reasoned document

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Reasoned document

1.0 Draft STR No.TI/STR/006, Rev`04‟for 25 kV Silicone Composite Insulators have been uploaded

on RDSO website for comments/suggestions from manufacturers.

2.0 Comments received from manufacturers on clauses modified/newly added have been

tabulated below.

3.0 On STR clauses where firms have not furnished any comments, it has been

considered as Nil comment.

Clause no Name of

firm

Comment by firm RDSO’s

remark

1.0 SCOPE

This Schedulecovers the technical

requirement for manufacture and

supply of Technical Requirement

(STR) is to assess the manufacturing

capability of the vendors for new

registration/approval of Silicone

Composite Insulators for 25 kV a.c.

50 Hz electric traction. This schedule

pertains to the manufacture of

Composite Insulator by direct

mouldingof polymer sleeveover the

FRP rodand the jointing of metal

fittings with FRP rod by

crimping/threaded engagement duly

sealed by Fevicol or other suitable

sealant.and consequently injection

moulding of Silicone Rubber

Compound over the FRP rod.

This STR shall be read in conjunction

with RDSO‟s Specification No.

TI/SPC/OHE/INSCOM/1071 (with

latest amendment).

DECCAN Nil. Accepted,

Spec no shall

be mentioned

as 1072.

ABI No comments.

AESPL Nil.

Prithvi The above referred scope is agreeable

subject to notification in specification

No.TI/SPC/OHE/INSCOM/1072, as you

have already drafted a new specification.

Raychem Nil.

Adinath Nil.

2.0GENERAL INFRASTRUCTURE

&MANUFATURING FACILITIES:

The manufacturer should have full

fledged in-house testing facilities in

India and indigenous manufacturers

who have developed such in-house

facilities shall be encouraged. Beside

he must have adequate covered

accommodation for storing raw

material, finished items awaiting

dispatch and arranging inspection. The

manufacturer should have system to

ensure that the product conforms to the

requirements of

RDSO'sprototypespecificationNo.TI/S

PC/OHE/INSCOM/1070.No.TI/SPC/O

HE/INSCOM/1071 with latest

amendment.

DECCAN Nil. Accepted,

Specification

no shall be

mentioned as

1072.

ABI No comments.

AESPL Nil.

Prithvi Please refer your new specification No.

TI/SPC/OHE/INSCOM/1072

Raychem Nil.

Adinath Nil.

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2.1 MACHINERY AND PLANT.

(i) Equipment for Injection moulding

of polymer sleeve Silicone Rubber

Compound over FRP rod with

Temperature Control.

DECCAN Nil. No change.

ABI No Comments.

AESPL Nil.

Prithvi Acceptable

Raychem Nil.

Adinath Nil.


(ii) Assembly jigs to align the metal

fittings and seal.

Deccan

AESPL

ABI

Raychem

Adinath

Nil. No change.

Prithvi Acceptable


(iii)Go & No Go Gauges for the overall

length of the insulator.

Deccan

AESPL

ABI

Raychem

Adinath

Nil. No change.

Prithvi Acceptable


(iv)Measuring equipment like vernier

caliper, inside & outside caliper etc.

Deccan

AESPL

ABI

Raychem

Adinath

Nil. No change.

Prithvi Acceptable


(v) Crimping Machine of suitable

capacity.

Deccan Nil

No change. ABI No comments.

AESPL Nil.

Prithvi Acceptable

Raychem Nil

Adinath Nil


(vi)Rheometer for determination of

processing parameters of Silicone

Rubber Compound.

Deccan Nil. Not accepted,

it is a

requirement as

per clause no

3.4.4 of Final

Draft

specification

No. TI/

SPC/OHE/IN

SCOM/1072.

ABI No comments.

AESPL This machine may not be required in

case of insulator manufacturer use ready

mixed rubber from approved supplier by

RDSO wherein all process/molding

parameter are pr-define by silicone

rubber supplier.

Prithvi A rheometer either in rotational or

oscillatory mode is used in a laboratory

to measure the reological properties of a

substance. The rheometer graph

highlight over three phase like

processing phase,curing phase and

physical properties phase.

The important results of processing

phase are ML(least torque) and ts1and

ts2i.e. scorch time. The time required for

the increase ofts1to ts2from minimum

torque. This number is an indicator of the

time required for the beginning of the

process of Cross Linking.

The important results of curing phase

are t10 (time corresponding to 10%),

t50(time corresponding to 50% curing),

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t90(time corresponding to 90% curing)

which is noted as optimum vulcanization

time.

The important test on physical

property phase highlights at the last part

on the reograph. MA maximum torque,

the time level of cross linking, the

quality of the rubber used, the filler used,

the compounding process.

This test is done from each batch

but not from each bale or bag is

applicable for immediate product not

final product. But in case of composite

insulator the silicone compound rubber is

a final product of the specified vendor.

They also provide the batch wise

rheometer values of the supplied batch.

So it is not meaning to have a rheometric

value of the supplied batch. So it is also

not meaningful to have a rheometer for

same testing of composite insulator

manufacturer‟s end. Our Mr. A. Sen has

already objected the same during the

meeting held at your office on dated

22.07.2016.

Raychem Nil

Adinath Nil


(vii) Cleaning Plant for FRP Rod and

Electric Oven with Temperature

Control.

Decan Nil. No change

ABI FRP Rod shall be free from dust and

other foreign particles. Electric oven for

preheating the rod.

AESPL Nil.

Prithvi Acceptable

Raychem Nil

Adinath Nil

2.2

The manufacturer shall procure FRP

rod from a reputed firm, according to

the specification made by him suitable

to the requirements of RDSO's

specification. The manufacturer shall

ensure the quality of the FRP rod

supplied by his vendor.

Deccan

AESPL

ABI

Raychem

Adinath

Nil. No change.

Prithvi Acceptable

2.3

The manufacturer shall procure the

polymer Silicone Rubber compound

from a reputed firm whose product

shall meet the requirement of the

RDSO's specification &should furnish

the product data sheet, if railways ask

for the same. The manufacturer shall

ensure the quality of polymer Silicone

Rubber Compound supplied by his

vendor.


ABI No Comments.

AESPL Nil.

Prithvi Acceptable.

Raychem Nil.

Adinath Nil

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2.4

The manufacturer shall ensure that his

vendors for supply of FRP rod,

polymer sleeve Silicone Rubber

Compound and metal fittings shall

render proper after sales service and

attend to the complaints, if any by

Railways, immediately and-implement

remedial action.

DECCAN The manufacturer shall ensure for supply

of FRP rod, Silicone Rubber Compound

and metal fittings shall render proper

after sales service and attend to the

complaints, if any by Railways

immediately and implement remedial

action.

No change.

ABI No Comments.

AESPL Nil.

Prithvi Acceptable .

Raychem Nil.

Adinath Nil

3.0.TESTING FACILITIES

(i)High voltage transformer set up to

suit the requirements of the

specification.

Deccan

AESPL

ABI

Raychem

Adinath

Nil. No change.

Prithvi Acceptable.


(ii)Equipment to conduct sudden load

release test at -20°C to -25°.

a) Arrangements shown in Fig

B-1 of IEC: 61109 may be

adopted with suitable device

for test to be conducted at -

20° C to - 25° C.

b) The equipment for Thermal

mechanical test may be suitably

modified and used.

Deccan

AESPL

ABI

Raychem

Adinath

Nil. No change.

Prithvi

Acceptable.


(iii)Equipment for Thermal

mechanical test.

Deccan

AESPL

ABI

Adinath

Nil. Not

acceptable.

Thermo-Mechanical test have been specified as per IEC-61109-2008 and parameters have been defined accordingly.

Raychem

Thermal mechanical test set up with

both tensile loading as per IEC 61109

& cantilever loading as per IEC 61952

& IEC 62231. This change is required

because stay arm & bracket Insulators

are having cantilever loading (bending

load) so design & type test needs to be

conducted with Maximum designed

Cantilever Load (MDCL) as defined in

standard IEC 62231 & IEC 61952.

Prithvi Acceptable.


(iv)UTM machine with facility for

conducting tensile and bending test or

separate machine with facility for

conducting tensile load test and

bending

test can also be provided.This should

be equipped with PLC control

interface.

DECCAN Nil. No change

ABI No Comments.

AESPL Nil

Prithvi Acceptable.

Raychem Nil.

Adinath Nil.

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(v)Test set up for test on control of the

slope of the strength - time curve of

the insulator.

Deccan

AESPL

ABI

Raychem

Adinath

Nil. No change.

Prithvi Acceptable.


(vi)Test set up for inclined plane

tracking and erosion test as per IEC:

60587.

Deccan

AESPL

ABI

Raychem

Adinath

Nil. No change.

Prithvi Acceptable.


(vii)Test set up for water immersion

test.

Deccan

AESPL

ABI

Raychem

Adinath

Nil. No change.

Prithvi Acceptable.


(viii)Test set up for dye penetration test

of the core material (FRP rod).

Deccan

AESPL

ABI

Raychem

Adinath

Nil. No change.

Prithvi Acceptable.


(ix)Test set up for water diffusion test

of core material (FRP rod) in

line with

Figure 2.3 and 4 of IEC: 61109.

Deccan

AESPL

ABI

Raychem

Adinath

Nil. No change.

Prithvi Acceptable.


(x)Test set up for water absorption test

of FRP rod.

Deccan

AESPL

ABI

Raychem

Adinath

Nil. No change.

Prithvi Acceptable.


(xi)Test set up to conduct galvanization

test on the metal fittings.

Deccan

AESPL

ABI

Raychem

Adinath

Nil. No change.

Prithvi Acceptable.


(xii)Tensile testing machine for

testing of tensile strength and

elongation ofPolymerSilicone

Rubber compound.


ABI No Comments.

AESPL Nil.

Prithvi Acceptable to us.

Raychem Nil.

Adinath Nil.


(xiii)Facility for conducting Tear

Strength.

Deccan

AESPL

ABI

Raychem

Adinath

Nil. No change.

Prithvi Acceptable.

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(xiv)Test equipment for measurement

of Hardness (Shore A & Barcol).


ABI For Barcol-Hardness test report will be

accepted from supplier who is having the

facility of Barcol equipment.

AESPL Nil.

Prithvi Acceptable to us.

Raychem Nil.

Adinath Nil.


(xv)Test equipments for conducting

tests for DC Volume resistivity and

Dielectric strength.

Deccan

AESPL

ABI

Raychem

Adinath

Nil. No change.

Prithvi Acceptable.


(xvi)Facility for conducting test for

specific gravity.

Deccan

AESPL

ABI

Raychem

Adinath

Nil. No change.

Prithvi Acceptable.


(xvii)Test equipment for testing

resistance to weathering & UV as

per ASTM G 53.

Deccan

AESPL

ABI

Raychem

Adinath

Nil. No change.

Prithvi Acceptable.


(xviii)Facility for conducting glass

content test on FRP rod.

Deccan

AESPL

ABI

Raychem

Adinath

Nil. No change.

Prithvi Acceptable.


(xix)Facility and arrangement for

conducting "Brittle fracture resistance

test”.

Deccan

AESPL

ABI

Raychem

Adinath

Nil. No change.

Prithvi Acceptable.


(xx)NDT Testing equipment to test

the bonding of rubber.

DECCAN Nil. Not accepted.

However, type

of NDT

testing shall

be specified as

per

specification.

i.e Ultrasonic,

radiography

etc.

ABI No Comments.

AESPL As this equipment may not be full proof

to ensure the perfect bonding throughout

length of insulator, hence this test set-up

should not be mandatory as peel off test

is already incorporated.

Prithvi

Regarding SN.(xx), kindly note our

following representation:

NDT (Non Destructive Testing) methods

are based on Acoustics Emission Testing

(AE), Electromagnetic Testing (ET),

Guided Wave Testing (GW), Ground

penetration Radar (GPR), Laser Testing

Method (LM) etc. if bonding is to be

cheeked here should not be „SQC‟

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system or checking of 100 % element is

not possible for total production, as peel

off strength checking system for

checking of silicone polymer to glass rod

bonding on „SQC‟ basis has already been

proposed by yourself, so for same testing

on „SQC‟ basis NDT is not required

rather irrevalent. This type of testing is

required for 220 kV or above

transmission insulators. Introduction of

this kind of odd non required testing will

help to shortlist the present vendors

which will help to create monopolistic

business for few vendors. Our Mr. A.Sen

objected in the joint meeting at RDSO

dated 22.07.2016 for such type of odd

implementation. Peel off test is also

sufficient to check bonding between the

silicone compound and FRP glass rod.

Raychem Nil.

Adinath Under clause no.3.0 of Testing Facilities

point no.XX, your goodself has proposed

for NDT Testing equipment to test the

bonding of rubber.

In respect to above proposed

machine we would like to request you to

please clarify the need to introduce the

same machine and also the exact type of

equipment to be arranged and the

procedure of testing the sample for the

required property. Also please provide us

the testing standard

viz.ASTM/IS/BIS/IEC etc whichever is

applicable for the same. Because from

the above description we are unable to

understand the exact type equipment

required and the testing procedure to be

followed.


(xxi)Test set up for testing of

Eccentric Loading Test (for

Sectioning Insulator manufacturer).


ABI No Comments.

AESPL Nil.

prithvi Not acceptable for us.

Raychem Nil.

Adinath Nil.


(xxii)Test set up for Torsion Test (for

Post Insulator manufacturer).


ABI No Comments.

AESPL Nil.

prithvi Not acceptable for us.

Raychem Nil.

Adinath Nil.

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3.1 OTHER REQUIREMENT

&TESTING FACILITIES:

i. The manufacturer should have

minimum 3 years experience in the

manufacture and supply of line

Insulators at least 66 kV and above.

DECCAN Other Requirement & Testing

Facilities:

i) The manufacturer should have

minimum 5 years experience in the

manufacture and supply of line

Insulators at least 66 kV and above.

ii) The Manufacturer should have a field

service performance of 5000 Nos of

Insulators of at least 66 kV and above for

a period of 3 years.

iii) The Firm should have a minimum

turnover of Rs.50 crores in the last 2

years.

Partially

accepted.

The paragraph

shall be

replaced by

following:

“The

manufacturer

should have

manufactured

and supplied

Insulators of

rating 25 kV

and above to

different

utilities.

ABI No Comments.

AESPL As the product rating of railways

composite insulators are 25 kV, hence

manufacture should have experience of

at least 36kV composite insulators

manufacturing. In case of specified

higher rating, there will possibility of

monopoly of only few insulators

manufacture.

However, This will be not applicable, in

case of manufacture is already approved

& supplying insulator to Indian

Railways.

Prithvi a)it should not be applicable because

considering all required parameter

registration has been provided to all

existing units.

b) The required load of Railways is 25

kV, hence, the experience if at all

required should be 33 kV only instead of

66 kV and above.

Raychem 1. Indian railways system works on 25

kV AC , hence experience of 66 kV and

above for 3 years is not relevant to this

requirement. This will restrict good

vendors already supplying to global

railways from long time.

2. Experience requirement should be as

follows " The manufacturer should have

minimum 3 years of experience in

manufacturing and supply of 25 kV &

above insulators to global

railways/utilities.

Adinath Under clause no.3.1 of Testing Facilities

point I, your goodself has proposed that

the manufacture should have minimum 3

years experience in the manufacture and

supply of the line insulators at least 66

kV and above.

In respect to above proposed clause,

we are unable to understand why the

same has been proposed with the

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condition for minimum 3 years

experience in manufacture and supply of

line insulators of 66 kV and above,

whereas the Railway insulators are of 25

kV rating only and any firm approved by

RDSO for the same is thoroughly

assessed for all type of quality and

infrastructure requirements as per

specified specification of RDSO and all

the required type tests,, design tests and

acceptance tests are performed on the

insulators by RDSO itself or by NABL

approved laboratory before the final

approval is granted to any new

manufacturer. Also above all this the

new manufacturer is approved as a part-

II supplier for the initial period with a

requirement to complete and supply the

minimum required quantity and

completion of minimum period before

upgrading the firm to part-I category and

this practice is followed only because the

new approved manufacturer can gain

some experience before being upgraded

as a regular pat-I supplier.

In view of above we would like to

submit that the same clause should not

be included in the STR requirements as

the same will not support with respect to

quality improvement which is the sole

aim for revision of STR in order to

enhance the quality of the product

whereas introduction of such a clause

will restrict the number of new entrants

to almost nil and will also even reduce

the number of approved manufacturers

from the list of approved vendors from

your list as because most of the present

manufacturers will also not be able to

meet this requirement of 3 years

experience in 66 kV insulators.

Please note that such action will not at

all enhance the quality requirement

whereas it will lead to minimum

manufactures in approval list and the

same will lead to monopolistic approach

and thereby offering of very high prices

in the tenders invited by railways and

will result in high financial loses due to

same.

Also as per speech dated

16.01.2016 of our Honorable Prime

Minister Shri Narender Modi (scanned

copy attached) it is proposed to

encourage the new Start-Up companies

to participate in the growth of our

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country.

We would request you to call for a

vendor meet in your office at RDSO to

discuss all the related points in relation

to STR and Specification before

finalizing anything.

3.1 OTHER REQUIREMENT

&TESTING FACILITIES:

ii. The manufacturer should have in-

house facility for designing of the

Insulator with adequate R & D

facility. To meet this requirement

manufacturer should have Design

software e.g. Auto CAD or any other

suitable 2D or 3D modeling etc. and

Electric Field modeling software e.g.

Electron-2D or any other suitable

software to validate design of

insulator.

Deccan Nil. Partially

accepted.

The para 3.1

(ii) shall be

replaced by

the

following:

“The

manufacturer

should have

in-house

facility for

designing of

the Insulator

with adequate

R & D

facility. To

meet this

requirement

manufacturer

should have

Design

software e.g.

Auto CAD or

any other

suitable 2D

or 3D

modeling etc.

and

Manufacturer

should also

have Electric

Field

modeling

software

e.g.Electron-

2D or any other suitable

software to

validate

design of

insulator

(alternatively

firm may out

source Electric Field

modeling to

NABL/NAB

CB

lab/agency).

ABI Electric field modeling software cost is

very high. Hence design validation can

be done at ERDA/CPRI where the

facility is available. Request you to

consider the suggestion.

AESPL Although the manufacturer should have

Auto CAD software for drafting the

design drawing but another software for

Electric Field modeling is not required as

all the design data of insulator i.e.

technical data, overall dimensions of

insulators has already been specified in

the RDSO specification.

prithvi Acceptable for us.

Raychem Nil.

Adinath Nil.

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4.1

The firm should have acquired ISO

9001:2000 2008 series certification for

the product for which an approval is

sought and the product should be

broadly covered in the scope of the

certification for manufacture and

supply.

DECCAN Nil. 2008 changed

to 2015. ABI No Comments.

AESPL Nil.

prithvi Acceptable.

Raychem Nil.

Adinath Ni.

4.2

Quality manual of the firm for ISO

9001:2000 2008 should clearly indicate

at any stage the control over

manufacturing and testing of the said

product.

DECCAN Nil. 2008 changed

to 2015. ABI No Comments.

AESPL Nil.

prithvi Acceptable.

Raychem Nil.

Adinath Ni.

4.3

There exists a system of easy

traceability of the product item at

supply by

vendor stage and finished product

stage.

Deccan

AESPL

ABI

Raychem

Adinath

Nil. No change.

Prithvi Acceptable.

4.4.

a. The Quality Assurance Plan (QAP)

should be prepared as per RDSO‟s

guideline and approved by RDSO.


ABI No Comments.

AESPL Nil.

prithvi Acceptable.

Raychem Nil.

Adinath Ni.

4.4.

b. The Firm should have an approved

copy of the product for

implementation.

DECCAN Nil. Word product

shall be

replaced

by”QAP”.

ABI No Comments.

AESPL Nil.

prithvi Acceptable.

Raychem Nil.

Adinath Ni.

4.5

The assembly of the insulator shall be

done by well trained staff under the

supervision of qualified staff with

experience in the field.

Deccan

AESPL

ABI

Raychem

Adinath

Nil. No change.

Prithvi Acceptable.

4.6

Quality manual of the firm indicating

the extent of control over production

and testing should be available.

Deccan

AESPL

ABI

Raychem

Adinath

Nil. No change.

Prithvi

Acceptable.

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4.7

System should exist for documentation

of the following:

a. Incoming raw material with TC

reference of supplier as well as

internal

test and audit checking from

outside agency & product data

sheet,

wherever required.

b. Ensure that the details regarding

stage inspection and

test result are available.

c. Ensure that a system exists for

calibration of testing

&measuring equipment and record is

maintained.

Deccan

AESPL

ABI

Raychem

Adinath

Nil. No change.

Prithvi

Acceptable.

4.8 System should exist for

documentation of the

following:

Deccan

AESPL

Prithvi

ABI

Raychem

Adinath

Nil. No change.

Other Points

Addition. Deccan In Testing facilities the following test

equipments to be included:

i)Water boiling equipment.

ii)Impulse Generator

Since all the equipment for conducting

Test on Interfaces and connections of

end fittings as per CL.10 of IEC 61109

are made available with the

manufacturer this test set up is also to be

included with the manufacturer.

The minimum

M & P and

testing

facilities

required for

manufacturing

Composite

Insulators have

been specified

in this STR.

To not incorporate. Prithvi Considering our above cited comments,

we request you to take a note of our

representation and not incorporate the

following items in the rectified STR:

1.Rheometer.

2.NDT testing equipment

3.Experience in manufacture and supply

of insulator at least 66 kV and above.

Covered in

clause no. 2.1

(vi), 3.0 (xx) &

3.1 (i)

respectively.

Addition Raychem

Test setup for the verification of the

maximum design cantilever load

(MDCL) as per IEC 61952, This test

setup is required because stay arm &

bracket insulators are loaded with

cantilever load in actual application &

defining MDCL load is must for these

insulators

Not accepted.

Tests have been specified as per IEC-61109-2008 and parameters /test methods have been defined accordingly.

of 13

Raychem

Raychem

Raychem

Raychem

Addition Surface roughness (Ra, Ry & Rz)

measuring equipment. (This is requried to check the inner bore

surface rougness of end fittings used in

insulators. Surface roughess

measurement is important as without

this there will not be consistency in

crimping with other parameters like

crimping pressure kept same. There is

also chance of FRP rod crack due to

sharp surface inside bore of Insulator, It

is practically impossible to get

consistent quality &mechanical

parameters without control on surface

roughness)

The minimum

M & P and

testing

facilities

required for

manufacturing

Composite

Insulators have

been specified

in this STR.

however

manufacturers

may have

additional

facilities.

These parameters shall be specified by manufacturers in their QAP along with acceptance criteria.

Addition Brinnel Hardness testing equpment

for End fittings. (This is required to

check the hardness of end fitting for

each lot. The hardness varies for each lot

& crimping pressure parameter depends

on hardness factor so it is very important

to know the batch hardness


Addition Reference standard should also

include IEC 62217, 61952 and 62231 as it gives direct reference to test clause

with MDCL values

IEC-61109

have been

specified for

composite

Insulators.

Other relevant

IECs are

referred in the

same.

Addition HV test setup for 100% routine testing

of FRP rod leakage current

measurement at pre stressed Voltage of

@ 175 V/mm length of FRP rod. The

setup should have least count of 0.01

mA & and with stray capacitive leakage

suppression.


reasoned document

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