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WAPDA DDS-84 & IEC 60076 · HEAVY POWER SUBSTATION EPC

5000 kVA Transformer in Pakistan (5 MVA) — Price, Specs & Turnkey Supply

The 5000 kVA (5 MVA) utility-grade power transformer represents the premier heavy substation class in Pakistan, serving large grid interconnections (132kV/11kV), 5 MW commercial solar power parks, mega cement clinker plants, high-capacity steel melting mills, and industrial Special Economic Zones (SEZs). Delivering 6,956.0 Amperes of low-voltage continuous current at 415V three-phase (or stepping down from 132kV to 11kV / 6.6kV / 3.3kV), this unit delivers exceptional mechanical endurance, active oil-forced cooling, and advanced numerical protection integration.

Rated LV Current 6,956.0 A (or 11kV distribution)
Rated HV Current 262.4 A @ 11kV (21.9 A @ 132kV)
Full Load Efficiency 99.0%
Impedance (%Z) 7.0% - 7.5%
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5000 kVA (5 MVA Utility & Power Substation) Unit Blueprint TL-5000KVA-IEC60076
5000 kVA POWER 6,956.0 A (or 11kV distribution)
✓ Prime Electrolytic Copper: 4,200 kg active copper with reinforced electrodynamic clamping.
✓ High Dielectric Oil: 5,500 Liters of Class-I mineral oil tested above 60 kV BDV.
✓ Grid Protection Integration: Buchholz relay, PRD, and RTD temperature sensors included.
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Commercial Transparency

5000 kVA Transformer Price in Pakistan (5 MVA Utility & Power Substation) — Key Cost Factors

Commercial pricing for a 5000 kVA (5 MVA Utility & Power Substation) transformer in Pakistan is dictated by raw engineering commodities and technical configurations rather than an arbitrary sticker price. Here is how your commercial proposal is structured:

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Winding Conductor Purity

Prime 99.99% Electrolytic Copper provides maximum conductivity, lower I²R losses, and longer service life (25-30 years). EC Grade Aluminium windings provide a lower initial cost option for budget-sensitive seasonal agricultural projects.

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Dielectric Oil vs. Dry-Type

Standard mineral oil-immersed (ONAN) with 5,500 Liters of Class-I inhibited oil is optimal for outdoor substations. Cast resin dry-type (AN/AF) is required for indoor commercial basements where fire regulations strictly prohibit oil.

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Tap Changer Mechanism

Standard units include a 5-position Off-Circuit Tap Changer (OCTC: ±2.5%, ±5%) for seasonal grid adjustment. On-Load Tap Changers (OLTC) with automatic voltage regulating relays are available for sensitive manufacturing loads.

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New vs. Certified Overhauled

TransfoLine manufactures brand-new units (with 18-month guarantee) and supplies thoroughly overhauled certified reconditioned units (with 12-month replacement warranty) providing 40% to 50% capital expenditure savings.

5000 kVA (5 MVA Utility & Power Substation) Commercial Summary

A 5000 kVA (5 MVA) power transformer represents a monumental industrial asset. Commercial pricing in Pakistan is governed by over 4,200 kg of pure 99.99% electrolytic copper, 5,500 liters of Class-I mineral oil, high-permeability laser-scribed CRGO core steel, motorized On-Load Tap Changer (OLTC) with RTCC panel, and comprehensive third-party high-voltage laboratory testing under WAPDA DDS-84 and IEC 60076. TransfoLine supplies brand-new 5 MVA units (18-month warranty) and certified reconditioned 5 MVA units (12-month warranty) with 40% to 50% capital savings.

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Engineering Datasheet

5000 kVA (5 MVA Utility & Power Substation) Technical Specifications (WAPDA DDS-84 & IEC 60076)

Complete electrical, mechanical, and protection coordination data for electrical consulting engineers and DISCO inspection officers:

Technical Parameter Design Value / Rating Standard & Engineering Notes
Nominal Power Rating 5000 kVA (5 MVA Utility & Power Substation) (4,000 kW (at 0.8 PF)) Continuous maximum rating at 50°C ambient temperature
Primary High Voltage (HV) 11,000 Volts (11 kV) / 33 kV / 132 kV 3-Phase, 3-Wire delta configuration (or customized)
Secondary Low Voltage (LV) 415 Volts (Line-Line) / 240 Volts (Line-Neutral) 3-Phase, 4-Wire star configuration with neutral bushing
Rated Secondary Current (LV) 6,956.0 A (or 11kV distribution) Continuous full load current at 415V secondary
Rated Primary Current (HV) 262.4 A @ 11kV (21.9 A @ 132kV) Continuous full load current on 11 kV grid side
System Frequency 50 Hz ±5% WAPDA / NTDC National Grid synchronized
Vector Group Dyn11 / YNd11 Delta HV / Star LV with 30° phase lag neutral
Cooling Designation ONAN / ONAF / OFWF Thermosiphon circulation through radiator banks (forced cooling available)
Percentage Impedance (%Z) 7.0% - 7.5% Guaranteed within ±10% IEC tolerance at 75°C reference
No-Load Losses (Iron Losses) 5,800 Watts Measured at rated voltage and frequency (CRGO core)
Full-Load Losses (Copper Losses) 40,000 Watts Measured at rated current at 75°C reference temperature
Transformer Mineral Oil Volume 5,500 Liters Uninhibited Class-I mineral oil (BDV > 60 kV fresh)
Total Weight (with Oil & Fittings) 15,500 kg (15.5 Tons) Active copper winding weight: 4,200 kg
Overall Physical Dimensions 3,950 mm (L) × 2,750 mm (W) × 3,650 mm (H) Overall clearance footprint including radiators and conservator
Recommended HT Protection Switchgear 11kV / 132kV Vacuum or SF6 Circuit Breaker Panel with Differential & REF Relays 11kV Vacuum Circuit Breaker with IDMT and Differential Relays
Recommended LT Main Circuit Breaker Dual 4000A Air Circuit Breakers (ACB) or Multiple Sub-Incomers Microprocessor-based electronic LSIG trip unit coordination
Recommended Low Voltage Cabling / Busway Double-Busbar Trunking System (BBT) or 11kV Underground XLPE Feeder Cables Copper Busbar Trunking (BBT) system sized for heavy current
Civil Foundation Mounting Dedicated Outdoor Substation Compound on Heavy Reinforced Plinth & Oil Retention Sump A 5000 kVA (5 MVA) substation is classified under DISCO B-4 industrial tariff or independent power producer (IPP) grid code. Installation mandates a formal 11kV or 132kV bay with SF6/vacuum circuit breakers, differential protection (87T), restricted earth fault (REF), neutral grounding resistors (NGR), and dual copper grounding grids (<0.5 Ohm).
Industrial Applications

Where is a 5000 kVA (5 MVA Utility & Power Substation) Transformer Deployed in Pakistan?

Real-world application engineering scenarios across Pakistani manufacturing complexes, commercial hubs, and industrial zones:

5 MW Commercial Solar Power Plant Grid Substation

Up to 4,000-5,000 kW Solar Inverter Export Capacity

Primary utility grid-interconnection substation stepping up multi-inverter medium-voltage solar power to 11kV or 132kV for national grid export under NEPRA licensing standards.

  • Electrostatic shielding against inverter harmonics
  • Low impedance voltage regulation under shifting solar irradiance
  • Complete synchronization testing with DISCO and NTDC

Mega Cement Clinker & Grinding Complexes

3,500 to 4,500 kW Continuous Heavy Mill Motive Power

Supplies continuous motive power for raw material crushing rolls, kiln drive motors, high-pressure grinding rolls (HPGR), clinker ball mills, and electrostatic precipitators.

  • High mechanical bracing against heavy shock loads
  • On-Load Tap Changer (OLTC) with 17 tap steps for automatic voltage control
  • Tested dielectric oil breakdown voltage (>60 kV)

Special Economic Zones (SEZ) Central Distribution Substations

4,000 to 5,000 kW Industrial Estate Feeder

Central primary distribution transformer serving multi-tenant industrial parks, dedicated industrial feeder zones, and captive power plant grid interconnections.

  • Buchholz relay, magnetic oil level gauge, and dial thermometer with trip contacts
  • Dual copper grounding grids (<0.5 Ohm)
  • 18-month warranty on brand-new prime copper units
Quality Assurance

Testing Protocols & DISCO Grid Energization Approval

Every TransfoLine 5000 kVA (5 MVA Utility & Power Substation) transformer undergoes stringent factory routine testing before dispatch to ensure 100% first-time approval during DISCO departmental inspection:

Mandatory Routine Tests Lab Certified

Insulation Resistance (Megger Test) Tested at 2500V DC (HV-LV, HV-Earth, LV-Earth) ensuring insulation values exceed 2,000 Mega-Ohms.
Winding DC Resistance Measurement Measured across all primary tap positions and secondary phases using Kelvin bridge for balance verification.
Voltage Ratio & Vector Group Verification Confirming exact transformation ratio and Dyn11/YNd11 phase shift.
Oil Dielectric Breakdown Voltage (BDV) Verified with 2.5mm sphere gap electrode test exceeding 60 kV fresh.
Separate Source AC Withstand Test HV winding tested at 28 kV AC (or 230kV AC for 132kV units) for 60 seconds.

DISCO Inspection & NOC Process Turnkey Assistance

B-3 / B-4 Load Sanctioning File Preparation Preparation of single line diagrams (SLD), protection coordination studies, and tariff change applications.
Substation Civil Pad Inspection Verification of concrete foundation dimensions, gravel oil-sump, and earth pit clearance distances.
Dual Earth Pit Verification (<0.5 Ohm) Separate copper grounding grid for transformer tank body, neutral star point, and lightning arrestors.
Departmental Testing & Meter Sealing Witnessing of testing by DISCO M&T (Metering & Testing) engineers and installation of bidirectional TOD meters.
Direct Quotation

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Technical Clarifications

5000 kVA (5 MVA Utility & Power Substation) Transformer Technical & Procurement FAQ

Direct engineering answers to frequently asked questions about purchasing, installing, and maintaining a 5000 kVA (5 MVA Utility & Power Substation) transformer in Pakistan:

What is the full load current of a 5000 kVA (5 MVA) transformer?

At standard 415V three-phase line-to-line, a 5000 kVA transformer delivers 6,956.0 Amperes of low-voltage (LV) full load current: 5,000,000 / (1.732 × 415) = 6,956.0 A. On the 11 kV primary high-voltage side, the rated full load current is 262.4 Amperes. When configured for 132kV transmission, primary current is 21.9 Amperes.

What switchgear is required for a 5000 kVA (5 MVA) substation?

On the high-voltage side, an 11kV or 132kV Vacuum/SF6 Circuit Breaker panel equipped with numerical differential (87T), overcurrent (50/51), and earth-fault (50N/51N) protection relays is mandated. On the secondary side, dual 4000A Air Circuit Breakers (ACB) with central bus coupler or medium-voltage 11kV/6.6kV/3.3kV feeder panels are utilized.

What are the foundation and space requirements for a 5000 kVA transformer?

A 5000 kVA transformer weighs approximately 15,500 kg (15.5 metric tons). It requires a heavy reinforced concrete foundation plinth (minimum 3500 psi concrete) measuring at least 4,200 mm × 3,000 mm × 500 mm deep, surrounded by an oil-soak gravel pit capable of containing 100% of the 5,500 liters of oil, enclosed by 2.4-meter security chain-link fencing.

What size PFI capacitor bank is required for a 5000 kVA substation?

A 1,500 kVAR to 2,000 kVAR automatic Power Factor Improvement (PFI) panel divided into 16 to 24 microprocessor-controlled capacitor steps with 7% detuned harmonic reactors is required to maintain plant power factor above 0.95.

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