMENTS OF THE STANDARD 4.1 Grade /Class/ Rating/ Variety/ Size as per Standard Three Phase Sealed Type and Non sealed type (up to and including 200kVA) Nominal System Voltage kva Rating Up to and including 11 kv 6.3, 10, 16, 20, 25, 40, 63, 100, 160 and 200 Above 11 kv &Up to & including 22 kv 63, 100, 160 and 200 Above 22 kv & Up to & including 33 kv 100, 160 and 200 Three Phase Sealed Type and Non sealed type (above 200 kva up to and including 2500kVA) Single phase transformer (Sealed Type) Up to and including 11 kv 250, 315, 400, 500, 630,1000, 1250, 1600, 2000 and 2500 Above 11 kv &Up to & including 22 kv 250, 315, 400, 500, 630, 1000, 1250, 1600, 2000, and 2500 Above 22 kv & Up to & including 33 kv 250, 315, 400, 500, 630, 1000, 1250, 1600, 2000, and kV 5, 10, 16 and 25 22kV 10, 16 and 25 33kV 16 and 25 Note 1: Rated Basic Insulation Level shall be as per Table 2, 5 & 8 of IS 1180 (Part 1) Note2: Maximum Total Losses up to 11KV Class Transformer shall be as per Table 3, 6 and 9 of of IS 1180 (Part 1)

29 4.2 Clause Wise Requirements Clause Wise Requirements Three Phase Sealed Type and Non sealed type (up to and including 200kVA) Sl.N Clause No. o. RAW MATERIALS Raw Material CRGO electrical steel IS 3024 Copper/Aluminium conductor Test Method (Clause/Reference) IS 191, IS 1897, IS 7404, IS 12444, IS 13730/IS 6162 series Kraft paper IS 9335 series Press board IS 1576 Mineral oil IS 335 Bushings IS 2099 /7421 & IS 3347 GENERAL Tests & Permissible flux density and IS 1180 (Part 1) & & over fluxing Minimum clearances in Air -do Construction of transformer -dotank Painting of Transformer Tank -do Conservator for non sealed type transformers -do- ROUTINE TESTS a) Measurement of Winding Resistance IS 2026 (Part-1) b) Measurement of Voltage Ratio and check of Phase Displacement c), , 8.8 Measurement of Short Circuit Impedance (principal tapping, when applicable) and load loss at 50 percent and 100 percent load IS 2026 (Part-1) IS 2026 (Part-1) d) Measurement of no load loss IS 2026 (Part-1) and current e) Measurement of insulation IS 2026 (Part-1) resistance f) Induced overvoltage withstand IS 2026 (Part-3) test g) Separate source voltage IS 2026 (Part-3) withstand test & 21.2 h) Pressure test Cl of IS 1180(Part-1): & 21.2 j) Oil Leakage test Cl of IS 1180(Part-1):2014 TYPE TESTS a) Lightning Impulse Test IS 2026 (Part-3) b), 6.10 Temperature rise test IS 2026 (Part-2) Critical/ Non Critical Remarks

30 7.10, c) Short Circuit withstand test IS 2026 (Part-5) (up to 200kVA) d) Pressure Test Cl of IS 1180 (Part-1):2014 SPECIAL TESTS a) Determination of Sound Levels IS 2026 (Part-10) c) No load current at 112.5% voltage Cl of IS 1180 (P-1): d) Paint adhesion test ASTM D e) BDV & Moisture Content of Transformer Oil IS Clause Wise Requirements Three Phase Sealed Type and Non sealed type (above 200 kva up to and including 2500kVA) Sl.No. Clause No. Test Method (Clause/Reference) RAW MATERIALS Raw Material CRGO electrical steel IS 3024 Copper/Aluminium conductor IS 191, IS 1897, IS 7404, IS 12444, IS 13730/IS 6162 series Kraft paper IS 9335 series Press board IS 1576 Mineral oil IS 335 Bushings IS 2099 /7421 & IS 3347 GENERAL Tests & Permissible flux density and over fluxing IS 1180 (Part 1) & & Minimum clearances in Air -do Construction of transformer tank -do Painting of Transformer Tank -do Conservator for non sealed type transformers -do- ROUTINE TESTS a) Measurement of Winding Resistance IS 2026 (Part-1) b) Measurement of Voltage Ratio and check of IS 2026 (Part-1) Phase Displacement c), 6.8 Measurement of Short Circuit Impedance IS 2026 (Part-1) 7.8, 8.8 (principal tapping, when applicable) and load loss at 50 percent and 100 percent load d) Measurement of no load loss and current IS 2026 (Part-1) e) Measurement of insulation resistance IS 2026 (Part-1) f) Induced overvoltage withstand test IS 2026 (Part-3) g) Separate source voltage withstand test IS 2026 (Part-3) & 21.2 h) Pressure test Cl of IS 1180(Part- 1): & 21.2 j) Oil Leakage test Cl of IS 1180(Part- 1):2014 TYPE TESTS a) Lightning Impulse Test IS 2026 (Part-3) b), , 8.10 Temperature rise test IS 2026 (Part-2)

31 c) Short Circuit withstand test IS 2026 (Part-5) (up to 200kVA) d) Pressure Test Cl of IS 1180 (Part-1):2014 SPECIAL TESTS a) Determination of Sound Levels IS 2026 (Part-10) b) Short Circuit withstand test IS 2026 (Part-5) (above 200kVA) c) No load current at 112.5% voltage Cl of IS 1180 (P-1): d) Paint adhesion test ASTM D e) BDV & Moisture Content of Transformer Oil IS Clause Wise Requirements Single phase transformer (Sealed Type) Sl.No. Clause No. Test Method (Clause/Reference) RAW MATERIALS Raw Material CRGO electrical steel IS 3024 Copper/Aluminium conductor IS 191, IS 1897, IS 7404, IS 12444, IS 13730/IS 6162 series Kraft paper IS 9335 series Press board IS 1576 Mineral oil IS 335 Bushings IS 2099 /7421 & IS 3347 GENERAL Tests & Permissible flux density and over fluxing IS 1180 (Part 1) & & Minimum clearances in Air -do Construction of transformer tank -do Painting of Transformer Tank -do Conservator for non sealed type transformers -do- ROUTINE TESTS a) Measurement of Winding Resistance IS 2026 (Part-1) b) Measurement of Voltage Ratio and check of IS 2026 (Part-1) Phase Displacement c), 6.8 Measurement of Short Circuit Impedance IS 2026 (Part-1) 7.8, 8.8 (principal tapping, when applicable) and load loss at 50 percent and 100 percent load d) Measurement of no load loss and current IS 2026 (Part-1) e) Measurement of insulation resistance IS 2026 (Part-1) f) Induced overvoltage withstand test IS 2026 (Part-3) g) Separate source voltage withstand test IS 2026 (Part-3) & 21.2 h) Pressure test Cl of IS 1180(Part- 1): & 21.2 j) Oil Leakage test Cl of IS 1180(Part- 1):2014 TYPE TESTS a) Lightning Impulse Test IS 2026 (Part-3) b), , 8.10 Temperature rise test IS 2026 (Part-2)

32 c) Short Circuit withstand test IS 2026 (Part-5) (up to 200kVA) d) Pressure Test Cl of IS 1180 (Part-1):2014 SPECIAL TESTS a) Determination of Sound Levels IS 2026 (Part-10) c) No load current at 112.5% voltage Cl of IS 1180 (P-1): d) Paint adhesion test ASTM D e) BDV & Moisture Content of Transformer Oil IS 335 Critical/non-critical to be decided for operation of BIS licence, irrespective of whether the Critical/non-critical parameters are defined in product standards or not. 5. GROUPING GUIDELINES Type/Class Three Phase (Sealed Type)/ (Non Sealed Type) Separate samples shall drawn sealed non-sealed type be for and Single phase transformer (Sealed Type) Grade / Rating As per Standard Nominal System kva Rating Voltage 3.3 kv Up to and including 200 kva Size Group Reason / Justification of grouping For Certification purpose One sample of highest rating and the highest energy efficiency offered by the applicant to cover all the ratings and energy efficiency levels up to that highest value. Group X 1 Basic Insulation Level is same for the same nominal system voltage. Compliance to higher energy efficiency level ensures compliance to lower energy efficiency levels 6.6 kv -do- Group X 2 -do- 11 kv -do- Group X 3 -do- Above 11 kv &Up to & including 22 kv Above 22 kv & Up to & including 33 kv -do- Group X 4 -do- -do- Group X 5 -do- 3.3 kv Above 200kVA -do- Group X 6 -do- 6.6 kv and up to & including do- Group X 7 -do- 11 kv kva, 3 Phase -do- Group X 8 -do- Above 11 kv &Up to & including 22 kv Above 22 kv & Up to & including 33 kv -do- Group X 9 -do- -do- Group X 10 11kV Up to and -do- Group including 25 X 11 22kV kva -do- Group 33kV -do- Group X 13 X 12 -do- -do- -do- -do-

33 6. SCOPE OF THE LICENCE Licence shall be granted with the following scope: Name of the Product Type (Sealed or Non sealed Type) OUTDOOR TYPE OIL IMMERSED DISTRIBUTION TRANSFORMERS Nominal System Voltage kva Ratings Energy Efficiency Levels All kva ratings to mentioned individually as per the standard Any other aspect required as per the Standard

34 7. Infrastructure for Production 7.1 Description of Plant & Machinery A typical list of manufacturing machinery and equipment is given below for guidance as a minimum requirement. Alternative machinery may be used based on advancement of technology by various manufacturers which may be built into this manual from time to time". PROCESS 1 Sl No Description of Machinery Capacity Remarks PROCESS 2 Sl No Description of Machinery Capacity Remarks PROCESS Sl No Description of Machinery Capacity Remarks

35 7.2 Manufacturing Process On the basis of Guaranteed Technical Parameters (Customers Requirement), a design is prepared. Based on the design, raw-materials are chosen. The major raw material is CRGO Steel used for manufacturing the Core of the transformer. The LV and HV windings are prepared using coil winding machines. Insulations are cut into different dimensions based on the design. The HV and LV coils are placed on the limbs of the core. The assembly is then put into an oven for removal of moisture this process referred to as baking. The tank of the transformer is fabricated on the basis of the design and the electrical and mechanical stress it has to withstand. This tank is shot blasted and primer coated. Mineral oils used in the transformer are centrifuged- which is generally termed as oil filtration. The assembled core with the windings on its limbs is placed in the transformer tank, the process which is called as tanking or box-up. Then, the transformer is tested to verify its compliance to the requirements. Oil leakage test is also performed to ensure no-leakage of the mineral oil from any of the joints. The transformer is painted, and made ready for dispatch.

36 7.3 MANUFACTURING PROCESS FLOW CHART - DISTRIBUTION TRANSFORMER GURANTEED TECHNICAL PARAMETERS DESIGN OF TRANSFORMER LV WINDING HV WINDING CRGO STEEL CORE ASSEMBLY COIL ASSEMBLY INSULATION CUTTING PROCESSING AND BAKING OIL TANKER OIL CENTRIFIGUI NG TANKING / BOX-UP SHOT BLASTING & PRIMING TANK FABRICATION TESTING LEAKAGE TEST PAINTING DESPATCH

37 8. Infrastructure for Testing Complete test facility for all the requirements covered under Routine Tests shall be available with the firm. For other tests, test report of conformity from BIS recognized/group-2 category of laboratories as per the frequency of STI shall be produced by the licensee to BIS (where in-house test facilities are not available for these tests and relaxation as given by BIS). A typical list of test equipment is given below for guidance as a minimum requirement. Alternative test equipment may be used based on advancement of technology which may be built into this manual from time to time based on revision / amendment in Indian Standard. Requirement Clause of Standard Frequency per Control Unit Importance of test requirement Test Equipment Least Count & Range Frequency of Calibration Approx Cost of test equipment In-house arrangement Or Outside Laboratory General Requirements Permissible flux density and over fluxing Minimum clearances in Air & One sample each of & & identical design/constr uction and of same nominal system voltage and rating once in five years. 11 Each transformer Measuremen t of magnetizatio n of core Electrical Safety Vernier Calipper 0.01mm, 0-150mm Construction of transformer tank Painting of Transformer Tank 15.1 Each transformer 15.5 Each transformer Electrical & Mechanical Safety Corrosion Protection Visual Visual

38 Conservator for non sealed type transformers 16 Each transformer Electrical & Mechanical Safety Visual Routine Test Measurement of winding resistance IS 2026 (Part 1). Measurement of voltage ratio and check of phase displacement IS 2026 (Part 1). Measurement of short-circuit impedance (principal tapping, when applicable) and load loss at 50 percent and 100 percent load IS 2026 (Part 1). Measurement of no-load loss and current IS 2026 (Part 1) a) Each transformer 21.2 b) Each transformer 21.2 c) Each transformer 21.2 d) Each transformer Performance requirement Compatibilit y and Loss Calculation To find out the circuit parameters Digital µ- ohm meter Kelvin Bridge Wheatston e Bridge Transform er Ratio Meter Current Transform er Potential Transform er Portable Wattmeter Portable AC Voltmeter Current transforme r Potential transforme r Portable wattmeter Portable AC voltmeter Frequenc 1µΩ, 199 µω KΩ 0.002mΩ, 0-11Ω 0.001Ω, Ω 0.01%, /5 A / 600V 1W, V, 5-10A 1/2/4V, V /5 A / 600V 1W, V, 5-10A 1/2/4V, V

39 y meter Digital Power Analyzer 0.5Hz, 45-55Hz 600V/20A Measurement of insulation resistance IS 2026 (Part 1) e) Each transformer To test the insulation resistance between HV and LV windings, HV winding and Ground, LV winding and Ground, Insulation Tester 0.1mΩ, mω/ 2500V Induced overvoltage withstand test IS 2026 (Part 3). Separate-source voltage withstand test IS 2026 (Part 3). Pressure Test 21.2 f) Each transformer 21.2 g) Each transformer 15.2 & 21.2 h) Each transformer To test the insulation of each winding between the turns and between winding to winding. To test the insulation between HV and LV side, HV side and GND, side GND To check any bulging of the tank LV and Double Voltage Double Frequency Generator with DC Drive Stop Watch High Voltage Power Transformer Stop Watch Compress or Pressure 0-5min, 0.1Sec 0-5min, 0.1Sec

40 Gauge Oil Leakage Test 15.2 & 21.2 j) Each transformer To check any leakage in the transformer tank Oil Conservat or tank Type Test Lightning Impulse Test Temperature rise test Short Circuit withstand test 21.3 a) One sample each of identical design/constr uction and of same nominal system voltage and rating once in five years b) One sample 6.10 from every lot 7.10 of transformers (of identical design/constr uction and of same nominal system voltage and rating) or part thereof c) One sample each of identical design/constr uction and of same nominal system voltage and rating once in five years. To check the actual temp. rise during operation of transformer To check the actual short circuit withstand capacity Impulse Generator Circuit Impulse recorder Temperature Sensors Power Source, AC Generator, SC breaker Generally from Outside Laboratory, considering the specialized nature of test o C, 1 O C Generally from Outside Laboratory, considering the specialized nature of test Generally from Outside Laboratory, considering the specialized nature of test

41 Pressure Test 21.3 d) One sample from every lot of 50 transformers (of identical design/constr uction and of same nominal system voltage and rating) or part thereof. To check any bulging of the tank Compress or Pressure Gauge SPECIAL TESTS / ADDITIONAL TESTS/ OPTIONAL TESTS / MUTUALLY AGREED TEST In house test Determination of Sound Levels Short Circuit withstand test No load current at 112.5% voltage Paint adhesion test BDV & Moisture Content of Transformer Oil 21.4 a) As agreed between purchaser and manufacturer 21.4 b) -do c) -do d) -do e) -do- To check the di-electric strength & moisture content Oil insulation test set 0-100kV, 2kV In house test facility

42 9. CONTROL UNIT & BATCH Control Unit : Control Unit : For the purpose of type tests, 50 transformers (of identical design / construction and of same nominal system voltage and rating) or part there of shall constitute one lot. For other tests, appropriate control as mentioned in STI shall be applicable.

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44 10. TEST RECORDS TO BE MAINTAINED BY FIRM Format I Class / Type Group / Rating/Size Important Parameters Date of manufacture Control Unit Quantity Under the Control Unit Quantity marked with Standard Mark Measurement of Winding Resistance Each transformer Measurement of Voltage Ratio and check of Phase Displacement Each transformer Measurement of Short Circuit Impedance (principal tapping, when applicable) and load loss at 50 percent and 100 percent load Each transformer Measurement of no load loss and current Each transformer Measurement of insulation resistance Each transformer Induced overvoltage withstand test Each transformer Separatesource voltage withstand test Each transform er Pressure Test Each transformer Oil Leakage Test Each transformer Test result Test result Test result Test result Test result Test result Test result Test result Test result

45 Other Parameters Date of manufacture Control Unit Quantity Under the Control Unit Quantity marked with Standard Mark Lightning Impulse Test Temperature rise test Short Circuit withstand test One sample each of identical design / construction and of same nominal system voltage and rating once in five years. One sample from every lot of 50 transformers (of identical design/construction and of same nominal system voltage and rating) or part thereof. One sample each of identical design / construction and of same nominal system voltage and rating once in five years. Pressure Test Test result Test result Test result Test result One sample from every lot of 50 transformers (of identical design/ construction and of same nominal system voltage and rating) or part thereof. Date of manufacture Control Unit Quantity Under the Control Unit Quantity marked with Standard Mark Permissible flux density and over fluxing One sample each of identical design/construction and of same nominal system voltage and rating once in five years. Minimum clearances in Air Construction of transformer tank Painting of Transformer Tank Conservator for non sealed type transformers Each transformer Each transformer Each transformer Each transformer Test result Test result Test result Test result

46 Format 2 S.No Control Unit & Date of Manufacture Total Quantity Marked under the Control Unit Quantity found Non conforming Segregation / Disposal of Non Conforming product Dispatch details Bill No Date Name and address of the consignee(s) Quantity (with Batch No.) Dispatched with Standard Mark Balance in stock S.No Batch No & Date of Manufacture Total Quantity Marked under the Control Unit Total Quantity Marked under the Batch Quantity found Non conforming Segregation / Disposal of Non Conforming product Dispatch details Bill No Date Name and address of the consignee(s) Quantity (with Batch No.) Dispatched with Standard Mark Balance in stock

47 Format 3 RAW MATERIAL (Outside testing) Sl No Date of receipt Name of the Raw Material Source In case ISI marked raw material -No of the corresponding IS Number & Licence No In case Testing done from Outside Laboratory Name of Lab Sample sent On TR No & date In case Non ISI raw material & accompanied by Test Certificate- Test Certificate No & Date Results Remarks

48 Format 4 RAW MATERIAL (In house Testing) Sl No Date of receipt Name of the Raw Material Source Test Results of In house Testing Remarks Date of Testing IS No Clause Result

49 11. MARKING AND LABELLING REQUIREMENTS Marking & labeling shall be defined as per the Clause 13 of standard Rating Plate - Each transformer shall be provided with rating plate made of anodized aluminium/stainless steel material securely fixed on the outer body, easily accessible, showing the information given in Fig. 1 of IS 1180 (Pt1) for 3 phase transformers and Fig. 2 of IS 1180 (Pr1) for single phase transformers. The entries on the rating plate shall be indelibly marked for example, by etching, engraving or stamping. Terminal Marking Plate- Each transformer shall be provided with a terminal marking plate in accordance with Fig. 3 to Fig. 5 of IS 1180 (Pt1) whichever is applicable. Energy Efficiency Level -Each transformer shall also be clearly marked with its Energy Efficiency Level rating BIS Certification Mark- Each transformer shall also be clearly marked with and BIS Certification Mark. 12. PRODUCT SAMPLE SIZE AND TEST REQUEST Quantity of sample Qty of sample required for testing to be indicated. Manner of packing (to avoid contamination/ damage during transit) Details to be Indicated in test Request 1. Size / Class / Grade/ Rating 2. Keeping Quality, Shelf life, Type of killing etc.. 3. Declaration / manufacturer specified value 4. Drawings 5. Special Test/Optional Test (if any) or any any other requirement required to be tested Instruction to Lab Any specific instruction or information to lab regarding testing of sample may be given here Manner of sealing Instruction for re removing / defacing label and/or manufacturer's identification Mechanism for dealing with the remnants of sample to be indicated- In case sample is required to be returned back to certified body/ applicant, the same shall be indicated

50 12. 2 RAW MATERIAL SAMPLE SIZE AND TEST REQUEST Quantity of sample Qty of sample required for testing to be indicated. Manner of packing (to avoid contamination/ damage during transit) Details to be Indicated in test Request 1. Size / Class / Grade/ Rating 2. Keeping Quality, Shelf life, Type of killing etc.. 3. Declaration / manufacturer specified value 4. Drawings 5. Special Test/Optional Test (if any) or any any other requirement required to be tested Instruction to Lab Any specific instruction or information to lab regarding testing of sample may be given here Manner of sealing Instruction for re removing / defacing label and/or manufacturer's identification Mechanism for dealing with the remnants of sample to be indicated- In case sample is required to be returned back to certified body/ applicant, the same shall be indicated 13. PRODUCT SPECIFIC GUIDELINES (If any) Document : Ref: CMD1(BD)/IS 1180 dated 27 Nov 2014, Guidelines for Certification of Outdoor Type Distribution Transformers as per IS 1180 IS 1180 (Part 1):2014 (Outdoor Type Oil Immersed Distribution Transformers Up to and Including 2500kVA, 33kV Specification Part 1 Mineral Oil Immersed) has been published, amalgamating IS 1180 (Part 1):1989 and IS 1180 (Part 2):1989. This version of IS 1180 has come into force with effect from All applications shall be recorded as per IS 1180 (Part 1):2014. This revised ISS covers both sealed and non-sealed type distribution transformers up to 2500 kva and nominal system voltage up to and including 33kV and also, single phase sealed type distribution transformer up to 25 kva rating and nominal system voltage up to and including 33kV. Moreover, in this revised version, the distribution transformers have been grouped under three different categories namely Energy Efficiency Level 1, Energy Efficiency Level 2 and Energy Efficiency Level 3 based on the maximum total loss. Transformers are designed based on the Basic Insulation Level (BIL) consideration. Accordingly, other parameters are also set for the transformer of a particular rating to achieve the desired performance. Therefore, the existing guidelines have been reviewed and the following

51 guidelines have been proposed for certification of Outdoor Type Distribution Transformers as per IS 1180 (Part 1):2014. A Application for GOL as per IS 1180 (Part 1):2014 shall be processed as follows: Type of Tests According to Cl.21 of IS 1180 (Part 1):2014, the tests on the transformers are classified into Routine test, Type test and Special test as given below: Routine Test Type Test Special Test a) Measurement of winding resistance IS 2026 (Part 1). b) Measurement of voltage ratio and check of phase displacement IS 2026 (Part 1). c) Measurement of short-circuit impedance (principal tapping, when applicable) and load loss at 50 percent and 100 percent load IS 2026 (Part 1). d) Measurement of no-load loss and current IS 2026 (Part 1). e) Measurement of insulation resistance IS 2026 (Part 1). f) Induced over-voltage withstand test IS 2026 (Part 3). g) Separate-source voltage withstand test IS 2026 (Part 3). h) Pressure Test i) Oil Leakage Test a) Lightning impulse test IS 2026 (Part 3). b) Temperature-rise test IS 2026 (Part 2). c) Short-circuit withstand test IS 2026 (Part 5) (up to 200 kva). d) Pressure test (As agreed between Manufacturer and purchaser) a) Determination of sound levels IS 2026 (Part 10) b) Short-circuit withstand test IS 2026 (Part 5) (above 200 kva) c) No load current at percent voltage d) Paint adhesion tests. The test is performed as per ASTM D3359 (Standard Test Methods for measuring adhesion by Tape test). e) BDV and moisture content of oil in the transformer (IS 335). B For Grant of Licence I. The applicant shall clearly indicate in the application, the ratings of the transformers for which BIS licence is required. Relevant drawings and technical parameters of the transformers of the said ratings shall also be submitted to BIS. In addition, an undertaking shall also be submitted by the applicant that whenever there is any change in technical design of the transformer, prior intimation would be given to BIS. The following shall be taken as a change in the design of the transformer, which would require type testing again: Change in flux density Type of construction (core type/shell type) Change in current density and type of winding material (Cu/Al) Change in type of connection (star/delta) & Vector Group Change in tank design Total loss and method of cooling The applicant is mandatorily required to have testing facilities in-house for all routine tests. In-house testing facilities for type tests i.e. Lightning Impulse Test, Short Circuit Test, Temperature Rise Test & Permissible Flux Density & Overfluxing Test, are desirable. However, considering the facts of specialized nature of tests and costly testing equipments, testing facilities of BIS recognized/group-2 category of laboratories may be availed by the applicant. Presently, CPRI (Bangalore and Bhopal) and ERDA (Vadodara) are having complete testing facilities as informed by PP&C(T&C).

52 II. III. Conformity of Raw Material: a. Compliance of CRGO Electrical Steel as per IS 3024(Clause 9.1 a) which is under compulsory BIS certification shall be ensured through test certificate of supplier. b. Compliance of Copper/Aluminium conductor (Clause 9.1 c) shall be ensured through a Test Certificate from supplier or applicant firm getting the same tested from BIS recognized/group-2 category of laboratories. c. Compliance of Kraft Paper (Cl. 9.1 d), Press Board (Cl. 9.1 e) and Gasket (Cl. 15.4) shall be ensured through a Test Certificate from supplier. d. Compliance of Transformer Oil (clause 10) as per IS 335 shall be ensured through a Test Certificate from supplier/isi Marked material with TC or applicant firm getting the same tested from a BIS recognized lab. e. Compliance of Bushings (clause 12) as per IS 2099 /7421 & relevant part of IS 3347 shall be ensured through a Test Certificate from supplier or applicant firm getting the same tested from BIS recognized/group-2 category of laboratories. Drawl of Samples and Conformity of Product: a. During Preliminary Inspection, samples shall be drawn from the following group to cover all the ratings of Three Phase Transformers: Nominal System Voltage Above 11 kv &Up to & including 22 kv Above 22 kv & Up to & including 33 kv Up to and including 200 kva, 3 Phase Standard Ratings Above 200kVA and up to & including 2500 kva, 3 Phase 3.3 kv One sample of highest rating One sample of highest rating 6.6 kv -do- -do- 11 kv -do- -do- -do- -do- -do- -do- b. For Single phase transformers, samples shall be drawn as per the following to cover all the ratings: Nominal System Voltage 11kV 22kV 33kV Standard Ratings One sample of highest rating -do- -do- c. During Preliminary Inspection, one sample of highest rating, offered by the firm shall be drawn to cover the entire range for which licence has been applied for, as per the above table. The relevant drawings of the samples of transformer shall also be collected and sent to the laboratory with the samples. Separate samples shall be drawn for sealed and non-sealed type transformers, wherever applicable. The conformity of the raw materials as per the requirements of the relevant standards shall be verified while drawl of samples. d. All tests shall be carried out at BIS recognized/group-2 category of laboratories. The licence shall be granted once the product passes in both the type tests and the routine tests as indicated above.

53 e. If transformers with higher energy efficiency level is drawn for testing and found passing, the scope of licence shall also cover transformers with lower energy efficiency levels, as specified in the ISS. f. The energy efficiency levels shall be clearly indicated in the licence document. B. For Operation of Licence 1. While operation of licence, surveillance inspections shall be carried out as per the renewal policy of the BIS licensees. During each such surveillance inspection, sample shall be drawn for independent testing at BIS recognized/group-2 category of laboratories for all parameters under Routine Tests. The licensee shall inform BIS its production schedule in advance for timely planning of surveillance inspection. 2. The requirements of Type Tests shall also be carried out, periodically, from a BIS recognized/group-2 category of laboratories. (The frequency of type test is to be decided in consultation with Ministry of Power.) 3. For inclusion of new rating of the transformer, licensee shall submit a complete test report indicating conformity of the product from BIS recognized/group-2 category of laboratories, along with the certified drawings and technical parameters. The scope of licence shall be extended to cover all the ratings, up to the highest rating tested so far, in the group as mentioned in the above tables, without any further type test/ routine test. However, when the highest rating is to be certified, the procedure as specified in III (c)/(e) above shall be fulfilled. These tests shall be valid for a period as stated above. 4. For Market Samples, any one of the following may be adopted, in consultation with Ministry of Power: a. Buyers (Electricity Utilities) to send samples directly to BIS recognized laboratory for testing b. BIS recognized Laboratory can draw samples on behalf of the Electricity Utilities and get them tested c. BIS can draw samples as per the current practice prevailing in case of other products 14. GUIDELINES FOR ASCERTAINING CONFORMITY OF PRODUCT AT THE TIME OF GRANT OF LICENCE Document : Ref: CMD1(BD)/IS 1180 dated 27 Nov 2014, Guidelines for Certification of Outdoor Type Distribution Transformers as per IS GUIDELINES FOR ASCERTAINING CONFORMITY OF PRODUCT BY WAY OF INDPENDENT TESTING DURING OPERATION OF LICENCE GENERAL Clause Requirement Periodicity of testing the requirement in Independent Testing & Permissible flux density and over fluxing & All requirements for every sample drawn for independent testing &