BIS/DGO( 428 )/2015L)-DGO_15012015.pdf · 2018-12-10 · of conformity from BIS recognized/Group-2 category of laboratories as per the frequency of STI shall be produced by the licensee

BIS/DGO( 428 )/2015

15 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 re-

structured 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 2015. 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 2015. 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 2015.

This is for information and necessary action by all concerned.

This issues with the approval of Competent Authority

Sd/- 15 01 2015

(V.K. Diundi )

Sc.F & Head

Ref.:CMD-II(L)/7

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.

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 – 110002

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.

1. Title of the latest Indian Standard, IS Number & Total number of Amendments

TITLE:

IS NO:

No. of Amendments:

2. LIST OF REFERRED STANDARDS

IS No. Title

3. INTRODUCTION

Objective:

This Product Manual on “Indian Standard IS 1180 (Pt1): 2014 - Outdoor Type Oil Immersed

Distribution Transformers Up to And Including 2 500 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.

.

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

4.2.1 Clause wise Requirements for Type/ Grade/ Variety - --------------

Sl.N

o.

Clause No. Test Method

(Clause/Reference)

Critical/

Non Critical

Remarks

RAW MATERIALS Raw Material

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.

4.2.2 Add on provisions for more type/grade/variety/ etc , if required

4.2.3 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

Sl no Grade / variety

as per Standard 1

Type/Class

as per Standard 1

Rating

as per Standard 1

Size

as per Standard 1

Group Remark 2 Justification

3

1 Group1

2 ….. Group 2

3 …… ……. ……. ……. …….. 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-----

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


PROCESS -----


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

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

Type Test

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

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.

10. TEST RECORDS TO BE MAINTAINED BY FIRM

Format I

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

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

Class / Type Group / Rating/ Size Important Parameters

Other Parameters

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

In case Non ISI

raw material &

accompanied by

Test Certificate-

Test Certificate

No & Date

Results Remarks

Name of

Lab

Sample

sent On

TR No &

date

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

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

12. 2 RAW MATERIAL SAMPLE SIZE AND TEST REQUEST




transit)


Request



etc..


4. Drawings





Manner of sealing









indicated

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 .

19 MARKING FEE#

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.

20.2 TEST(S) TO BE CARRIED OUT DURING ROM VISIT – All requirements as far possible

and requirements which has failed.

20.3 TEST REPORT PERFORMA (To be linked with test report format of T &C)

21. SCHEME OF TESTING & INSPECTION

Unit

Unit rate

Marking Fee (Minimum) Large scale

Marking Fee (Minimum) Small scale

MF Rates effective from

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 – 110002

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.

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

2. LIST OF REFERRED STANDARDS

IS No. Title

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

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 1 000 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: Up to and including 1 kV: Section 1 Porcelain parts

(Part 1/Sec 2) : 1979 Part 1: Up to and including 1 kV: Section 2 Metal parts

(Part 2/Sec 1) : 1979 3.6 kV Bushings : Section 1 Porcelain parts

(Part 2/Sec 2) : 1979 3.6 kV Bushings: Section 2 Metal parts

(Part 3/Sec 1) : 1988 17.5 kV Bushings: Section 1 Porcelain parts

(Part 3/Sec 2) : 1988 17.5 kV Bushings: Section 2 Metal parts

(Part 4/Sec 1) : 1988 24 kV Bushings: Section1 Porcelain parts

(Part 4/Sec 2) : 1982 24 kV Bushings: Section 2 Metal parts

(Part 5/Sec 1) : 1979 36 kV Bushings: Section 1 Porcelain parts

(Part 5/Sec 2) : 1979 36 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

(Part 1) : 1971

Paper-covered aluminum conductors Round conductors

6162 (Part 2) : 1971 Rectangular conductors

7404(Part1) : 1991 Paper covered copper conductors: Part 1 Round conductors

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

11149 : 1984 Specification for rubber gaskets

12444 : 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

16081 : 2013 Insulating liquids - Specification for unused synthetic organic esters for

electrical purposes

3. INTRODUCTION

Objective:

This Product Manual on “Indian Standard IS 1180 (Pt1): 2014 - Outdoor Type Oil Immersed

Distribution Transformers Up to And Including 2 500 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): 2014 - Outdoor Type Oil Immersed Distribution

Transformers Up to And Including 2 500 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 2 500 KVA both non-

sealed type and sealed type.

c) Single phase ratings up to and including 25 KVA sealed type.

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.

.

4. REQUIREMENTS OF THE STANDARD

4.1 Grade /Class/ Rating/ Variety/ Size as per Standard

Nominal System Voltage kVA Rating

Three Phase Sealed Type and

Non sealed type (up to and

including 200kVA)

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)

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 2500

Single phase transformer

(Sealed Type)

11kV 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)

4.2 Clause Wise Requirements

4.2.1 Clause Wise Requirements Three Phase Sealed Type and Non sealed type (up to

and including 200kVA)

Sl.N

o.

Clause No. Test Method

(Clause/Reference)

Critical/

Non Critical

Remarks


1. 9.1 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

1. 6.9.1 & 6.9.2

7.9.1 & 7.9.2

8.9.1 & 8.9.2

Permissible flux density and

over fluxing

IS 1180 (Part 1)

2. 11 Minimum clearances in Air -do-

3. 15.1 Construction of transformer

tank

-do-

4. 15.5 Painting of Transformer Tank -do-

5. 16 Conservator for non sealed type

transformers

-do-

ROUTINE TESTS

1. 21.2 a) Measurement of Winding

Resistance

IS 2026 (Part-1)

2. 21.2 b) Measurement of Voltage Ratio

and check of Phase

Displacement

IS 2026 (Part-1)

3. 21.2 c), 6.8

7.8, 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)

4. 21.2 d) Measurement of no load loss

and current

IS 2026 (Part-1)

5. 21.2 e) Measurement of insulation

resistance

IS 2026 (Part-1)

6. 21.2 f) Induced overvoltage withstand

test

IS 2026 (Part-3)

7. 21.2 g) Separate source voltage

withstand test

IS 2026 (Part-3)

8. 15.2 &

21.2 h)

Pressure test Cl. 21.5 of IS

1180(Part-1):2014

9. 15.2 &

21.2 j)

Oil Leakage test Cl. 21.5 of IS

1180(Part-1):2014

TYPE TESTS

1. 21.3 a) Lightning Impulse Test IS 2026 (Part-3)

2. 21.3 b), 6.10 Temperature rise test IS 2026 (Part-2)

7.10, 8.10

3. 21.3 c) Short Circuit withstand test IS 2026 (Part-5)

(up to 200kVA)

4. 21.3 d) Pressure Test Cl. 21.5 of IS 1180

(Part-1):2014

SPECIAL TESTS

1. 21.4 a) Determination of Sound Levels IS 2026 (Part-10)

2. 21.4 c) No load current at 112.5%

voltage

Cl. 5.9.3 of IS 1180

(P-1):2014

3. 21.4 d) Paint adhesion test ASTM D 3359

4. 21.4 e) BDV & Moisture Content of

Transformer Oil

IS 335

4.2.2 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)



Copper/Aluminium conductor IS 191, IS 1897, IS 7404,

IS 12444, IS 13730/IS

6162 series


Press board IS 1576

Mineral oil IS 335

Bushings IS 2099 /7421 & IS 3347

GENERAL Tests

1. 6.9.1 & 6.9.2

7.9.1 & 7.9.2

8.9.1 & 8.9.2

Permissible flux density and over fluxing IS 1180 (Part 1)


3. 15.1 Construction of transformer tank -do-


5. 16 Conservator for non sealed type transformers -do-

ROUTINE TESTS

1. 21.2 a) Measurement of Winding Resistance IS 2026 (Part-1)

2. 21.2 b) Measurement of Voltage Ratio and check of

Phase Displacement

IS 2026 (Part-1)

3. 21.2 c), 6.8

7.8, 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)

4. 21.2 d) Measurement of no load loss and current IS 2026 (Part-1)

5. 21.2 e) Measurement of insulation resistance IS 2026 (Part-1)

6. 21.2 f) Induced overvoltage withstand test IS 2026 (Part-3)

7. 21.2 g) Separate source voltage withstand test IS 2026 (Part-3)

8. 15.2 &

21.2 h)

Pressure test Cl. 21.5 of IS 1180(Part-

1):2014

9. 15.2 &

21.2 j)

Oil Leakage test Cl. 21.5 of IS 1180(Part-

1):2014

TYPE TESTS


2. 21.3 b), 6.10

7.10, 8.10

Temperature rise test IS 2026 (Part-2)


(up to 200kVA)


(Part-1):2014

SPECIAL TESTS


2. 21.4 b) Short Circuit withstand test IS 2026 (Part-5)

(above 200kVA)

3. 21.4 c) No load current at 112.5% voltage Cl. 5.9.3 of IS 1180

(P-1):2014


5. 21.4 e) BDV & Moisture Content of Transformer Oil IS 335

4.2.3 Clause Wise Requirements Single phase transformer (Sealed Type)

Sl.No. Clause No. Test Method

(Clause/Reference)



Copper/Aluminium conductor IS 191, IS 1897, IS 7404,

IS 12444, IS 13730/IS

6162 series


Press board IS 1576

Mineral oil IS 335

Bushings IS 2099 /7421 & IS 3347

GENERAL Tests

1. 6.9.1 & 6.9.2

7.9.1 & 7.9.2

8.9.1 & 8.9.2

Permissible flux density and over fluxing IS 1180 (Part 1)


3. 15.1 Construction of transformer tank -do-


5. 16 Conservator for non sealed type transformers -do-

ROUTINE TESTS

1. 21.2 a) Measurement of Winding Resistance IS 2026 (Part-1)

2. 21.2 b) Measurement of Voltage Ratio and check of

Phase Displacement

IS 2026 (Part-1)

3. 21.2 c), 6.8

7.8, 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)

4. 21.2 d) Measurement of no load loss and current IS 2026 (Part-1)

5. 21.2 e) Measurement of insulation resistance IS 2026 (Part-1)

6. 21.2 f) Induced overvoltage withstand test IS 2026 (Part-3)

7. 21.2 g) Separate source voltage withstand test IS 2026 (Part-3)

8. 15.2 &

21.2 h)

Pressure test Cl. 21.5 of IS 1180(Part-

1):2014

9. 15.2 &

21.2 j)

Oil Leakage test Cl. 21.5 of IS 1180(Part-

1):2014

TYPE TESTS


2. 21.3 b), 6.10

7.10, 8.10

Temperature rise test IS 2026 (Part-2)


(up to 200kVA)


(Part-1):2014

SPECIAL TESTS


2. 21.4 c) No load current at 112.5% voltage Cl. 5.9.3 of IS 1180

(P-1):2014


4. 21.4 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 Grade / Rating

As per Standard

Size Group Reason / Justification of

grouping

Nominal System

Voltage

kVA Rating For Certification purpose

Three Phase

(Sealed

Type)/ (Non

Sealed Type)

Separate

samples

shall be

drawn for

sealed and

non-sealed

type

3.3 kV Up to and

including 200

kVA

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 X1 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 X2 -do-

11 kV -do- Group X3 -do-

Above 11 kV

&Up to &

including 22 kV

-do- Group X4 -do-

Above 22 kV &

Up to &

including 33 kV

-do- Group X5 -do-

3.3 kV Above 200kVA

and up to &

including 2500

kVA, 3 Phase

-do- Group X6 -do-

6.6 kV -do- Group X7 -do-

11 kV -do- Group X8 -do-

Above 11 kV

&Up to &

including 22 kV

-do- Group X9 -do-

Above 22 kV &

Up to &

including 33 kV

-do- Group

X10

-do-

Single phase

transformer

(Sealed

Type)

11kV Up to and

including 25

kVA

-do- Group

X11

-do-

22kV -do- Group

X12

-do-

33kV -do- Group

X13

-do-

6. SCOPE OF THE LICENCE

“Licence shall be granted with the following scope:

Name of the

Product

OUTDOOR TYPE OIL IMMERSED DISTRIBUTION

TRANSFORMERS

Type (Sealed or

Non sealed Type)

Nominal System

Voltage

kVA Ratings All kVA ratings to mentioned individually as per the standard

Energy Efficiency

Levels

Any other aspect

required as per the

Standard

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


PROCESS 2


PROCESS -----


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.

7.3 MANUFACTURING PROCESS FLOW CHART - DISTRIBUTION

TRANSFORMER

LV WINDING HV WINDING

CORE

ASSEMBLY

CRGO

STEEL

COIL

ASSEMBLY

INSULATION

CUTTING

PROCESSING

AND BAKING

OIL

TANKER

OIL

CENTRIFIGUI

NG

TANKING /

BOX-UP

SHOT

BLASTING &

PRIMING

TANK

FABRICATION

TESTING

LEAKAGE

TEST

DESPATCH

PAINTING

GURANTEED TECHNICAL

PARAMETERS

DESIGN OF

TRANSFORMER

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

6.9.1 &

6.9.2

7.9.1 &

7.9.2

8.9.1 &

8.9.2

One sample

each of

identical

design/constr

uction and of

same nominal

system

voltage and

rating once in

five years.

Measuremen

t of

magnetizatio

n of core

Minimum

clearances in

Air

11 Each

transformer

Electrical

Safety Vernier

Calipper

0.01mm,

0-150mm

Construction of

transformer

tank

15.1

Each

transformer

Electrical &

Mechanical

Safety

Visual

Painting of

Transformer

Tank

15.5 Each

transformer

Corrosion

Protection Visual

Conservator for

non sealed type

transformers

16 Each

transformer

Electrical &

Mechanical

Safety

Visual

Routine Test Measurement

of winding

resistance IS

2026 (Part 1).

21.2 a) Each

transformer

Performance

requirement Digital µ-

ohm meter

Kelvin

Bridge

Wheatston

e Bridge

1µΩ, 199 µΩ -19.99KΩ

0.002mΩ, 0-

11Ω

0.001Ω, 0-

106Ω

Measurement of

voltage ratio

and check of

phase

displacement IS

2026 (Part 1).

21.2 b) Each

transformer

Compatibilit

y and Transform

er Ratio

Meter

0.01%,

0.9-900

Measurement of

short-circuit

impedance

(principal

tapping, when

applicable) and

load loss at 50

percent and 100

percent load IS

2026 (Part 1).

21.2 c)

6.8

7.8

8.8

Each

transformer Loss

Calculation

Current

Transform

er

Potential

Transform

er

Portable

Wattmeter

Portable

AC

Voltmeter

5-10-25-50-

100/5 A

2000-1800/

600V

1W, 150-300-

600V, 5-10A

1/2/4V, 150-

300-600V

Measurement of

no-load loss and

current IS 2026

(Part 1).

21.2 d) Each

transformer

To find out

the circuit

parameters

Current

transforme

r

Potential

transforme

r

Portable

wattmeter

Portable

AC

voltmeter

Frequenc

5-10-25-50-

100/5 A

2000-1800/

600V

1W, 150-300-

600V, 5-10A

1/2/4V, 150-

300-600V

y meter

Digital

Power

Analyzer

0.5Hz, 45-

55Hz

600V/20A

Measurement of

insulation

resistance IS

2026 (Part 1).

21.2 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, 0-

5000 mΩ/ 2500V

Induced over-

voltage

withstand test

IS 2026 (Part

3).

21.2 f) Each

transformer

To test the

insulation of

each

winding

between the

turns and

between

winding to

winding.

Double

Voltage

Double

Frequency

Generator

with DC

Drive

Stop

Watch

0-5min, 0.1Sec

Separate-source

voltage

withstand test

IS 2026 (Part

3).

21.2 g) Each

transformer

To test the

insulation

between HV

and LV side,

HV side and

GND, LV

side and

GND

High

Voltage

Power

Transformer

Stop Watch

0-5min, 0.1Sec

Pressure Test 15.2 &

21.2 h)

Each

transformer

To check

any bulging

of the tank

Compress

or

Pressure

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

21.3 a) One sample

each of

identical

design/constr

uction and of

same nominal

system

voltage and

rating once in

five years.

Impulse

Generator

Circuit

Impulse

recorder

Generally from Outside

Laboratory, considering the

specialized nature of test

Temperature

rise test

21.3 b)

6.10

7.10

8.10

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 the

actual temp.

rise during

operation of

transformer

Temperature

Sensors 0-100

oC, 1

OC Generally from Outside



Short Circuit

withstand test

21.3 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 short

circuit

withstand

capacity

Power

Source, AC

Generator,

SC breaker

Generally from Outside



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

In house test

SPECIAL TESTS / ADDITIONAL TESTS/ OPTIONAL TESTS / MUTUALLY AGREED TEST

Determination

of Sound Levels

21.4 a) As agreed

between

purchaser and

manufacturer

Short Circuit

withstand test

21.4 b) -do-

No load current

at 112.5%

voltage

21.4 c) -do-

Paint adhesion

test

21.4 d) -do-

BDV &

Moisture

Content of

Transformer Oil

21.4 e) -do- To check the

di-electric

strength &

moisture

content

Oil

insulation

test set

0-100kV, 2kV In house test facility

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.

10. TEST RECORDS TO BE MAINTAINED BY FIRM

Format I

Date of

manufacture

Control

Unit

Quantity

Under the

Control Unit

Quantity

marked

with

Standard

Mark

Measurement

of Winding

Resistance

Measurement of

Voltage Ratio

and check of

Phase

Displacement

Measurement of

Short Circuit

Impedance

(principal tapping,

when applicable)

and load loss at 50

percent and 100

percent load

Measurement

of no load

loss and

current

Measurement

of insulation

resistance

Induced

overvoltage

withstand

test

Separate-

source

voltage

withstand

test

Pressure Test Oil Leakage

Test

Each

transformer Each

transformer

Each transformer Each

transformer

Each

transformer

Each

transformer

Each

transform

er

Each

transformer Each

transformer

Test result Test result Test result Test result Test result Test result Test

result Test result Test result

Class / Type Group / Rating/Size Important 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

Pressure 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.

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

Minimum

clearances in Air

Construction of

transformer tank

Painting of

Transformer

Tank

Conservator for non sealed

type transformers

One sample each of identical


same nominal system

voltage and rating once in

five years.

Each transformer Each transformer Each transformer Each transformer


Other Parameters

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


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


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

In case Non ISI

raw material &

accompanied by

Test Certificate-

Test Certificate

No & Date

Results Remarks

Name of

Lab

Sample

sent On

TR No &

date

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

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




transit)


Request



etc..


4. Drawings





Manner of sealing









indicated

12. 2 RAW MATERIAL SAMPLE SIZE AND TEST REQUEST




transit)


Request



etc..


4. Drawings





Manner of sealing









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 19.07.2014. 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

guidelines have been proposed for certification of Outdoor Type Distribution Transformers as per IS

1180 (Part 1):2014.

Application for GOL as per IS 1180 (Part 1):2014 shall be processed as follows:

A 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

(As agreed between

Manufacturer and purchaser)

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

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

112.5 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 Change in current density and type

of winding material (Cu/Al)

Change in tank design

Type of construction (core

type/shell type)

Change in type of connection

(star/delta) & Vector Group

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).

II. 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.

III. 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

Standard Ratings

Up to and including 200 kVA,

3 Phase

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-

Above 11 kV &Up to &

including 22 kV

-do- -do-

Above 22 kV & Up to &

including 33 kV

-do- -do-

b. For Single phase transformers, samples shall be drawn as per the following to cover

all the ratings:

Nominal System Voltage Standard Ratings

11kV One sample of highest rating

22kV -do-

33kV -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.

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 1180

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

6.9.1 &

6.9.2

7.9.1 &

7.9.2

8.9.1 &

Permissible flux density and over

fluxing

All requirements for every sample drawn for independent testing

8.9.2

11 Minimum clearances in Air

15.1 Construction of transformer tank

15.5 Painting of Transformer Tank

16 Conservator for non sealed type

transformers

ROUTINE TEST

Clause Requirement

21.2 a) Measurement of Winding

Resistance

All requirements for every sample drawn for independent testing 21.2 b) Measurement of Voltage Ratio

and check of Phase

Displacement

21.2 c)

6.8

7.8

8.8

Measurement of Short Circuit

Impedance (principal tapping,

when applicable) and load loss

at 50 percent and 100 percent

load

21.2 d) Measurement of no load loss

and current

21.2 e) Measurement of insulation

resistance

21.2 f) Induced overvoltage withstand

test

21.2 g) Separate source voltage

withstand test

15.2 & 21.2 h) Pressure test

15.2 & 21.2 j) Oil Leakage test


Clause Requirement

21.3 a) Lightning Impulse Test Once in five years or and whenever there is any change in

design

21.3 b) 6.10

7.10, 8.10

Temperature rise test Every sample drawn for independent testing

21.3 c) Short Circuit withstand test Once in five years or and whenever there is any change in

design

21.3 d) Pressure Test Every sample drawn for independent testing

SPECIAL TEST (If applicable, as agreed between purchaser and manufacturer)

21.4 a) Determination of Sound Levels All requirements for every sample drawn for independent testing

, if applicable (As agreed between purchaser and

manufacturer) 21.4 b) Short Circuit withstand test

21.4 c) No load current at 112.5% voltage

21.4 d) Paint adhesion test

21.4 e) BDV & Moisture Content of

Transformer Oil

16. GUIDELINES FOR OPERATION OF LICENCE IN CASE LICENCE BEING

OPERATED BASED ON FACTORY TESTING

NA

17. GUIDELINES TO ENSURE CONFORMITY OF RAW MATERIAL DURING GRANT

OF LICENCE



18. GUIDELINES TO ENSURE CONFORMITY OF RAW MATERIAL DURING

OPERATION OF LICENCE



19 MARKING FEE#

20. TEST REPORT –

201.1 TEST(S) TO BE CARRIED OUT DURING REGULAR SURVEILLANCE –All

requirements as far possible to be tested during regular surveillance is to be indicated.

201.2 TEST(S) TO BE CARRIED OUT DURING ROM VISIT – All requirements as far

possible and requirements which has failed.

20.3 TEST REPORT PERFORMA (To be linked with test report format of T &C)

21. SCHEME OF TESTING & INSPECTION

(attached)

Draft

Doc: STI 1180 (Part 1)

SCHEME OF TESTING AND INSPECTION FOR OUTDOOR TYPE OIL IMMERSED

DISTRIBUTION TRANSFORMERS UP TO AND INCLUDING 2500 KVA, 33kV

AS PER IS 1180 (Part 1):2014

1.0 LABORATORY/TESTING STATION: A laboratory/testing station shall be maintained, which

shall be suitably equipped and staffed, to carry out different tests and inspections according to the

Standard.

Unit One kVA

Unit rate

Marking Fee (Minimum) Large scale

Marking Fee (Minimum) Small scale

MF Rates effective from

1.1 Environmental conditions wherever applicable shall be maintained.

2.0 TEST RECORDS: All records of tests and analysis shall be kept in suitable formats

2.1 Copies of any records or connected papers that may be required by BIS shall be made available at

any time on request.

2.2 For all stages of manufacture, the factory shall maintain appropriate controls and checks to ensure

that their product conforms to the various requirements of the Standard

3.0 QUALITY CONTROL: It is recommended that, as far as possible, Statistical Quality Control

(SQC) methods may be used for controlling the quality of the product during production as envisaged

in this Scheme. See IS 397(Part 1), IS397(Part 2), IS 397(Part 3) and IS 397(Part 4)].

3.1 In addition, efforts should be made to gradually introduce Quality Management System in

accordance with IS/ISO 9001.

4.0 CALIBRATION: Testing instruments/equipments shall be carried out periodically from NABL

accredited calibration laboratories wherever they are available in the same city. In case where such

laboratories are not available, traceability to a National Measurement System (NPL) to be ensured. All

records of such calibrations to be kept.

5.0 STANDARD MARK: The standard mark as given in column 1 of the First Schedule of the

license shall be applied clearly and indelibly by stencilling/screen or ink jet

printing/embossing/etching/engraving on the rating plate, provided that the distribution transformers

conform to specified requirements of the Indian Standard.

5.1 RATING PLATE : The rating plate shall be according to Clause 13 of IS 1180(Part 1):2014 and

shall be fitted in a visible position.

5.2 MARKING: In addition, the BIS Certification Mark Licence No. (CM/L XXXXXXX) shall be

clearly and indelibly marked on the rating plate:

5.3 TERMINAL MARKING PLATE: Each transformer to be provided with a terminal marking

plate as per Clause 13.2 of IS 1180 (Part 1):2014

6.0 LEVELS OF CONTROL: The tests, as indicated in Table 1 and at the levels of control specified

therein, shall be carried out on the whole production of the factory which is covered by this Scheme

and appropriate records and charts maintained in accordance with paragraph 2.0 above.

6.1 The criterion of acceptance/rejection of production will be as given below.:

6.1.1 Each transformer when tested shall pass the routine tests. If a transformer fails in any one or

more of the requirements it shall be unfit for the purpose of marking.

6.1.1.1 The transformer rejected in 6.1.1 may however, be suitably repaired and the defects rectified.

Such repaired transformers when tested again shall conform to all the routine tests.

6.2 For the purpose of type tests (Table 1), 50 transformers (of identical design/construction and of

same nominal system voltage and rating) or part there of shall constitute one lot.

6.3 In respect of all other clauses of the Indian Standard, appropriate control and checks to be

maintained in order to ensure that the product conforms to the various requirements of the Indian

Standard.

6.4 All the production which conforms to the Indian Standard and covered by this License shall be

marked with the Standard Mark.

7.0 REJECTION: A separate record shall be maintained giving information relating to the rejection

of products which do not conform to the Indian Standard and the method of their disposal. Such

products shall in no case be stored together with those conforming to the Indian Standard.

8.0 SAMPLES: The licensee shall supply free of charge, the sample or samples required in

accordance with Bureau of Indian Standards (Certification ) Regulation, from his factory or godown.

BIS shall pay for the samples taken by it from the open market.

9.0 REPLACEMENT: Whenever a complaint is received soon after the product with Standard Mark

have been purchased and used, and if there is adequate evidence that the product has not been

misused, defective product shall be replaced or repaired free of cost by the licensee in case the

complaint is proved to be genuine and the warranty period (where applicable) has not expired. The

final authority to judge conformity of the product to the Indian Standard shall be with BIS. The firm

shall have own complaint investigation system as per IS/ISO 10002

9.1 In the event of any damages caused by the product bearing the Standard Mark, or claim being filed

by the consumers against BIS Standard Mark and “ not conforming” to the relevant Indian Standard, entire liability arising out of such non conforming product shall be of the licensee and BIS shall not in

any way be responsible in such cases

10.0 STOP MARKING: The marking of the product shall be stopped under intimation to BIS, if at

any time, there is some difficulty in maintaining the conformity of the product to the Standard, or the

testing equipment goes out of order. The marking may be resumed as soon as the defects are removed

under intimation to BIS.

The marking of the product shall be stopped immediately if directed by BIS for any reason.

The markingmay then be resumed only after permission by BIS. The information regarding

resumption of marking shallalso be sent to BIS.

11.0 PRODUCTION DATA: The licensee shall send to BIS as per the enclosed Proforma-1

authenticated by a Chartered Accountant, a statement of quantity produced, marked and exported by

them and the trade value thereof at the end of each operative year of the license.

SCHEME OF TESTING AND INSPECTION FOR OUTDOOR TYPE OIL IMMERSED

DISTRIBUTION TRANSFORMERS UP TO AND INCLUDING 2500 KVA, 33kV

AS PER IS 1180 (Part 1):2014

TABLE-1: LEVELS OF CONTROL

TEST DETAILS

LEVELS OF CONTROL

REMARKS No. of

Samples

Frequency

Clause No. Requirements Test Method

(Clause/Reference)

Frequency

RAW MATERIALS

9.1 a) CRGO Electrical Steel Shall be ISI marked Each consignment of a

particular grade as received

9.1 b) Amorphous core

material

9.1 c) Copper/Aluminium

Conductor

ISI marked or Test

certificate of

conformity to the

relevant ISS as per

Annex A of IS 1180

(Part-1), from the

manufacturer/ BIS

recognized OSL

Each consignment

9.1 d) Kraft Paper -do- -do-

9.1 e) Press board -do- -do-

9.1 f) Mineral Oil -do- Each Drum of Oil received

15.3 Bolts, Nuts & Washers -do- Each consignment

15.4 Gasket -do- -do-

GENERAL

6.9.1 & 6.9.2

7.9.1 & 7.9.2

8.9.1 & 8.9.2

Permissible flux

density and over

fluxing

IS 1180 (Part 1) One sample each of identical


same nominal system

voltage and rating once in

five years.

11 Minimum clearances

in Air

-do- Each transformer

15.1 Construction of

transformer tank


15.5 Painting of

Transformer Tank


16 Conservator for non

sealed type

transformers


ROUTINE TESTS

21.2 a) Measurement of

Winding Resistance

IS 2026 (Part-1) Each transformer

21.2 b) Measurement of

Voltage Ratio and

check of Phase

Displacement


21.2 c)

6.8

7.8

8.8

Measurement of Short

Circuit Impedance

(principal tapping,

when applicable) and

load loss at 50 percent

and 100 percent load


21.2 d) Measurement of no

load loss and current


21.2 e) Measurement of

insulation resistance


21.2 f) Induced overvoltage

withstand test


21.2 g) Separate source

voltage withstand test


15.2 & Pressure test Cl. 21.5 of IS Each transformer

21.2 h) 1180(Part-1):2014

15.2 &

21.2 j)

Oil Leakage test Cl. 21.5 of IS

1180(Part-1):2014

Each transformer


21.3 a) Lightning Impulse

Test

IS 2026 (Part-3) One sample each of identical design/construction

and of same nominal system voltage and rating

once in five years.

21.3 b)

6.10

7.10

8.10

Temperature rise test IS 2026 (Part-2) One sample from every lot of 50 transformers (of

identical design/construction and of same nominal

system voltage and rating) or part thereof.

21.3 c) Short Circuit

withstand test

IS 2026 (Part-5)

(up to 200kVA)

One sample each of identical design/construction

and of same nominal system voltage and rating

once in five years.

21.3 d) Pressure Test Cl. 21.5 of IS

1180(Part-1):2014

One sample from every lot of 50 transformers (of

identical design/construction and of same nominal

system voltage and rating) or part thereof.

SPECIAL TESTS: To be carried out on mutual agreement between manufacturer and purchaser

21.4 a) Determination of

Sound Levels

IS 2026 (Part-10) As agreed between

purchaser and manufacturer

21.4 b) Short Circuit

withstand test

IS 2026 (Part-5)

(up to 200kVA)

-do-

21.4 c) No load current at

112.5% voltage

Cl. 5.9.3 of IS

1180(P-1):2014

-do-

21.4 d) Paint adhesion test ASTM D 3359 -do-

21.4 e) BDV & Moisture

Content of

Transformer Oil

IS 335 -do-

PROFORMA - 1

PROFORMA FOR YEARLY PRODUCTION DETAILS

Period covered *

Name of Licensee

CM/L No.

Name of Articles (s) IS No.

Grade/Type/Size

1.1 Brand/Trade/Name(s) of BIS Certification Marked Products

2. Total production of the articles(s) licensed for certification marking

2.1 Total production of the article(s) conforming to Indian Standard

3. Production covered with BIS Certification Mark and its approximate value

a) Quantity

b) Invoice sale price

3.1 Brand Name used on production covered under BIS Certification Mark

3.2 Calculation of marking fee on unit rate basis: Marking Fee per unit

a) Unit

b) Quantity covered with BIS Certification Mark

------------------------------------------------------------------------------------------------------------

*Information to be filled up by BO before forwarding to the licensee.

Note : In case a clause is not applicable, suitable remarks may be given against it.

c) Marking fee rounded off in whole rupees as obtained by applying unit rates given in

(a) on quantity given in (b)

4. Quantity not covered with BIS Certification Mark. If any, and the reasons for such non-

coverage

4.1 Brand Name under which non-certified goods were sold

5.0 Quantity Exported with BIS Standard Mark and its value

5.1 Brand Name under which BIS Certified goods are exported

6.0 Authentication by Chartered Accountant

Documents

BIS/DGO( 428 )/2015L)-DGO_15012015.pdf · 2018-12-10 · of conformity from BIS recognized/Group-2 category of laboratories as per the frequency of STI shall be produced by the licensee