Agenda Electrical Transformers (Quality Control) Order Obtaining BIS Licence Requirements of Guidelines / IS 1180-1: 1: 2014 / STI Concerns in Getting BIS Licence Experience with BEE Regulations Recommendations Conclusion
Electrical Transformers (Quality Control) Order, 2014
Electrical Transformers (Quality Control) Order, 2014: Came in to Force: 27.07.2014 Electrical Transformers (Quality Control) Amendment Order, 2014 : Coming in to Force: 01.02.2015
Salient points of Electrical Transformers Quality Order: Obligation for certification: All manufacturers of electrical Transformers shall make an application to the Bureau for obtaining licence, within a period of six months from the date of coming into force of this order. No person shall commence manufacture, without obtaining a valid licence from the Bureau On obtaining certification marks licence, no person shall by himself or through any person on his behalf manufacture or store for sale, sell or distribute any electrical transformers specified in column (3) of the schedule, which do not confirm to the specified standards and do not bear Standard Mark of Bureau
Pros Improvement in Manufacturing Quality Reduction in failure rate Qualification of Manufacturers by BIS Confidence levels of clients will get increased Cons Commercial impact with Marking fee Delay in tendering activities if cycle time is more in getting the Licence
Few Concerns DTRs are made against order. If customer requirement is not in line with the requirements of IS 1180-1:2014, what manufacturer has to do? Lack of awareness to all customers and hence purchase policies are yet to be aligned with the obligations of the Quality Order (Till date no tender is floated with new requirements). BIS Guidelines & STI as per IS 1180-1: 2014 were issued lately in 1 st week of Dec-14 Lack of Clarity on some Guidelines to Manufacturers / BIS
BIS Licence
Obtaining Licence Submission of application BIS inspection Evaluation of Manufacturing facilities and Drawl of Sample for testing at BIS approved laboratories Receipt of Licence Operation of Licence Surveillance inspections Extension of Scope of Licence Tests on Market Samples
Licence Scope: Standard ratings as per IS 1180-1: 2014 Voltage Class > 200 kva and 2500 200 kva,3-ph,dtrs 25 kva, 1-Ph DTRs kva, 3-Ph DTRs 11 kv 250, 315, 400, 500, 6.3, 10, 16, 20, 25, 40, 630, 1000, 1250, 1600, 5, 10, 16 & 25 63, 100, 160 & 200 2000 & 2500 > 11 kv and 22 kv 63, 100, 160 & 200 250, 315, 400, 500, 630, 1000, 1250, 1600, 10, 16 & 25 2000 & 2500 > 22 kv and 33 kv 100, 160 & 200 250, 315, 400, 500, 630, 1000, 1250, 1600, 16 & 25 2000 & 2500 No. of Ratings: voltage classes (3.3, 6.6, 11, 22 & 33kV) and Sealed & Non sealed Total Grand Total 2*(10*3 + 4 + 3) = 74 2*(10*3 +10 + 10)=100 (4*3 + 3 + 2) = 17 74 +100 +17 = 191 (Without considering Energy Efficiency Levels) 3 * 191 = 573 (If Energy Efficiency Levels are considered)
Action Plan
BIS Licence - Documents Guidelines for Certification IS 1180-1: 2014 Scheme of Testing & Inspection (STI)
Guidelines for Certification
As per Guidelines, all applications shall be recorded as per IS 1180 (Part 1):2014. (Note: As per the amendment of Quality Order, schedule (3) is substituted the ratings as per New Standard. ) Clarity is needed on how to execute running orders / tenders floated as some of the designs may not be meeting all the requirements of IS 1180-1: 2014
Grant of Licence (Cl B.I) Following details to be submitted along with application - Ratings of the transformers for which BIS licence is required. - Relevant drawings and - Technical parameters of the said ratings Clarity is required on - whether Drawings to be submitted for all the ratings - list of drawings to be submitted
Grant of Licence, (Cl. B.I): Change in following parameters shall be taken as a change in the design, which would require type testing again: - Flux density - Current density and type of winding material (Cu/Al) - Tank design - Type of construction (core type/shell type) - Type of connection (star/delta) & Vector Group - Total loss and - Method of cooling The requirement may need to be reviewed for simplification. Ex: - Change in only vector group ----> Terminations will get changed. - Change in only method of cooling ----> Will effect only Temp. rise, but not SC, Impulse, etc.
Drawl of Samples and Conformity of Product, (Cl B.III): During Preliminary Inspection, samples shall be drawn from the following group to cover all the ratings Three phase transformers Nominal System Voltage 200 kva, 3 Phase > 200kVA and 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 > 11 kv and 22 kv -do- -do- > 22 kv and 33 kv -do- -do- Single phase transformers Nominal System Standard Ratings Voltage 11 kv One sample of highest rating 22 kv -do- 33 kv -do-
Drawl of Samples and Conformity of Product, During Preliminary Inspection (Cl B.III): - One sample of highest rating, offered by the firm to cover the entire range for which licence has been applied for, as per the above table. - Separate samples for sealed and non-sealed type DTRs - Scope of licence with higher energy efficiency level DTR shall also cover DTRs with lower energy efficiency levels To obtain Licence for entire range at once, is it acceptable to get the tests done on below 5 samples having Energy Efficiency Level-3 1) 200 kva, 33 kv, 3-ph, Sealed DTR 2) 200 kva, 33 kv, 3-ph, Non-Sealed DTR 3) 2500 kva, 33 kv, 3-ph, Sealed DTR 4) 2500 kva, 33 kv, 3-ph, Non-Sealed DTR 5) 25 kva, 33 kv, 1-ph, Sealed DTR
Drawl of Samples and Conformity of Product, (Cl B.III): The licenceshall be granted once the product passes in both the type tests and the routine tests as indicated. It is presumed that only type & routine tests are to be conducted and special tests are not required. Ex: SC test is required only up to 200 kva T/Fs
A. Type of Tests Routine Tests Type Tests Special Tests a) Measurement of winding resistance a) Lightning a) Determination of sound b) Measurement of voltage ratio & impulse test levels check of phase displacement b) Temperature-rise b) Short-circuit withstand c) Measurement of short-circuit test test (above 200 kva) impedance (principal tapping, when applicable) & load loss at 50 c) Short-circuit withstand test c) No load current at 112.5 percent voltage percent and 100 percent load (up to 200 kva). d) Paint adhesion tests. d) Measurement of no-load loss & d) Pressure test e) BDV and moisture current e) Measurement of insulation resistance f) Induced over-voltage withstand test g) Separate-source voltage withstand test h) Pressure Test i) Oil Leakage Test content of oil in the transformer
For inclusion of new rating of the transformer - If rating < Scope of Licence: Licensee shall submit a complete test report from BIS approved laboratories - If rating > Scope of Licence: testing. BIS shall plan preliminary inspection and draw a sample for Time limit may be defined by BIS for review of test reports / extension of scope of License as any delay will affect the tendering activities
For Operation of Licence Type Tests 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.) Clarity is yet to be given on the below - Frequency of type tests - Methodology to be followed for selection - To ensure same sampling against all Manufacturers across India
For Operation of Licence Compliance of Market Samples: One of the following, in consultation with Ministry of Power: a. Buyers (Electricity Utilities) to send samples directly to BIS recognized laboratories b. BIS recognized Laboratory can draw samples on behalf of the Electricity Utilities c. BIS can draw samples as per the current practice prevailing in case of other products Clarity is yet to be given on the below - Methodology to be followed (Field/store sampling, data sharing, Compliance to the other clause of standards in addition to the testing, etc) - Frequency of testing on Market samples - To ensure same sampling against all manufacturers across India - Consideration of inter lab variations
IS 1180-1: 2014
If Customer specification calls for a deviation with IS 1180-1:2014.????
Standard Tapping range (For 3 Phase DTRs) : 200 kva: +2.5% to -5% in steps of 2.5% variation > 200 kva & 2500 kva: +5% to -10% in steps of 2.5% variation > 500 kva& 2500 kva: +5% to -15% in steps of 2.5% variation(oltc-optional) If customer wants a range of +5% to -5% in steps of 2.5%Terms.????
Terminal arrangements for 3-ph, Sealed type DTRs: Terminal arrangement shall be such that it shall be possible to replace bushings (external) without opening the top cover and affecting the sealing of the transformer. HV & LV Bushings: The bushing shall be made in two parts. The outer bushing shall be of porcelain. The internal bushing shall be of either porcelain or tough insulating material, like epoxy and shall have embedded stem. Note: Any other suitable arrangement can be used subjected to agreement b/w user & supplier. - Availability of huge quantities two part HV bushings.???? - It is Different from the IS standard and hence replacement may become difficult for utilities - Clarity on note is needed as without using two part bushing, effectiveness of sealing can t be ensured.
Transformer Tank: All nuts/bolts/washers exposed to atmosphere shall be of Stainless Steel if the size 12mm (Cl 15.3) If customer insist to take deviation to reduce cost.???? Is BIS going to ensure compliance of this requirement for all the quantities.????
Standard Fittings: Inspection hole, for DTRs above 200 kva rating. (Cl 20.1.r) If customer insist to take deviation to avoid additional welding / source of leakage.????
Scheme of Testing & Inspection (STI)
As per STI, from every lot Temperature Rise Test to be performed on one sample of 50 transformers (of identical design/ construction and of same nominal system voltage and rating) or part thereof. The sampling need to be amended as follows: One sample each of identical design/construction and of same nominal system voltage and rating once in five years (Like other type tests).
Experience with BEE Regulations
Requirements: - Every DTR being manufactured, commercially purchased or sold in India shall meet the compliance requirements - Sampling for verification and challenges would be carried out after the deliveries are made to the utility on the basis of tender. - BEE would conduct label verification survey in the market about the availability of registered models at various authorized dealers/retailers/warehouse of user. - Till date, some of the clients are not calling for such requirements - No evidence for conducting label verification survey uniformly across India. - It has become burden to the manufacturers those who are following rules honestly
Recommendations
User Guidelines for usage of BIS certified DTRs may be required for Site operations Storage / Handling Installation Maintenance Proper usage of Overloading / over voltage / over current protection system
Good Practices followed by some Utilities Better Handling System Proper storage
Proper Storage with elevated Platform
Improper Handling / Storage Dumped on road Dumped all material without any gap
Improper handling
Non Usage of Protection System MCCB is bypassed Arcing horns are not in place
Conclusions
Support Expecting from BIS Instant technical / administrative support from all BIS offices (Branch / Regional) Simplification of certification process for numerous varieties of DTRs BIS may take ownership on the products those are having BIS marking so that confidence levels of clients goes up and additional testing at factory / sites may intended to get reduced Ex: (1) Some customers are asking to conduct temp. rise test on 1 sample per 100 nos lot. Ex: (2) Routine tests to be conducted on all samples as part of Acceptance tests BIS to take lead in bridging the gaps with the requirements of customers Guidelines for site operations to be formulated and made mandatory for users of BIS certified product BEE label to be eliminated as BIS product meets the efficiency standards defined by BEE