1. Do the BIL levels for switchgear and transformers need to be coordinated. For example, if switchgear is rated for 90kv BIL and the transformer is rated for 30kv BIL is the transformer under rated? Most people opt to investing specifying equipment with dielectric insulation with proven good performance rather than invest in expensive insulation coordination study to lower the equipment BIL. Since your case dielectric rating are unusual, something must be done to prevent a catastrophic failure.
Please provide additional details: System voltage, type of transformer (dry/liquid), indoor or outdoor installation, shielding protection, underground or overhead lines, lightning activity (keraunic or flash density level) and any other relevant information.
2. Is it typical to provide surge protection on transformers that are served on the primary from vacuum CB from switching surges?. Yes, it is typical to provide surge protection for distribution and power transformer. For standard small transformer unit, surge protection sometime is not economically justifiable.
3. Is it typical to also install surge capacitors in addition to the surge arresters? It's my understanding that the arresters are ineffective at controlling a surge's rate of rise. Not, it is not typical to install surge capacitors in transformers. For standard dry type transformer with lower BIL than the liquid immersed units, surge-protective capacitors are specified in rare situations to correct problem applications particularly where cable length is inadequate to achieve transient voltage rate-of-rise control.
The advances in surge arrester combined with better performance of VCB switching eliminate in most cases the need for surge capacitor.
4. - Could the surge arresters be installed in the breaker cubicle instead of at the transformer. This is not the best location for transformer surge protection. In addition to SA in the transformer, some switchgear designer add extra SA for UG cable protection and overvoltage control.