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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:
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
Sl No Description of Machinery Capacity Remarks
PROCESS -----
Sl No Description of Machinery Capacity Remarks
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
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
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)
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
RAW MATERIALS Raw Material
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)
RAW MATERIALS Raw Material
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
7.10, 8.10
Temperature rise test IS 2026 (Part-2)
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 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
4. 21.4 d) Paint adhesion test ASTM D 3359
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)
RAW MATERIALS Raw Material
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
7.10, 8.10
Temperature rise test IS 2026 (Part-2)
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
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
Sl No Description of Machinery Capacity Remarks
PROCESS 2
Sl No Description of Machinery Capacity Remarks
PROCESS -----
Sl No Description of Machinery Capacity Remarks
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
Laboratory, considering the
specialized nature of test
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
Laboratory, considering the
specialized nature of test
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.
Test result Test result Test result Test result
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
design/construction and of
same nominal system
voltage and rating once in
five years.
Each transformer Each transformer Each transformer Each transformer
Test result Test result Test result Test result
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
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
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
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
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 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
TYPE TESTS: To be carried out at the first instance and whenever there is any change in design
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
Document : Ref: CMD1(BD)/IS 1180 dated 27 Nov 2014 , Guidelines for Certification of Outdoor
Type Distribution Transformers as per IS 1180
18. GUIDELINES TO ENSURE CONFORMITY OF RAW MATERIAL DURING
OPERATION OF LICENCE
Document : Ref: CMD1(BD)/IS 1180 dated 27 Nov 2014 , Guidelines for Certification of Outdoor
Type Distribution Transformers as per IS 1180
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
design/construction and of
same nominal system
voltage and rating once in
five years.
11 Minimum clearances
in Air
-do- Each transformer
15.1 Construction of
transformer tank
-do- Each transformer
15.5 Painting of
Transformer Tank
-do- Each transformer
16 Conservator for non
sealed type
transformers
-do- Each transformer
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
IS 2026 (Part-1) Each transformer
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) Each transformer
21.2 d) Measurement of no
load loss and current
IS 2026 (Part-1) Each transformer
21.2 e) Measurement of
insulation resistance
IS 2026 (Part-1) Each transformer
21.2 f) Induced overvoltage
withstand test
IS 2026 (Part-3) Each transformer
21.2 g) Separate source
voltage withstand test
IS 2026 (Part-3) Each transformer
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
TYPE TESTS: To be carried out at the first instance and whenever there is any change in design
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