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Tech. Specification NIT No. NESCO Utility/ Shifting of L& S / 06/ 26.5.17

SECTION-IV

TECHNICAL SPECIFICATION OF MATERIALS

FOR

SHIFTING OF EXISTING

ELECTRICAL NETWORK FOR

WIDENING OF NH-215

TENDER N O T I C E NO:- NESCO Utility / Shifting of L&S / 06/17-18/ 5872

Date: 26.05.17


TECHNICAL SPECIFICATION FOR SHIFTING OF

33KV, 11KV AND LT DISTRIBUTION LINES & SUB-STATIONS 1.0 NATURE OF WORK

The work covered by this Specification is for shifting of existing 33KV, 11KV, LT distribution lines

and distribution Sub-stations by constructing new network , testing ,commissioning and dismantled the

existing electrical network thereafter & returned the materials to NESCO Utility store for widening of NH

215 as specified herein and in the attached Schedules.

1.1 SCOPE OF WORK

Name of Works : 1) Package –I : Shifting of electrical network from Remuli to Guali (163 Km to 184 Km) under

Keonjhar District

2) Package –II : Shifting of electrical network from Remuli to Guali (185 Km to 206 Km) under

Keonjhar District

Pack

age

Elec

tric

al D

ivisi

on

33 K

V L

ine

(Sin

gle/

Dou

ble

line)

11

KV

Lin

e (S

ingl

e/D

oubl

e lin

e)

LT L

ine (

with

AB

Cab

ling

(3x5

0+1x

35+1

x16)

mm

²

LT L

ine (

with

AB

Cab

ling

(3x9

5+1x

70+1

x16)

mm

²

10 K

V 1

1/0.

23 K

V S

/S

16 K

V 1

1/0.

23 K

V S

/S

25K

V 1

1/0.

4 K

V S

/S

63K

V 1

1/0.

4 K

V S

/S

100

KV

11/

0.4

KV

S/S

Qty (in Km.)

Qty (in Km.)

Qty (in Km.)

Qty (in Km)

Qty (in Nos.)

Qty (in Nos.)

Qty (in Nos.)

Qty (in Nos.)

Qty (in Nos.)

Package-I JED, Joda 12.0 16.9 4.36 2.0 0 3 6 0 2

Package-II JED, Joda 27.0 11.0 0.9 0 2 0 4 3 2

Total 39.0 27.9 5.26 2.0 2 3 10 3 4


1.2 Location Details under Keonjhar District:

1. Package – I

Sl. No.

Shifting Location

Name of Electrical Section

Distance location

33 K

V L

ine

(Sin

gle/

Dou

ble l

ine)

11

KV

Lin

e (S

ingl

e/D

oubl

e lin

e)

LT

Lin

e ( w

ith A

B C

ablin

g (3

x50+

1x35

+1x1

6)m

m²

LT

Lin

e ( w

ith A

B C

ablin

g (3

x95+

1x70

+1x1

6)m

m²

10 K

V 1

1/0.

23 K

V S

/S

16 K

V 1

1/0.

23 K

V S

/S

25K

V 1

1/0.

4 K

V S

/S

63K

V 1

1/0.

4 K

V S

/S

100

KV

11/

0.4

KV

S/S

Qty (in

Km.)

Qty (in Km.)

Qty (in Km.)

Qty (in Km)

Qty (in Nos.)

Qty (in Nos.)

Qty (in Nos.)

Qty (in Nos.)

Qty (in Nos.)

1 Remuli to Guali

Remuli 163 Km to

171 Km 0 4.9 0.36 0 0 1 3 0 1

2 - do- Joda

172 Km to 184 Km 12.0 12.0 4.0 2.0 0 2 3 0 1

Total 12.0 16.9 4.36 2.0 0 3 6 0 2

2. Package- II

Sl. No.

Shifting Location

Name of Electrical Section

Distance location 33

KV

Lin

e (S

ingl

e/D

oubl

e lin

e)

11

KV

Lin

e (S

ingl

e/D

oubl

e lin

e)

LT L

ine (

with

AB

Cab

ling

(3x5

0+1x

35+1

x16)

mm

²

LT L

ine (

with

AB

Cab

ling

(3x9

5+1x

70+1

x16)

mm

²

10 K

V 1

1/0.

23 K

V S

/S

16 K

V 1

1/0.

23 K

V S

/S

25K

V 1

1/0.

4 K

V S

/S

63K

V 1

1/0.

4 K

V S

/S

100

KV

11/

0.4

KV

S/S

Qty (in Km.)

Qty (in Km.)

Qty (in Km.)

Qty (in Km)

Qty (in Nos.)

Qty (in Nos.)

Qty (in Nos.)

Qty (in Nos.)

Qty (in Nos.)

1 Remuli to Guali

Remuli

185 Km to 206 Km

27.0 11.0 0.9 0 2 0 4 3 2

Total 27.0 11.0 0.36 0 2 0 4 3 2


1.4 Item Description : The electrical installation work to be carried out for shifting of electrical networks due to widening of NH215 from Remuli to Guali on “turnkey‟ basis with supply of materials . Details item description shall include the material .

Sl no. Item Particulars Include the supply materials

1

Shifting of 33 KV Lines with supply & erection of all materials.

(Using 13mtr long 150x150 mm RS joist pole with all accessories)

13 mtr long, 150x150 mm RS Joist 33 KV 'V' Cross Arm GI (19.7 Kg each) Back Clamp for 'V' Cross Arm (8mm GI Flat) 33 KV Pole Top Bracket GI 100X50mm Channel (5.5 Kg each) 33 KV top bracket Clamp GI 33 KV Pin Insulator 33 KV G.I. Pin 90 KN B&S Disc Insulator 33KV B&S hard ware fittings 20 mm GI stay sets ( with stay clamp, 7/8 SWG stay wire, stay insulator) 100x50x6 mm MS Chanel 75x40x5 mm MS chanel 50x50x6 MS angle 100 mm² AAA Conductor 4 pole structure , Line DP , Cut points Guarding on Road crossing Earthing device 6/8 SWG GI wire Danger Board Barbed wire 16 mm GI Nuts & Bolts with washer Coil Earthing Mass concreting of line poles & stay set Red oxide primer & Aluminium paint

2

Shifting of 11 KV Lines with supply & erection of all materials.

(Using 11mtr long 150x150 mm RS joist pole with all accessories)

11 mtr long, 150x150mm RS Joist 11 KV 'V' Cross Arm GI (11.2 Kg each) Back Clamp for 'V' Cross Arm GI (8 mm Flat) 11 KV Pole Top Bracket GI 75X40mm Channel (2.8 Kg each) 11 KV Pin Insulator 11 KV G.I. Pin 11KV Disc insulator (T&C) 45 KN 11KV T&C hard ware fittings 18mm GI stay sets ( with stay clamp, 7/10SWG stay wire, stay insulator) 100x50x6 mm MS Chanel 75x40x5 mm MS chanel 50x50x6 MS angle 100 mm² AAA Conductor 4 pole structure , Line DP, Cut points Guarding on Road crossing Earthing device Danger Board Barbed wire 16 mm GI Nuts & Bolts with washer


Coil Earthing 6/8 SWG GI wire Mass concreting of line poles & stay set Red oxide primer & Aluminium paint

3

Shifting of LT lines with supply & Erection of all materials

(Using 9mtr 300Kg PSC Pole with following size of AB Cables)

9 mtr long, 300Kg PSC Pole

Pole Clamp for Eye Hook

Eye Hook for AB Cable

Nuts & Bolts

16 mm GI stay set with stay clamp, 7/12 SWG stay wire & stay insulator

Pole concreting , Stay concreting

i) (3x50+1x35+1x16)mm2 AB cable with all accessories.

(3X50+1X35+1X16)mm² LT AB Cable Suspension Clamp Dead End Clamp Sundries

ii) (3x95+1x70+1x16)mm2 AB cable with all accessories.

(3X95+1X70+1X16)mm² LT AB Cable Suspension Clamp Dead End Clamp Sundries

4

Shifting of 10KVA 11/0.23 KV Sub-station with supply & erection of all materials (except transformer).

(Using 11mtr long 150x150 mm RS joist SP structure with all accessories) .

10 KVA,11/0.23 KV DTR (NESCO Supply) 11 mtr. long 150x150 mm RS joist (SP) SP transformer mounting bracket 2 pole 200 Amp. AB switch 2 pole 200 Amp.HG fuse 100x50x6 mm MS Chanel 75x40x5 mm MS chanel 50x50x6 MS angle Earthing device & earthing materials Lightening Arrester Distribution box for 10 KVA S/S 6 SWG GI wire/ GI flat earthing 18mm GI stay sets ( with stay clamp, stay wire, stay insulator) Danger board Barbed wire fencing around S/S with metal speeding & gate. Mass concreting of line poles & stay set Red oxide primer & Aluminium paint


5

Shifting of 16KVA 11/0.23 KV Sub-station with supply & erection of all materials (except transformer).

(Using 11mtr long 150x150 mm RS joist SP structure with all accessories) .

16 KVA,11/0.23 KV DTR (NESCO Supply) 11 mtr. long 150x150 mm RS joist (SP) SP transformer mounting bracket 2 pole 200 Amp. AB switch 2 pole 200Amp. HG fuse 100x50x6 mm MS Chanel 75x40x5 mm MS chanel 50x50x6 MS angle Earthing device & earthing materials Lightening Arrester Distribution box for 16 KVA S/S 6 SWG GI wire/ GI flat earthing 18mm GI stay sets ( with stay clamp, stay wire, stay insulator) Danger board Barbed wire fencing around S/S with metal speeding & gate. Mass concreting of line poles & stay set Red oxide primer & Aluminium paint

6

Shifting of 25 KVA 11/0.4KV Sub-station with supply & erection of all materials (except transformer).

(Using 11mtr long 150x150 mm RS joist DP Structure with all accessories) .

25 KVA,11/0.4 KV DTR (NESCO Supply) 11 mtr. long 150x150 mm RS joist (DP) 3 pole 200 Amp.AB switch 3 pole 200 Amp.HG fuse 100x50x6 mm MS Chanel 75x40x5 mm MS chanel 50x50x6 MS angle Earthing device & earthing materials Lightening Arrester Distribution box for 25 KVA S/S 3.5 Core x50 mm² PVC LT Cable GI flat (25 x4 mm) earthing 18mm GI stay sets ( with stay clamp, stay wire, stay insulator) Danger board Barbed wire fencing around S/S with metal speeding & gate. Mass concreting of line poles & stay set Red oxide primer & Aluminium paint

7



63 KVA,11/0.4 KV DTR (NESCO Supply) 11 mtr. long 150x150 mm RS joist (DP) 3 pole 200 Amp.AB switch 3 pole 200 Amp.HG fuse 100x50x6 mm MS Chanel 75x40x5 mm MS chanel 50x50x6 MS angle Earthing device & earthing materials Lightening Arrester Distribution box for 63KVA S/S 3.5Core x 150 mm² PVC LT cable GI flat (25 x4 mm) earthing 18mm GI stay sets ( with stay clamp, stay wire, stay insulator) Danger board


Boundary wall around S/S with metal spreading & gate Mass concreting of line poles & stay set Red oxide primer & Aluminium paint

8



100 KVA,11/0.4 KV DTR (NESCO Supply) 11 mtr. long 150x150 mm RS joist (DP) 3 pole 200 Amp.AB switch 3 pole 200 Amp.HG fuse 100x50x6 mm MS Chanel 75x40x5 mm MS chanel 50x50x6 MS angle Earthing device & earthing materials Lightening Arrester Distribution box for 100KVA S/S 3.5Core x 150 mm² PVC LT cable GI flat (25 x4 mm) earthing 18mm GI stay sets ( with stay clamp, stay wire, stay insulator) Danger board Boundary wall around S/S with metal spreading & gate Mass concreting of line poles & stay set Red oxide primer & Aluminium paint

N.B : 1. All MS materials such as V cross ms, Clamps , Pole top bracket , channel , angle ,Nuts, bolts ctc.

should be hot dip galvanized as per IS : 2629 and Joist poles should be painted by two coat of red oxide primer & aluminium paint.

2. The bidders should be furnished type test reports of offered major materials such as insulator, Stay

wire , GI Pin , AB Cable, ,AB cable accessories, AB Switch , HG Fuse etc to be used in the turnkey project . The bid shall accompanying with type-test reports conducted at Central Power Research Institute / NABL accredited laboratory for offered materials conducted within Five years before the date of opening of the tender. Bid not accompanied with type test reports conducted within five years & the drawings of the offered Materials duly approved by the Type Testing Agency shall not be considered for evaluation. For other offered materials should have been Inspected/Tested b y a ny Distribution Utility/ Reputed Private Organization/ State Govt./ Central Govt. or their undertaking(s)/NABL or CPRI.

3. The bidders should furnish GTP formats duly filled and signed for the offered materials.

Methodology:- The complete procedures for the execution of the project are explained herewith;

i. Detailed survey of substation, line and preparation of SLD & BOQ. ii. Complete manufacture details, including shop testing & supply of materials from the approved vendors

(materials which are to be supplied by the bidder) on prior approval of the NESCO Utility.

iii. Providing Engineering drawing, data, operational manual, etc wherever applicable for approval of NESCO Utility. iv) All required materials you have to supply cover under the turnkey contract except distribution transformers. The distribution transformers will be provided by NESCO Utility. v. Packing and transportation of materials from the manufacturer’s works/ NESCO store to the site.


vi. Receipt, storage, preservation and conservation of equipment at the site. vii. Pre-assembly, if any, erection testing and commissioning of all the equipment; viii. Reliability tests and performance and guarantee tests on completion of commissioning;

ix. Loading, unloading and transportation as required. x. Shifting of LT/HT lines & Sub-stations by installation new of electrical networks and dismantle thereof.

xi. HT lines to be shifted by using RS Joist poles .

xii. LT lines to be shifted by using PSC poles.

xiii. Fencing of S/S with Barbed wire.

xiv. Concreting of all poles.

xv. Testing, Commissioning of lines / installations xvi. Getting the lines inspected by Electrical Inspector after completion of work.

xvii. Dismantling of existing electrical network and return of these dismantled items at the NESCO Utility’s stores,

safe custody of the items and return of unused NESCO Utility’s supplied materials to the NESCO Utility’s stores.

For details the Technical Specification specified :

2.0.1 SURVEY (detail & check, estimating of quantities & spotting of Poles)

Walk over survey shall have to be carried out to ascertain the location wise nature of work to be executed.

Bidder may be made field survey of the site before bidding.

2.0.2 GENERAL: The Right of way shall be resolved by the contractor and all expenses there of shall

be borne by him. However, NESCO Utility shall render all helps in co-ordination with law and order and

forest department for solving the same.

2.0.3 Provisional quantities/numbers of different types of work have been estimated and indicated in the

BOQ Schedule given. However final quantities for work shall be as determined by the successful bidder,

on completion of the detail survey.

2.0.4 After completing the detailed survey, the contractor shall submit the final survey report for approval

of the employer. .

2.0.5 (a) Shifting of Lines & Sub-stations : I. Pole Spotting

The contractor shall shifting the existing electrical network with spot of poles at new location in such a

way so that proper ground clearance should be maintained and there shall be minimum s ag in a

span.

II. Fittings Common to all Line

Pin Insulator Binding: The contractor shall use AL. Binding wire for binding shall be as per REC Construction Standards No. C-5 or better thereof.


III Stringing of Aerial Bunched Cable (ABC)

2.0.6 Fixing of Suspension & Tension/ Dead end fittings to the Poles. The suspension clamp is to be hung on eye hook/ suspension hook, which is fixed to the pole at a minimum

distance of 0.15 mt. from top end of the pole. The messenger wire of bunched cable resting on a pulley is

separated from the cable by separating wedges and inserted in the conductor groove of the suspension

clamp.

The bolt is tightened to a torque of 20 N after which the pulley and wedges are to be removed. The cable is tied to the messenger wire with nylon tie on both sides of clamps. Pole clamps 50 x 8 mm flat

shall be used. Eye hook of 16mm dia MS rod to be used as per the drawing. The pole clamp shall be made

to suite the pole width. This shall be installed as per Fig. No. 2 (a) of REC Construction Standard. All

ferrous items shall be hot dip galvanized with zinc coating of 610gms / m2. 2.0.7 Fittings & Accessories of AB Cables:

The following hardware fittings and accessories shall be used to install, erect & join the aerial bunched cable.

a) Suspension Clamp with Eye-Hook – The Contractor shall install the suspension clamp with eye hook.

This hook shall be used to attach the AB cable on the pole by means of a dead end clamp in terminal poles

and for attaching a suspension clamp suitable for holding AB cables of size 35mm2 to 95mm2 in straight

lines and angle up to 90 Deg.-

b) Suspension fittings & the corresponding eye hook shall be as per REC Construction Standard No.

e –34. The eye hooks shall be made from minimum 16mm dia MS rods with eye on one end and the other

end being suitably flattened with two holes for M16 bolt & nut to fix with the back clamps made from

minimum 50x8mm flats as per drawing. The eye hook, back clamp and bolts & nuts are to be hot dip

galvanized.

c) Dead End fittings shall be bolted type as per REC Construction Standard No. E-35 & the corresponding

eye hook shall be as specified above. The dead clamps are to be anchored with the pole with similar

arrangement of eye hook & back clamp. In this case, the back clamp shall have two nos. of holes on both

sides for M16 bolts. One side of the clamp shall be used for holding the eye hook with dead end clamp and

the other side shall be used for anchoring the Stay.

d) Nylon Tie- The contractor shall supply nylon ties. These ties shall be used for tying the

conductors with the messenger wire to prevent the phase conductors from chatting against suspension

clamp. The nylon tie is made of weather resistant black nylon.

e) Connectors- The contractor shall supply connector. These shall be used as non-tension aluminum to aluminum connections for conductor joints. f) Plastic Covers for Connectors- The contractor shall install Plastic Covers for Connectors. These


covers shall be used with aluminum/aluminum connectors to protect connectors against corrosion caused by climatic conditions. 2.0.8 Installation of Cable

The contractor shall be fully responsible for all activities related to installation of AB cable. His responsibilities consists of handling, pulling, stringing & jointing of the cable and effecting service connection to consumers as per direction of the Engineer-in-charge.

2.0.9 Handling of AB Cable

The contractor shall observe following precautions while handling the AB Cable: The cable drums must be stored and transported in an upright position. While loading/unloading, the drums shall not be thrown from transport vehicles. Cable contact with sharp articles shall be avoided. In order to prevent damage to the insulation, the cable shall not be dragged on the ground. Pulleys shall be

used for this purpose.

In order to prevent strands from spreading, always cut the cable with a cutter.

Use nylon ties or electrical tape to prevent the cable from spreading away from messenger wire after the

cutting. Staple the end of the cable on to the drum in order to prevent loosening.

Do not remove the protective boards from the cable drum before the cable is pulled off the drum.

While moving the drum by rolling it on ground, always roll the drum in the direction indicated by the

arrow on the flange. When pulling the cable, the spinning direction must be opposite.

Do not store the drums on wet soil, sandy or humid places.

Store the accessories in good order for quick easy and correct handling. 2.10 Pulling the Cable

The principle is to pull the cable under mechanical tension so that contact with the ground or any other

obstacles is avoided. The cable drum should be perfectly in alignment with line to be strung and fixed about

15-20 mts

From the holding the first pulley. Open the cover of the drum to check and ensure that the

insulation is not damaged.

The pulling which is sent up upto the cable drum is about 15-20 mts from the pole holding to the last

pulley. The pulleys are directly hung to such hook on the poles. The pulley tandem is to be used on

angle poles if the line is deviating more than 60º Pull the guiding rope through all the pulleys. Normal care shall be taken to assume a smooth passage of whole cable through the pulleys,

especially in the first pole and on angle poles. One worker should act s brakeman at the cable drum so that

the cable is not loosened during the pulling. One worker should follow the cable going through the pulleys

and stop the pulling if anything goes wrong.


2.11 Final Checking, Testing and Commissioning After stringing have been done as approved by the engineer, to ensure that everything is complete in all

respects, the works shall be thoroughly inspected keeping in view the following main points.

All the bolts and nuts should be of hot dip galvanized materials as per relevant IS.

The stringing of the cable has been done as per the approved sag and desired clearances are

achieved.

No damage, minor or major to the cable, messenger wire and accessories

The contractor shall submit a report to the above effect to the Engineer in Charge, who shall inspect and

verify the correctness of the report. In case it is noticed that some or any of the above is not fulfilled, the

engineer shall get such items rectified by the contractor no extra cost to the purchaser. After final checking,

the line shall be tested for insulation resistance in accordance with IS 1255:1983.

All arrangements for such testing or any other test desired by the Engineer-in-charge shall be done by the

contractor and necessary labour, transport and equipment shall be provided by him. Any defect found out as

a result of such tests shall be rectified by the contractor, forthwith at no extra cost to the purchaser.

In addition to the above, the contractor shall be responsible for testing and ensuring that the total and

relative sags of the cable as within the specified tolerance. Such tests shall be carried out at selected points

along the route as required by the Engineer-in-charge and the contractor shall provide all necessary

equipment and labour to enable the tests to be carried out. After satisfactory test on the line and approval by

the Engineer in Charge, the line shall be energized at full operating voltage before handling over. The cable

shall be megger tested before and after jointing. The AB cable shall be tested for.

i) Continuity of messenger wire and conductors

ii) Absence of cross phasing

iii) Insulation resistance to earth

iv) Insulation resistance between conductors

v) DC Resistance

vi) Capacitance

As per the latest issue IS 1255:1983 and as per manufacturer‟s instructions. Sufficient backfilled earth covers

each foundation pit and is adequately compacted.

All poles are used strictly according to final approved drawing and are free of any defect or damage

whatsoever.

The stringing of the conductors and earth wire has been done as per the approved sag and tension

charts and desired clearances are clearly available.


All conductor and messenger wire accessories are properly installed.

The insulation of the line as a whole is tested by the Contractor through provision of his own equipment,

labour etc., to the satisfaction of the NESCO Utility.

3.0 JOIST POLES / PSC POLES In case of 33KV, 11KV and LT lines and sub - s ta t ion s the conventional R S Jo is t / PSC poles may be used. . The materials must conform to IS: 800. All the test on materials and fabrication etc will be as per the relevant Indian standards. 4.0 ERECTION WORK

When the survey is approved, the contractor shall submit to the employer a complete detail schedule of all materials to be used in the line. Size and length of conductor etc. are also to be given in the list. This schedule is very essential for finalizing the quantities of all line materials. The contractor shall furnish the same. 4.1 SCHEDULE OF ERECTION PROGRAMME

After due approval of the detailed and check survey, the contractor shall submit to the employer a complete detailed schedule of erection programme with a Bar-Chart for construction of the lines indicating there in the target date of completion. 5.0 CONSTRUCTION OF FOUNDATION FOR JOIST/ PSC POLES 5.0.1 ERECTION OF POLE, CONCRETING OF POLES AND COMPACTION OF SOIL

Drawing for the excavation of pits, Foundation of both wet and Black cotton soil is enclosed which are

to be adopted. If better design with less volume approved or tested by any other distribution agencies

will also be acceptable.

5.0.2 Following arrangement shall be adopted for proper erection of poles and properly compacting of

the soil around the base / foot of the poles, under this package.

(a) Excavation has to done as per the drawing to the required depth and size. After final excavation the pit

should be dressed properly so that uneven portion and loose soil should be removed before PCC (M-

7.5) i.e 1:4:8 of thickness 75 mm is laid. The base footing of the pole concreting RCC (M-12.5) i.e 1:3:6 has

to be done by proper alignment and verticality.

(b) The verticality and leveling of pole/structure should be done by the help of plum bob or with theodolite

and leveling instrument.

5.0.3 CEMENT CONCRETE AND BACK FILLING etc. A) Materials

All materials whether to be consumed in the work or used temporarily shall conform to relevant IS specification, unless stated otherwise, and shall be of the best approved quality.


B) Cement

Cement to be used in the work under the contract shall generally conform to IS:269/455-1989. Cement bags

shall be stored by the contractor in a water tight well ventilated store sheds on raised wooden platform

(raised at least 150 mm above ground level) in such a manner as to prevent deterioration due to moisture

or intrusion of foreign matter. Cements to be used within three months from the date of manufacture. Sub-

standard or partly set cement shall not be used and shall be removed from the site by the contractor at his

cost.

C) Coarse Aggregates i.e Stone chips or stone ballast. For M15 concrete (mix 1:2:4) the aggregate will be

in the ranges from 12mm to 20mm.size and for M7.5 concrete (mix 1:4:8) these will be from 25mm to

40mm size. D) Pole erection

1. After proper alignment, checking of verticality and leveling, the pole or structure should be properly

tied before placing of base concrete of required height. Again the verticality and leveling should be

checked.

2. The PCC pedestal concrete (M-12.5) is to be done by providing good quality of shutters, so that

there will no leakage of cement slurry during concreting. The cooping height should be 450 mm above the

existing ground level . The top portion of the cooping should be made tapered.

3. The back filling of locations should be done by using the excavated soil only in layers (each layer

should not be more than 500 mm) by putting water and ramming by using wooden rammers. In no

case stone of size more than 75mm used for back filling. Back-filling has to be done 75mm above ground

level or as specified.6. 5.0.4 All the persons working on p o l e s shall wear safety helmet, safety belt and safety

shoes, Similarly all the persons working on ground shall wear safety helmet and safety shoes.

5.0.4.1. If there is any LT/HT power line near the vicinity of erection, necessary shutdown of the

power line shall be obtained in writing from the concerned Agency in order to avoid electrical hazards

caused by accidental touching of stay/Guy ropes with power line.

5.0.4.2 Safety precaution Safety shall be given utmost importance during stringing. The following need to

be ensured.

5.0.4.3 Safe working conditions shall be provided at the stringing site.

5.0.4.4 Full proof communication through walky- talkie / mobile phones shall be used in order to

avoid any damage to workmen or public on ground.


5.0.5 33KV, 11KV lines and Distribution Sub-station with RS Joist and LT Lines with PSC Poles 5.05 (A) RS Joist (150x150 mm 11 Mtr. & 13 Mtr.)

TECHNICAL SPECIFICATION OF R.S Joist Pole

1.0 Scope of Work:

This specification covers design, manufacture, testing and supply of 150x150mm RS Joist designed for a working load of 346kg. The bidder should enclose Performance Certificates from the above users, issued in favour of the Sub Vendor / manufacturer, as proof of successful operation in field.

Applicable Standards:

This specification covers the manufacturing, testing before dispatch and delivery of following R.S Joists

Sl No

150x150mmRS Joist

1 150 x 150 mm R.S. Joist length:-13mtr&11mtr 34.6kg/mtr MT

2.0 Standards:

The R.S Joists shall comply with the requirements of latest issue of IS – 2062 Gr – A except where

specified otherwise.

3.0 Climatic Conditions :

The climatic conditions at site under which the store shall operate satisfactory, are as follows

Maximum temperature of air in shade 45º c

Maximum temperature of air in shade 0 c Maximum temperature of air in shade 50º c Maximum rain fall per annum 2000mm Maximum temperature of air in shade 45º c Maximum ambient temperature 45º c Maximum humidity 100% Av. No. of thunder storm days per annum 70%

Av. No. of dust storm per annum 20

Av. Rain fall per annum 150mm

4.0 Rolled Steel Joists

The Rolled Steel joist (RSJ) support structures shall be fabricated from mild steel, grade A and in lengths

dictated by design parameters .The joists, may include, but shall not be limited to the size i.e.150 X 150

mm;


4.1 Dimensions and Properties

RSJ DESIGNATION 150 x 150 mm ISHB

Length of Joist in Mtr with +100mm/-

0% Tolerance

13mtr,11mtr,9mtr

Weight kg/m with±2.5% Tolerance 30.6

Sectional Area (cm2) 39.00 Depth(D) of Section (mm) with

+3.0mm/ -2.0mm Tolerance as per IS

1852-1985

150.00

Width (B)of Flange(mm) ±4.0mm Tolerance for 150 x 150 mm ISHB IS 1852-1985

150.00

Thickness of Flange(Tf) (mm)

with±1.5mm Tolerance 9.00

Thickness of Web(Tw) (mm) with±1.0mm Tolerance

8.40

Corner Radius of fillet or root (R1) (mm) 8.00 Corner Radius of Tow (R2) (mm) 4.00 Moment of Inertia

Ixx (cm4) Iyy (cm4)

1540.00

460.00

Radius of Gyration (cm) Rxx

Ryy

6.29

3.44 Flange Slope(α) in Degree 94.0 Tolerance in Dimension As perIS:1852

4.2 MECHANICAL PROPERTIES:

Tensile Test : Requirement as per IS:2062/ 1999 Grade-A

Yeild Stress(MPa) Min250 Tensile Strength(MPa) Min410 Lo=(5.65√So)Elongation% Min23 Bend Test Shall not Crack

4.3. CHEMICAL PROPERTIES:

Chemical Composition Requirement as per IS:2062/ 1999 Grade-A

Permissible variation over the Specified Limit,Percent,Max

Grade A - Chemical Name Fe-410W A - Carbon(%Max.) 0.23 0.02


Manganese(%Max.) 1.5 0.05 Sulphur(%Max.) 0.050 0.005 Phosphorous(%Max.) 0.050 0.005 Silicon(%Max.) 0.40 0.03 Carbon Equivalent(%Max.) 0.42 - Deoxidation Mode Semi-killed or killed - Supply condition As rolled -

4.4. However, In case of any discrepancy between the above data & the relevant ISS, the values indicated in

the IS shall prevail.

4.5. The Acceptance Tests shall be carried out as per Relevant ISS.

5.2.150x150mm RS Joists:

RS Joists of Specific Weight 34.6kg/mtr with length 15mtr, 13mtr,11mtr & 9mtr pole of 9n0s,20nos,41nos

and 11nos respectively with specified weight in MT shall have to be supplied as per IS:2062;2006

Grade”A” , IS:808;1989/2001, IS1608:1995 & IS:12779-1989 and their latest amendment if

any complying the required Dimension, Weight, Chemical & Mechanical properties confirming to the

relevant IS, as per the Tolerance given Below.

5.3. APPLICABLE TOLLERANCES :

1. Length of each pole = + 100mm / - 0 % As per relevant IS: 12779-1989

(With proportionate change in no of Poles)

2. Specific Weight of RS Joists = ±2.5% As per relevant IS:1852/1985

3. Weight for whole lot of supply for all categories = ±3.0% As per relevant IS: 12779-1989 for both type

of RS Joists.

6.0. EMBOSSING ON EACH R.S JOIST:

Following distinct non-erasable embossing is to be made on each R.S Joists .

a) Name & Logo of the Manufacturer.

b) B.I.S Logo (ISI Mark) if applicable.

c) Size of the R.S Joist


GUARANTEED TECHNICAL PARTICULARS FOR (RS JOISTS of sizes 150x150mm)

(To be submitted along with offer) 1.1. Dimensions and Properties :

PARTICULARS Specification Specification By the

Bidder

Length of Joist in Mtr with +100mm/-0% Tolerance 13mtr &11mtr Weight kg/m with±2.5% Tolerance 30.6 Sectional Area (cm2) 39.00 Depth(D) of Section (mm) with +3.0mm/ -

2.0mm Tolerance as per IS 1852-1985 150.00

Width (B)of Flange (mm) with ±2.5mm

Tolerance for116 x 100 mm ISMB &

±4.0mm Tolerance for 150 x 150 mm

ISHB IS 1852-1985

150.00

Thickness of Flange (Tf) (mm)

with±1.5mm Tolerance 9.00

Thickness of Web(Tw) (mm) with±1.0mm

Tolerance 8.40

Corner Radius of fillet or root (R1) (mm) 8.00 Corner Radius of Tow (R2) (mm) 4.00 Moment of Inertia

Ixx (cm4) Iyy (cm4)

1540.00

Radius of Gyration (cm)

Rxx

Ryy

6.29

3.44

Modulus of Section

Zxx(cm3) Zyy(cm3)

205

60.2

Flange Slope(α) in Degree 94.0 Tolerance in Dimension As per IS:1852 Distinct Non-Erasable Embossings to be

made on each R.S. Joist a) Name & Logo of the Manufacturer.

b) B.I.S Logo (ISI Mark) if applicable.

c) Size

Signature of the bidder with Seal


5.0.5 (B) PSC Pole (9Mtr x 300 Kg) TECHNICAL SPECIFICATIONS

I. Qualification Criteria of Sub Vendor / Manufacturer:-

The prospective bidder may source PSC Poles from manufacturers. The bidder should enclose Performance Certificates from the users, issued in favour of the Sub Vendor / manufacturer, as proof of successful operation in field. Applicable Standard: The Poles shall comply with latest standards as under: REC Specification No. 15/1979, REC Specification No. 24/1983, IS 1678, IS 2905, IS 7321.

II.Materials :

Cement Cement to be used in the manufacture of pre-stressed concrete poles shall be ordinary for rapid hardening Portland cement confirming to IS: 269-1976 (Specification for ordinary and low heat Portland cement) or IS: 8041 E-1978 (Specification for rapid hardening Portland cement). Aggregates Aggregates to be used for the manufacture of pre-stressed concrete poles shall confirm to IS: 383 (Specification for coarse and fine aggregates from natural sources for concrete) .The nominal maximum sizes of aggregates shall in no case exceed 12 mm. Water Water should be free from chlorides, sulphates, other salts and organic matter. Potable water will be generally suitable. Admixture Admixture should not contain Calcium Chloride or other chlorides and salts which are likely to promote corrosion of pre-stressing steel. The admixture shall conform to IS: 9103. Pres-Stressing Steel Pre-stressing steel wires including those used as un tensioned wires should conform to IS:1785 (Part-I) (Specification for plain hard-drawn steel wire for pre-stressed concrete, Part-I cold drawn stress relieved wire).IS:1785 (Part-II)(Specification for plain hard-drawn steel wire) or IS:6003 (Specification for indented wire for pre-stressed concrete).The type design given in the annexure are for plain wires of 4 mm diameter with a guaranteed ultimate strength of 160 kg/mm². All pre-stressing steel shall be free from splits, harmful scratches, surface flaw, rough, aged and imperfect edges and other defects likely to impair its use in pre-stressed concrete. Concrete Mix Concrete mix shall be designed to the requirements laid down for controlled concrete (also called design mix concrete) in IS: 1343-1980 (Code of practice for pre-stressed concrete) and IS: 456 – 1978 (Code of practice for plain and reinforced concrete) subject to the following special conditions: Minimum works cube strength at 28 days should be at least 420 Kg/cm². The concrete strength at transfer should be at least 210 Kg/cm². The mix should contain at least 380 Kg of cement per cubic meter of concrete. The mix should contain as low water content as is consistent with adequate workability. It becomes necessary to add


water to increase the workability the cement content also should be raised in such a way that the original value of water cement ratio is maintained. III. Design Requirements The poles shall be designed for the following requirements: The poles shall be planted directly in the ground with a planting depth as per IS: 1678. Wherever, planting depth is required to be increased beyond the specified limits or alternative arrangements are required to be made on account of ground conditions e.g. water logging etc., the same shall be in the scope of the bidder at no extra cost to NESCO Utility. The bidder shall furnish necessary design calculations/details of alternative arrangements in this regard. The working load on the poles should correspond to those that are likely to come on the pole during their service life. The factor of safety for all poles 9.0Mts. Shall not be less than 2.0 and for 8.0 M poles, the factor of safety shall not be less than 2.5. The average permanent load shall be 40% of the working load. The F.O.S. against first load shall be 1.0. At average permanent load, permissible tensile stress in concrete shall be 30 kg/cm². At the design value of first crack load, the modulus of rupture shall not exceed 53.0kg/cm² for M-40. The ultimate moment capacity in the longitudinal direction should be at least one fourth of that in the transverse direction. The maximum compressive stress in concrete at the time of transfer of pre-stress should not exceed 0.8 times the cube strength. The concrete strength at transfer shall not be less than half, the 28 days strength ensured in the design, i.e. 420x0.5=210kg/cm². For model check calculations on the design of poles, referred to in the annexure, a reference may be made to the REC “Manual on Manufacturing of solid PCC poles, Part-I-Design Aspects”. IV. Dimensions and Reinforcements The cross-sectional dimensions and the details of pre-stressing wires should conform to the particulars given in the enclosed drawing. The provisions of holes for fixing cross-arms and other fixtures should conform to the REC specification No.15/1979. All pre-stressing wires and reinforcements shall be accurately fixed as shown in drawings and maintained in position during manufacture. The un-tensioned reinforcement as indicated in the drawings should be held in position by the use of stirrups which should go round all the wires. All wires shall be accurately stretched with uniform pre-stressed in each wire. Each wire or group of wires shall be anchored positively during casing. Care should be taken to see that the anchorages do not yield before the concrete attains the necessary strength. V. Cover The cover of concrete measured from the outside of pre-stressing tendon shall be normally 20 mm. VI. Welding and Lapping of Steel The high tensile steel wire shall be continuous over the entire length of the tendon. Welding shall not be allowed in any case. However, joining or coupling may be permitted provided the strength of the joint or coupling is not less than the strength of each individual wire. VII. Compacting Concrete shall be compacted by spinning, vibrating, shocking or other suitable mechanical means. Hand compacting shall not be permitted.


VIII. Curing The concrete shall be covered with a layer of sacking, canvass, Hessian or similar absorbent material and kept constantly wet up to the time when the strength of concrete is at least equal to the minimum strength of concrete at transfer of pre-stress. Thereafter, the pole may be removed from the mould and watered at intervals to prevent surface cracking of the unit the interval should depend on the atmospheric humidity and temperature. The pre-stressing wires shall be de- tensioned only after the concrete has attained the specified strength at transfer (i.e. 200 or 210 kg/cm² as applicable).The cubes cast for the purpose of determining the strength at transfer should be coursed, a sear as possible, under condition similar to those under which the poles are cured. The transfer stage shall be determined based on the daily tests carried out on concrete cubes till the specified strength indicated above is reached. Thereafter the test on concrete shall be carried out as detailed in IS: 1343(code of practice for pre-stressed concrete). The manufacture shall supply, when required by the NESCO Utility or his representative, result of compressive test conducted in accordance with IS: 456 (Code of practice for plain and reinforced concrete) on concrete cubes made from the concrete used for the poles. If the manufacture so desired, the manufacture shall supply cubes for test purpose and such cubes shall be tested in accordance with IS: 456 (Code of practice for plain and reinforced concrete). IX. Lifting Eye-Hooks or Holes Separate eye-hooks or hoes shall be provided for handling the transport, one each at a distance of 0.15 times the overall length, from either end of the pole. Eye-hooks, if provided, should be properly anchored and should be on the face that has the shorter dimension of the cross-section. Holes, if provided for lifting purpose, should be perpendicular to the broad face of the pole. X. Holes for Cross Arms etc Sufficient number of holes shall be provided in the poles for attachment of cross arms and other equipments. XI. Stacking & Transportation Stacking should be done in such a manner that the broad side of the pole is vertical. Each tier in the stack should be supported on timber sleeper located as 0.15 times the overall length, measured from the end. The timber supported in the stack should be aligned in vertical line. XII. Earthing (a) Earthing shall be provided by having length of 8 / 6 SWG GI wire embedded in Concrete during manufacture and the ends of the wires left projecting from the pole to a length of 100mm at 250 mm from top and 1000 mm below ground level. (b) Earth wire shall not be allowed to come in contract with the pre-stressing wires GUARANTEED TECHNICAL PARTICULARS of 9 Mtr. 300 KG PSC Pole (To be submitted along with offer in line with the Standard Design)

Sl No.

Description

Unit Req. Specification

Bidders Offer

1 Name of the Manufacturer & Address

To be specified

2 Type of pole Pre- Stress Concrete

3 Factor of Safety 2.5

4 Overall Length of Pole Meters

Mtr. 9


5 Working Load Kg Kg 300

6 Point of application of load 600 mm below from top

7 Depth of plantation mm 1500

8 Overall Dimensions

i) Bottom Depth mm 355 ii) Top Depth mm 185 iii) Breadth mm 100 9 Reinforcement Detail: i) Diameter of Pre-stressing wire mm 4

ii) No. of Tensioned wires Nos. 16

iii) No. of Un-tensioned wire Nos. --

iv) Length of each Pre-stressing wire Mtr. 9

v) Ultimate Tensile Strength Strength (UTS)

Kg/cm² 17500 vi) Steel Quantity Kg/pole 14.20 10 Concrete Detail i) Cement Type Ordinary Portland

Cement

ii) Concrete mix strength Kg/cm² a) 210 Kg/cm² at time of transfer of prestress (min)

Kg/cm² b) 420 Kg/cm² at age of 28 days (min)

iii) Concrete Quantity Cubic meter/pole

0.243 m³

iv) Concrete covering to wires mm 20

11 GI earthing wire SWG 6

12 Weight of PSC Pole Kg 607

13 Standard confirming to: Pole IS: 1678 /2000 Cement IS: 8041 Aggregates IS: 383/1970 Pre-stressing wire IS: 6003/1983 Concrete Mix IS: 456/2000 14 Tolerances Dimensions a)±15 mm on overall

length of pole

b) ±5 mm on sectional dimension

c)0.5% on the uprightness of pole



5.0.5.1 All the poles shall be provided with a RCC block base having dimensions as mentioned at

5.0.2 ( C) as per the site requirement to be decided by Engineer in Charge. The decision of Engineer in Charge

will be Final.

5.0.5.2 The poles shall then be lifted to the pit with the help of wooden supports. The pole shall then be kept in the vertical position with the help of 25 mm (min.) manila ropes, which will act as the temporary anchor. The verticality of the pole shall be checked by spirit level in both

longitudinal & transverse directions. The temporary anchor shall be removed only when poles set properly in the

pit for foundation concreting & backfilling with proper compacting the soil.

5.0.5.3 Concreting of foundation up to a minimum height of 1/6 th of the height of the pole from the bottom of the

pit with a circular cross-section of radius 0.25 mtrs. (volume of 0.3 cu.mtr. per pole) in the ratio of 1:3:6 shall

be done at the following locations: The depth has to be increased to 2mtr or as required at site condition if

poles more than 11 Mts. are to be used.

i) At all the tapping points and dead end poles. ii) At all the points as per REC construction dwg. No. A-10 (for the diversion angle of 10-60 degree) or better

there of as per the instruction of Engineer in charge. The decision of Engineer in charge will be final.

iii)Both side poles at all the crossing for road, Nallaha railway crossings etc. iv)Where Rail poles, Joist poles, double pole and four pole structures are to be erected. 6.0 CROSS ARMS “V” and straight Cross Arms should be made by using G I 100x50 I S M C mm for 33 KV & 75 x 40 ISMC for 11 KV line.

33KV , 11 KV “V” CROSS ARM, BACK CLAMP FOR “V”CROSS ARM & POLE TOP BRACKET

(F CLAMP) TECHNICAL SPECIFICATIONS

6.0.1 Qualifying Criteria :- The prospective bidder may source the above items from manufacturers /suppliers full filling the technical specification. a) Hot Dip Galvanised Cross arms and Pole Top Brackets for both 33KV & 11KV construction at intermediate and light angle pole shall be fabricated from grade 43A mild steel of channel section and for heavy angle poles, end poles and section poles fabricated from grade 43A mild steel of angle section. The grades of structural steel shall conform to IS – 226: 1975. b) The Back Clamp for both 33KV & 11 KV ‘V’ cross arm shall be made out of 50 x 8 GI Flat and shall be suitably designed to fit 150x150 mm RS Joist pole.


c)The Pole Top Bracket (F Clamp) shall be made out of 100x50 mm MS Channel (GI) for 33 KV & 75x40 MS channel (GI) suitably designed to fit 150 x150xmm RS Joist pole. Except where otherwise indicated all dimensions are subject to the following tolerances: dimensions up to and including 50mm:+1mm: and dimensions greater than 50mm: +2% All steel members and other parts of fabricated material as delivered shall be free of warps, local deformation, unauthorized splices, or unauthorized bends. Bending of flat strap shall be carried out cold. Straightening shall be carried out by pressure and not by hammering. Straightness is of particular importance if the alignment of bolt holes along a member is referred to its edges. Holes and other provisions for field assembly shall be properly marked and cross referenced. Where required, either by notations on the drawing or by the necessity of proper identification and fittings for field assembly, the connection shall be match marked. A tolerance of not more than 1mm shall be permitted in the distance between the center lines of bolt holes. The holes may be either drilled or punched and, unless otherwise stated, shall be not more than 2mm greater in diameter than the bolts. When assembling the components force may be used to bring the bolt holes together (provided neither members nor holes are thereby distorted) but all force must be removed before the bolt is inserted. Otherwise strain shall be deemed to be present and the structure may be rejected even though it may be, in all other respects, in conformity with the specification. The back of the inner angle irons of lap joints shall be chamfered and the ends of the members cut where necessary and such other measures taken as will ensure that all members can be bolted together without strain or distortion. In particular, steps shall be taken to relieve stress in cold worked steel so as to prevent the onset of embitterment during galvanizing. Similar parts shall be interchangeable. Shapes and plates shall be fabricated and assembled in the shop to the greatest extent practicable. Shearing flame cutting and chipping shall be done carefully, neatly and accurately. Holes shall be cut, drilled or punched at right angles to the surface and shall not be made or enlarged by burning. Holes shall be clean-cut without torn or ragged edges, and burrs resulting from drilling or reaming operations shall be removed with the proper tool. Shapes and plates shall be fabricated to the tolerance that will permit field erection within tolerance, except as otherwise specified. All fabrication shall be carried out in a neat and workmanlike manner so as to facilitate cleaning, painting, galvanizing and inspection and to avoid areas in which water and other matter can lodge. Contact surfaces at all connections shall be free of loose scale, dirt, burrs, oil and other foreign materials that might prevent solid seating of the parts.

6.0.2 Fabrication has to be made as per drg. of „ V „ X-arm, Back clamp & „ F „ clamp. GALVANISING


All type of cross arms back clamps, F clamps & stay clamps shall be hot dip galvanized, are as following: All galvanizing shall be carried out by the hot dip process, in accordance with Specification IS 2629. However, high tensile steel nuts, bolts and spring washer shall be electro galvanized to Service Condition 4. The zinc coating (610 gms per sq.mt) shall be smooth, continuous and uniform. It shall be free from acid spot and shall not scale, blister or be removable by handling or packing. There shall be no impurities in the zinc or additives to the galvanic bath which could have a detrimental effect on the durability of the zinc coating. Before picking, all welding, drilling, cutting, grinding and other finishing operations must be completed and all grease, paints, varnish, oil, welding slag and other foreign matter completely removed. All protuberances which would affect the life of galvanizing shall also be removed. The weight of zinc deposited shall be in accordance with that stated in Standard IS 2629 and shall not less than 0.61kg/m² with a minimum thickness of 86 microns for items of

thickness more than 5mm, 0.46kg/m² (64 microns) for items of thickness between 2mm and 5mm and 0.33kg/m² (47 microns) for items less than 2mm thick. Parts shall not be galvanized if their shapes are such that the pickling solutions cannot be removed with certainty or if galvanizing would be unsatisfactory or if their mechanical strength would be reduced. Surfaces in contact with oil shall not be galvanized unless they are subsequently coated with an oil resistant varnish or paint. In the event of damage to the galvanizing the method used for repair shall be subject to the approval of the Engineer in Charge or that of his representative. In no case the repair of galvanisation on site will be permitted. The threads of all galvanized bolts and screwed rods shall be cleared of spelter by spinning or brushing. A die shall not be used for cleaning the threads unless specifically approved by the Engineer in Charge. All nuts shall be galvanized. The threads of nuts shall be cleaned with a tap and the threads oiled. Partial immersion of the work shall not be permitted and the galvanizing tank must therefore be sufficiently large to permit galvanizing to be carried out by one immersion. After galvanizing no drilling or welding shall be performed on the galvanized parts of the equipment excepting that nuts may be threaded after galvanizing. To avoid the formation of white rust galvanized materials shall be stacked during transport and stored in such a manner as to permit adequate ventilation. Sodium dichromate treatment shall be provided to avoid formation of white rust after hot dip galvanization. The galvanized steel shall be subjected to test as per IS-2633.


6.0.3 11 KV V Cross Arm (GI) : The Cross arm is to be made out of ISMC 75x40 with 50mmx6mm flat packing on top & bottom flange of the channel where the insulator pin is to be mounted conforming to REC construction standard & drawing . Galvanized the V cross arm as per IS-2633/1972.(Latest Amendment) , IS :2629/1985 (1st. Revision).

Guaranteed Technical Particulars of 11KV 'V' Cross Arm

Sl. No.

Description

Specified

Bidders Offer

1 Type of Cross Arm ISMC 75x40

2 Channel Weight

7.14 Kg/mtr

3 Grade of Steel

FY 250

4

Steel Standard

IS:2062-1992

5 Fabrication Standard

IS:802 (part - 2) - 1978

6 Dimension (75x40x4.8)mm

7

Size of M S Flat welded at both ends

50x8mm

8

Steel Tensile Strength

1500kgf/cm²

9

Working Load

200/300/350/400Kg

10

Total Weight (with tolerance per meter + 4%)

11.2 Kg (approx.)


33KV ‘V’ Cross arm (GI) 33 KV ‘V’ cross arm made out of 100x50x6 mm M.S Channel as per REC Standard M-1. The cross arm shall be fabricated out of 100x50x6 mm size channel having 9.2 Kg/Mtr. After fabrication the cross arm shall be Galvanized

as per IS-2633/1972.(Latest Amendment) , IS :2629/1985 (1st. Revision)conforming to REC construction standard & drawing.


Guaranteed Technical Particulars of 33 KV 'V' Cross Arm

Sl. No.

Description

Specified

Bidders Offer

1

Type of Cross Arm

ISMC 100x50

2

Channel Weight

9.2 Kg/mtr

3

Grade of Steel

FY 250

4

Steel Standard

IS:2062-1992

5

Fabrication Standard

IS:802 (part - 2) - 1978

6

Dimension

(100x50x6)mm

7 Size of M S Flat welded at both ends

50x8mm

8

Steel Tensile Strength

1500kgf/cm²

9

Working Load

400/ 450/ 550/600Kg

10

Total Weight

19.7 Kg (approx.)

Signature of the bidder with Seal 33 KV F Clamp/ Pole top Bracket (GI) : 33 KV line pole top bracket made out of 65 mm long 100x50x6 mm M.S channel welded with 65x65x6 mm M.S

Angle & hot dip galvanize as per IS-2633/1972.(Latest Amendment) , confirming to REC Construction Standard.M-

4 & drawing .

GUARANTEED TECHNICAL PARTICULARS FOR 11KV POLE TOP BRACKET

Sl.No. Constructional Features Specified Bidders

Offer

1. Material used 65x65x6 mm MS Angle &

100x50x6 mm MS Channel


2. Overall height 380 mm

3. Flange Width (one welded &

65 mm

4. Spacing between two flanges 100mm

5. Spacing of 2 nos of 18 mm holes

for fixing on pole top

100mm

6. C/L Distance of 2nos of 25mm

holes on top flanges of the bracket

40mm from edge

of the flange

7. Galvanization Hot dip

8. ISS 2062 ,2633

9. Drawing enclosed

Name & Signature of Bidder with seal

6.0.4 11KV POLE TOP BRACKETS (F CLAMP)

GURANTEED TECHNICAL PARTICULARS (To be submitted along with offer)

Sl. No.

Description Unit Unit Bidder‟s offer

11 Kv 1 Type of crossarm 2 Grade of steel 3 Steel standard 4 Fabrication Standard 5 Dimensions Mm 6 Steel section utilized 7 Steel tensile strength N/cm² 8 Working load Kg 9 Details of galvanizing method utilized and

standard/specification conforming to?

10 Weight of bracket Kg 11 Whether drawing has been submitted with the

bid



6.0.5 BACK CLAMP FOR “V” CROSS ARM GURANTEED TECHNICAL PARTICULARS (To be submitted along with offer)

Sl. No.

Description Unit Unit Bidder‟s offer

11 Kv 33 Kv 1 Type of Clamp 2 Grade of steel 3 Steel standard 4 Fabrication Standard 5 Dimensions Mm 6 Steel section utilized 7 Steel tensile strength N/cm² 8 Working load Kg 9 Details of galvanizing method utilized and

standard/specification conforming to?

10 Weight of back clamp Kg 11 Whether drawing has been submitted with the

bid


6.0.6 Fixing of Cross Arms After the erection of supports and providing guys, the cross-arms are to be mounted on the support with

necessary clamps, bolts and nuts. The practice of fixing the cross arms before the pole erection should be

followed.

7.01 GI Clamp for HT Stay set : HT stay clamp suitable for 150x150 mm Joist pole made out of 50x8 mm GI Flat, confirming to latest IS Specification and . 7.02 GI Clamp for LT Stay set : LT stay clamp suitable for PSC poles made out of 50x6 mm GI Flat, confirming to latest IS Specification.

8.0 INSTALLATION OF LINE MATERIALS

8.0.1 Insulator and Bindings - These materials are to be procured from the approved vendors only

subsequent to the design approval. 8.0.2 Insulator hoisting

a) Insulators shall be completely cleaned with soft and clean cloth.


b) It shall be verified that there is no crack or any other damage to insulators. The pins for insulators shall be fixed in the holes provided in the cross-arms and the pole top brackets. The

insulators shall be mounted in their places over the pins and tightened. In the case of strain or angle supports,

where strain fittings are provided for this purpose, one strap of the strain fittings is placed over the cross-arm

before placing the bolt in the hole of cross-arms. The nut of the straps shall be so tightened that the strap can

move freely in horizontal direction.

All materials, which are to be supplied by the contractor should be procured from the approved

Manufacture/suppliers only. Procurement from any suppliers will not be permitted. All the related

drawings of materials have to be approved by department. All the materials has to be tested in

presence of authorized representative of department as well as officers of third party engaged by

Government if any also.

9.0 Stringing of AB Cables

9.1 Fixing of Suspension & Tension/ Dead end fittings to the Poles. The suspension clamp is to be hung on eye hook/ suspension hook, which is fixed to the pole at a minimum

distance of 0.15 mt. from top end of the pole. The messenger wire of bunched cable resting on a pulley is

separated from the cable by separating wedges and inserted in the conductor groove of the suspension

clamp. The bolt is tightened to a torque of 20 N after which the pulley and wedges are to be removed. The

cable is tied to the messenger wire with nylon tie on both sides of clamps. A hole of minimum diameter is

to be made through poles for erection of suspension clamp. In case, drilling is not possible to make hole

through poles, pole clamps/eye hook 50 x 6 mm flat shall be used. Eye/hook pole clamp shall be made to

suite the pole width. This shall be installed as per Fig. No. 2 (a) & 2(b) of REC Construction Standard No.

E-34 for suspension clamps and as Fig. No. 2 (a) of REC Construction Standard No. E-35 for tension (Dead

end)clamps. 9.2 Fittings & Accessories The following hardware fittings and accessories shall be used to install, erect & join the aerial bunched

cable.

a) Suspension Hook (Eye-Hook) – The Contractor shall install the suspension hook (eye hook). This hook shall be used to attach the AB cable on the pole by means of a dead end clamp in terminal

poles and for attaching a suspension clamp in straight lines and angle up to 90 Deg.-

b) Suspension fittings & the corresponding eye hook shall be as per REC Construction Standard No. e –34.

c) Dead End fittings shall be bolted type & the corresponding eye hook shall be as per REC


Construction Standard No. E-35.

d) Nylon Tie- The contractor shall supply nylon ties. These ties shall be used for tying the conductors with the messenger wire to prevent the phase conductors from chatting against suspension clamp. The nylon tie is made of weather resistant black nylon. e) Connectors- The contractor shall supply connector. These shall be used as non-tension aluminum to aluminum connections for conductor joints.

f) Plastic Covers for Connectors- The contractor shall install Plastic Covers for Connectors. These covers shall be used with aluminum/aluminum connectors to protect connectors against corrosion caused by climatic conditions. 9.3 Installation of Cable The contractor shall be fully responsible for all activities related to installation of AB cable. His

responsibilities consists of Handling of the cable Pulling of the cable Stringing of the cable Jointing of the

cable

Handling of AB Cable. The contractor shall observe following precautions while handling the AB Cable: The cable drums must be stored and transported in an upright position. While

loading/unloading, the drums shall not be thrown from transport vehicles. Cable contact with sharp articles

shall be avoided. In order to prevent damage to the insulation, the cable shall not be dragged on the

ground. Pulleys shall be used for this purpose. In order to prevent strands from spreading, always cut the

cable with a cutter.

Use nylon ties or electrical tape to prevent the cable from spreading away from messenger wire after the

cutting. Staple the end of the cable on to the drum in order to prevent loosening.

Do not remove the protective boards from the cable drum before the cable is pulled off the drum.

While moving the drum by rolling it on ground, always roll the drum in the direction indicated by the

arrow on the flange. When pulling the cable, the spinning direction must be opposite. Do not store the

drums on wet soil, sandy or humid places. Store the accessories in

good order for quick easy and correct handling. b) Pulling the Cable. The principle is to pull the cable under mechanical tension so that contact with the ground or any other

obstacles is avoided. The cable drum should be perfectly in alignment with line to be strung and fixed about

15-20 mts. from the holding the first pulley. Open the cover of the drum to check and ensure that the

insulation is not damaged .The pulling which is sent up up-to the cable drum is about 15-20 mts from the


pole holding to the last pulley.

The pulleys are directly hung to such hook on the poles. The pulley tandem is to be used on angle poles

if the line is deviating more than 60º Pull the guiding rope through all the pulleys. Normal care shall be taken

to assume a smooth passage of whole cable through the pulleys, especially in the first pole and on angle

poles. One worker should act s brakeman at the cable drum so that the cable is not loosened during the

pulling. One worker should follow the cable going through the pulleys and stop the pulling if anything goes

wrong. 10. PIN INSULATORS

10.0.1 33 Kv Pin Insulators.-IS-731/77 (Porcelain Insulator for O/H power lines with nominal voltage

greater than 1000 volts.

10.0.2 33 Kv GI Pin: - Confirming to IS-2486 Part-I/1971.

10.0.3 11 Kv Pin Insulators: - IS-731/77 (Porcelain Insulator for O/H power lines with nominal voltage

greater than 1000 volts.

10.0.4 11 Kv GI Pin: - Confirming to IS-2486 Part-I/1971.

TECHNICAL SPECIFICATIONS OF 33 KV PIN INSULATOR

1.0 Scope of Work:

This Specification covers design, engineering, manufacture, assembly, stage testing, inspection & testing before supply and delivery at site of the 33KV Pin Insulator.

2.0 APPLICABLE STANDARDS

Unless otherwise stipulated in this specification, the insulators shall comply with the Indian standard specification IS:731-1971 and the insulator fittings with IS:2486(Pt . I )-1971 and IS:2486(Pt . II)-1974 or the latest version thereof.

3.0 INSULATORS 3.1 General Requirements

3.1.1 The Porcelain shall be sound, free from defects, thoroughly vitrified and smoothly glazed.

3.1.2 Unless otherwise specified, the glaze shall be brown in colour. The glaze shall cover all the

porcelain parts of the insulator except those areas which serve as supports during firing or are left unglazed for the purpose of assembly.

3.1.3 The design of the insulator shall be such that stresses due to expansion and contraction in any part

of the insulator shall not lead to deterioration. The porcelain shall not engage directly with hard metal.


3.1.4 Cement used in the construction of the insulator shall not cause fracture by expansion or loosening by contraction and proper care shall be taken to locate the individual parts correctly during cementing. The cement shall not give rise to chemical reaction with metal fittings, and its thickness shall be as uniform as possible.

3.2 Creepage Distance The minimum creepage distance shall be as under:

Highest System Voltage

Normal and Moderately Polluted Atmospheres(total)

Heavily polluted Atmospheres(Total)

(1) (2) (3) 36 KV 580 mm 840 mm

Note: For insulator used in an approximately vertical position the values given in col.(2) or (3) shall apply. For insulators used in an approximately horizontal position, the value given in col. (2) shall apply but the value in Col.(3) may be reduced by as much as 20%.

3.3 Tests: The insulators shall comply with the following tests as per IS:731-1971.

3.3.1 Type tests

a) Visual examination b) Verification of dimensions c) Visible discharge test d) Impulse voltage withstand test. e) Wet power-frequency voltage withstand test. f) Temperature cycle test. g) Electro-mechanical failing load test. h) Mechanical failing load test (for those of type B strin insulator units to which electro

mechanical failing load test (g) is not applicable. i) Twenty four hours mechanical strength test (for string insulators only when specified by the purchaser). j) Puncture test k) Porosity test and l) Galvanising test.

3.3.2 Acceptance Tests The test samples after having withstood the routine tests shall be subjected to the following acceptance test in the rder indicated below:

a) Verification of dimensions. b) Temperature cycle test. c) Twenty four hours mechanical strength test(for string insulator units only when specified by the

purchaser) d) Electro-Mechanical failing load test. e) Puncture test f)Porosity test and g) Galvanising test.

3.3.3 Routine Test a)Visual examination. b) Mechanical routine test (for string insulator units only) and c) Electrical routine test (for string insulator units only)


3.4 Marking 3.4.1 Each Insulator shall be legibly and indelibly marked to show the following.

a) Name and trade mark of the manufacturer. b) Month and year of manufacture c) Minimum failing load in Newtons d) Country of the manufacturer and e) ISI Certification mark,if any. f) Specific Parameters & Layout Conditions.

3.4.2 Marking on porcelain shall be printed and shall be applied before firing. 3.5 Packing

All insulators (without fittings) shall be packed in wooden crates suitable for easy but rough handling and acceptable for rail transport. Where more than one insulator are packed in a crate, wooden separators shall be fixed between the insulators to keep individual insulators in position without movement within the crate.

GURANTEED TECHNICAL PARTICULARS OF 33KV PIN INSULATOR Sl.No.

Description

Specified

Bidder's offer

1

Manufacture Name

2 Address of Manufacture

3 Normal working voltage

33KV(rms)

4

High system voltage 36KV(rms)

5 Visible Discharge Voltage dry

PF

27KV(rms)

6 Dry Power frequency 1

Minute withstand voltage

95KV(rms)

7

Wet Power frequency 1 Minute withstand voltage

75KV(rm

s)

8

PF puncture withstand voltage 180KV(rms)

9 Impulse withstand voltage 170 KV 11 Minimum failing load 10KN 12 Minimum creepage distance 580mm 13 Colour of glaze Brown 14 Weight per unit To be submitted by bidder 15 Size of Insulator

a) Height To be submitted by bidder b) Diameter To be submitted by bidder

16 Material of thimble Lead 17 Steel head Larg

e


18 Standard IS: 731/1971

19

Tolerance Tolerance will be allowed as per

IS:731/1971 or latest amendments if any.

20

Drawing & Sample

To be submitted by bidder

PACKING: All insulators shall be packed in wooden crates suitable for easy but rough handling &

acceptable for road transport. Where more than one insulator are packed in a crate, Separator shall be fixed between the insulators to keep individual insulator in position without movement in the crate.

NB- Every insulator should bear the marking of manufacturer’s name & Purchaser’s name and ISI mark.


11 KV PIN INSULATOR

1.SCOPE :

The specification cover the manufacture, testing at works supply and delivery of Porcelain insulators for overhead power lines with a nominal voltage below 12KV . Both Pin and Shackle type insulators are covered. 2.APPLICABLE STANDARDS:

Except when they conflict with the specific requirements of this specification, the insulators shall comply

with IS : IS:731 & IS: 3188 or the latest version thereof.

3.GENERAL REQUIREMENTS:

The porcelain shall be sound, free from defects, thoroughly vitrified and smoothly glazed. The design of

the insulators shall be such that the stresses due to expansion and contraction in any part of the insulator

shall not lead to its deterioration. The glaze shall be brown in color for insulators. The glaze shall cover the

entire porcelain surface parts except those areas that serve as supports during firing. The insulators shall be

suitable for use with all Aluminum Conductor or Copper conductor or ACSR upto 100 sq.mm. The

insulators should withstand the conductor tension the reversible wind load as well as the high frequency

vibrations set due to wind.

4.SYSTEM CONDITIONS:

Frequency : 50 Hz

Nominal System Voltage : 11KV Maximum System Voltage LT System : 12 KV Minimum LT Voltage : 11KV

Power frequency one minute withstand Voltage(wet): 35KV


5. TYPE OF INSULATORS:

The standard Pin insulators shall be of designation Type –B of IS : 731 or its latest revision.

6. TESTS:

6.1 Type tests:

a) Visual examination

b) Verification of dimensions

c) Temperature cycle test

d) Dry one minute power frequency withstand test

e) Wet one minute power frequency withstand test

f) Mechanical strength test

g) Porosity test

6.2 Acceptance test:

The insulators, after having withstood the routine test shall be subjected to the following

acceptance tests in the order given below:

a) Verification of Dimensions.

b) Temperature cycle test

c) Mechanical strength test

d) Porosity test

6.3 Routine tests:

ii) Visual examination

7.TESTING FACILITIES:

a. The Bidder must clearly indicate what testing facilities are available in the works of the manufacturer

and whether the facilities, are adequate to carry out all the routine as well as type tests. These facilities

should be made available to Purchaser‟s Engineers if deputed to carry out or witness the tests. If any tests

cannot be carried out at the manufacturer’s works, the reasons should be clearly stated in the tender.

b. The Bidder shall furnish detailed type test reports of the offered 11KV Pine insulator as per clause

6.1 of this specification. All the above Type Tests shall be carried out at laboratories, which are accredited,

by the National Accreditation Board of Testing and Calibration Laboratories (NABL) of Government of

India to prove that the insulators offered meet the requirements of the specification. These Type Tests should

have been carried out within five years prior to the date of opening of this tender. c. There offered L.T. shackle Insulators & pin insulators are already fully Type Tested at Laboratories

accredited by the National Accreditation Board of Testing and Calibration Laboratories (NABL) within five


years prior to the date of opening of the tender.

There is no change in the design of Type tested L.T. shackle Insulators and those offers against this

tender.

8. Drawings :

The tender shall be accompanied with the detailed drawings showing the dimensions of the

individual insulator, giving all the design dimensions of various component parts. Generally it shall

be as per IS.

9. MARKING:

a. Each insulator shall be legibly and indelibly marked to show the

following:

i) Name of Purchaser- NESCO

ii)Name or trade mark of the manufacturer

iii) Year of manufacturer

iv) ISI certificate, mark, if any.

b. Marking on porcelain shall be applied before firing.

10. Packing :

All insulators shall be packed in crates or boxes suitable for rough handling. Packing shall be marked with the strength and voltage rating.

GUARANTEED TECHNICAL PARTICULARS 11 KV PIN INSULATOR

Sl. No.

Description Specific Requirement Bidders offer

Name of Manufacturer. & Address To be specified by the bidder

Location of type testing To be specified by the bidder

Applicable standard IS: 731,IS 3188 or the latest version thereof

1 Normal working voltage 11 Kv (rms) 2 High system voltage. 12 Kv (rms) 3 Visible Discharge voltage dry PF. 9 Kv (rms) 4 1 Minute withstand voltage wet PF. 65 Kv (rms) 5 1 Minute withstand voltage................. 35 Kv (rms) 6 PF puncture withstand voltage. 110 Kv (rms)


7 Impulse withstand voltage : (+ ve) 80 Kv peak (- ve) 80 Kv peak 8 Impulse flashover voltage :

(+ ve) 90 Kv peak (- ve) 120 Kv peak 9 Minimum failing load. 5 KN. 10 Minimum creepage distance. 240 mm. 11 Colour of glaze. Brown. 12 Weight per unit. 1.4 Kg. (Apprx.) 13 Size of insulator. (Height) 125 mm.

(Diameter)

125 mm. 14 Material of thimble. Lead. 15 Steel head. Small head. 16 Standard. IS : 731/1971. 17 Tolerance. Tolerance will be allowed as per IS :

731/1971 or latest amendments if any. 18 Drawing To be submitted

19 Conforming standard As per IS



TECHNICAL SPECIFICATION OF 90KN (B&S) DISC INSULATOR

SCOPE: This specification provides for design, manufacture, engineering, inspection and testing before dispatch packing and delivery FOR (destination) for Indian manufacturers of disc. Insulators as per technical requirements furnished in this specification.

These insulators are to be used in suspension and tension insulators strings for the suspension and anchoring of the bus-bar conductors.

Following is the list of documents constituting this package.

(i) Technical specification.

(ii) Technical data sheet.

(iii) Drawings of insulators

All the above volumes along with amendments there of shall be read and interpreted together. However, in case of a contradiction between the ―Technical Specification and any other volume, the provisions of this volume will prevail.


The insulators shall conform in all respects to high standards of engineering, design workmanship and latest revisions of relevant standards at the time of offer and purchaser shall have the power to reject any work or material which in his judgment, is not in full accordance therewith.

STANDARDS:

Except as modified in this specification, the disc insulators shall conform to the following Indian Standards, which shall mean latest revisions and amendments. Equivalent International and Internally recognized standards to which some of these standards generally correspond are also listed below.

Sl. No. Indian

Standard

Title. International

Standard

1. IS: 206 Method for Chemical Analysis of Slab Zinc.

2. IS: 209 Specification for Zinc. BS: 3436

3. IS: 731 Porcelain insulators for overhead

power lines with a normal voltage greater than 1000V

BS: 137(I&II);

IEC 274 IEC 383

4. IS: 2071

Part-(I) Part-(II) Part-(III)

Method of High Voltage Testing.

5. IS: 2121

(Part-I)

Specification of Conductors and Earth wire Accessories for

Overhead Power lines. Armour Rods, Binding wires and tapes

for conductor.

6. IS: 2486 Specification for Insulator fittings

for overhead power lines with a nominal voltage greater than

1000V. Part – I General Requirement and Tests. BS: 3288 Part – II Dimensional Requirements. IEC: 120 Part – III Locking devices. IEC: 372

7. IS: 2629 Recommended practice for Hot Dip Galvanisation for iron and steel.

8. IS: 2633 Testing for Uniformity of Coating of Zinc coated articles.

9. IS: 3138 Hexagonal Bolts & Nuts. ISO/R 947 & ISO/R272

10. IS: 3188 Dimensions for Disc Insulators. IEC: 305 11. IS: 4218 Metric Screw Threads ISO/R 681969

R 261963,

R 262-1969 & R965-1969


12. IS: 6745 Determination of weight of zinc

coating on zinc coated iron and steel articles.

13. IS: 8263 Methods of RIV Test of HV

insulators.

IEC 437 NEMA

Publication No.107/1964

CISPR

14. IS: 8269 Methods for switching impulse test on HV insulators.

IEC: 506

15. Thermal mechanical performance test and mechanical performance

test on string insulator units.

IEC: 575

16. IEC Long Rod Insulators IEC-433

The standards mentioned above are available from:

Reference. Abbreviation. Name & Address:

BS British Standards, British Standards

Institution, 101, Pentonvile Road, N-19

IEC /

CISPR

International Electro technical commission

Electro Technique International. 1, Rue de verembe Geneva SWITZERLAND. IS Bureau of Indian Standards, Manak Bhavan,

9 Bahadurshah Zafar Marg, New Delhi-

ISO International Organisation for

Standardization. Danish Board of Standardization Dansk Standardizing Sraat Aurehoegvej-12 DK-2900 Helleprup

DENMARK. NEMA National Electric Manufacturers Association

1`55, East 44th. Street New York, NY 10017

PRINCIPAL PARAMETERS.

DETAILS OF DISC INSULATORS:

The Insulator strings shall consist of standard discs for use in three phases, 50 Hz 33/11KV S/S, 33 KV & 11KV Lines of NESCO Utility in a moderately polluted atmosphere. The discs shall be cap and pin, ball and socket type, radio interference and have characteristics as shown in Table-I and all ferrous parts shall be hot dip galvanized as per the latest edition of IS 2629. The zinc to be used for making sleeves shall be 99.95 % pure.


The size of disc insulator, minimum creepage distance the number to be used in different type of strings, their electromechanical strength and mechanical strength of insulator string along with hardware shall be as follows:

Sl.

No

Type of

String.

Size of disc.

Insulator

(mm)

Minimum

creepage distance of

each disc(mm)

No. of

standard discs

33KV

Electro-mechanical strength of insulator string fittings (KN)

1. Single

suspension

255x145 430 1x3 70KN/90KN Antifog Insulator

2. Double

suspension

-do- -do- 2x3 70KN/90KN Antifog Insulator

3. Single Tension 280x170 320 1x4 70KN/90KN Normal Insulator

4. Double

Tension

-do- -do- 2x4 70KN/90KN Normal Insulator

SPECIFICATION DRAWINGS:

The specification in respect of the disc insulators are described. These specification for information and guidance of the Bidder only. The drawings to be furnished by the supplier shall be as per his own design and manufacture and in line with the specification.

GENERAL TECHNICAL REQUIREMENTS:

Porcelain:

The porcelain used in the manufacture of the shells shall be ivory white nonporous of high dielectric, mechanical and thermal strength, free from internal stresses blisters, laminations, voids, forgone matter imperfections or other defects which might render it in any way unusable for insulator shells. Porcelain shall remain unaffected by climatic conditions ozone, acid, alkalis, zinc or dust. The manufacturing shall be by the wet process and impervious character obtained by through verification.

The insulator shall be made of highest grade, dense, homogeneous, wet-process porcelain, completely and uniformly vitrified throughout to produce uniform mechanical and electrical strength and long life service. The porcelain shall be free from warping, roughness, cracks, blisters, laminations, projecting points foreign particles and other defects, except those within the limits of standard accepted practice. Surfaces and grooves shall be shaped for easy cleaning. Shells shall be substantially symmetrical.

Porcelain glaze:

Surface to come in contact with cement shall be made rough by stand glazing. All other exposed surfaces shall be glazed with ceramic materials having the same temperature coefficient of expansion as that of the insulator shell. The thickness of the glaze shall be uniform throughout and the colour of the glaze shall be brown. The Glaze shall have a visible luster and smooth on surface and be capable of satisfactory performance under extreme tropical climatic weather conditions and prevent ageing of the porcelain. The glaze shall remain under compression on the porcelain body throughout the working temperature range.

METAL PARTS:

(i) Cap and Ball Pins:


Ball pins shall be made with drop forged steel caps with malleable cast iron. They shall be in one single piece and duly hot dip galvanized. They shall not contain parts or pieces joined together welded, shrink fitted or by any other process from more than one piece of materials. The pins shall be of high tensile steel, drop forged and heat-treated. The caps shall be cast with good quality black heart malleable cast iron and annealed. Galvanizing shall be by the hot dip process with a heavy coating of zinc of very high purity. The bidder shall specify the grade composition and mechanical properties of steel used for caps and pins. The cap and pin shall be of such design that it will not yield or distort under the specified mechanical load in such a manner as to change the relative spacing of the insulators or add other stresses to the shells. The insulator caps shall be of the socket type provided with nonferrous metal or stainless steel cotter pins and shall provide positive locking of the coupling.

(ii) Security Clips:

The security clips shall be made of phosphor bronze or of stainless steel.

FILLER MATERIAL:

Cement to be used, as a filler material be quick setting, fast curing Portland cement. It shall not cause fracture by expansion or loosening by contraction. Cement shall not react chemically with metal parts in contact with it and its thickness shall be as small and as uniform as possible.

MATERIALS DESIGN AND WORKMANSHIP:

GENERAL:

All raw materials to be used in the manufacture of these insulators shall be subject to strict raw material quality control and to stage testing/ quality control during manufacturing stage to ensure the quality of the final end product. Manufacturing shall conform to the best engineering practices adopted in the field of extra high voltage transmission. Bidders shall therefore offer insulators as are guaranteed by them for satisfactory performance on Transmission lines.

The design, manufacturing process and material control at various stages be such as to give maximum working load, highest mobility, best resistance to corrosion, good finish elimination of sharp edges and corners to limit corona and radio interference voltages.

INSULATOR SHELL:

The design of the insulator shells shall be such that stresses due to expansion and contraction in any part of the insulator shall not lead to deterioration. Shells with cracks shall be eliminated by temperature cycle test followed by mallet test. Shells shall be dried under controlled conditions of humidity and temperature.

METAL PARTS:

i. The twin ball pin and cap shall be designed to transmit the mechanical stress to the shell by compression and develop uniform mechanical strength in the insulator. The cap shall be circular with the inner and outer surfaces concentric and of such design that it will not yield or distort under loaded conditions. The head portion of the pinball shall be suitably designed so that when the insulator is under tension the stresses are uniformly distributed over the pinhole portion of the shell. The pinball shall move freely in the cap socket either during assembly of a string or during erection of a string or when a string is placed in position.

ii. Metal caps shall be free from cracks, seams, shrinks, air holes, blowholes and rough edges. All metal surfaces shall be perfectly smooth with no projecting part or irregularities, which may cause corona. All load bearing surfaces shall be smooth and uniform so as to distribute the loading stress uniformly. Pins shall not show any microscopically visible cracks, inclusions and voids.


GALVANIZING:

All ferrous parts, shall be hot dip galvanized in accordance with IS: 2629. The zinc to be used for galvanizing shall conform to grade Zn 99.5 as per IS: 209. The zinc coating shall be uniform, smoothly adherent, reasonably light, continuous and free from impurities such as flux, ash, rust stains, bulky white deposits and blisters. Before ball fittings are galvanized, all die flashing on the shank and on the bearing surface of the ball shall be carefully removed without reducing the designed dimensional requirements.

CEMENTING:

The insulator design shall. Be such that the insulating medium shall not directly engaged with hard metal. The surface of porcelain and coated with resilient paint to offset the effect of difference in thermal expansions of these materials. High quality Portland cement shall be used for cementing the porcelain to the cap & pin.

SECURITY CLIPS (LOCKING DEVICES)

The security clips to be used as locking device for ball and socket coupling shall be ‗R‘shaped hump type to provide for positive locking of the coupling as per IS: 2486 (Part-IV). The legs of the security clips shall allow for spreading after installation to prevent complete withdrawal from the socket. The locking device shall resilient corrosion resistant and of sufficient mechanical strength. There shall be no possibility of the locking device to be displaced or be capable of rotation, which placed in position, and under no circumstances shall it allow separation of insulator units and fittings. ‗W‘type security clips are also acceptable. The hole for the security clip shall be counter sunk and the clip shall be of such design that the eye of the clip may be engaged by a hot line clip puller to provide for disengagement under energized conditions. The force required for pulling the clip into its unlocked positions shall not be less than 50 N (5 kg.) or more than 500 N (50 kgs.).

MARKING:

Each insulator shall have the rated combined mechanical and electrical strength marked clearly on the porcelain surface. Each insulator shall also bear symbols identifying the manufacturer, month, and year of manufacture. Marking on porcelain shall be printed, not impressed, and shall be applied before firing.

BALL AND SOCKET DESIGNATION:

The dimensions of the ball and sockets for 70 and 90 KN discs shall be of 16 mm and for 120

KN and 160 KN discs shall be of 20 mm designation in accordance with the standard dimensions stated in IS: 2486 (Part-II).

DIMENSIONAL TOLERANCE OF INSULATOR DISCS:

It shall be ensured that the dimensions of the disc insulators are within the limits specified below:

a) Diameter of Disc (mm)

Standard Maximum Minimum

70 KN Disc 255 266 244

90 KN Disc 255 266 244

b)Ball to Ball spacing Between Discs (mm)

Standard Maximum Minimum

70 KN Disc 145 149 141


90 KN Disc 145 149 141

INTERCHANGEABILITY:

The insulators inclusive of the ball and socket fittings shall be of standard design suitable for use with hardware fittings of any make conforming to relevant Indian Standards.

FREEDOM FROM DEFECTS:

Insulators shall have none of the following defects:

1) Ball pin shake.

2) Cementing defects near the pin like small blow holes, small hair cracks lumps etc.

3) Sand fall defects on the surface of the insulator.

INSULATOR STRINGS:

TYPE AND RATING:

The insulator strings shall be formed with standard discs described in this specification for use on 3 phases 33 KV 50 Hz effectively earthed systems in an atmosphere with pollution level as indicated in project synopsis. Suspension insulator strings for use with suspension/tangent supports are to be fitted with discs 70 KN EMS rating while tension insulator strings for use with Anchor / Tension towers are to be fitted with discs of 90 KN EMS level rating.

STRING SIZE:

The sizes of the disc insulator, the number to be used in different types of strings, their electromechanical strength and minimum nominal creep age distance shall be as given in this specification

Insulator units after assembly shall be concentric and coaxial within limits as permitted by Indian

Standards.

The strings design shall be such that when units are coupled together there shall be contact between the shell of one unit and metal of the adjacent unit.

DIMENSIONAL TOLERANCE OF INSULATORS DISCS

It shall be ensured that the dimensions of the long rod insulators are within the limits as per relevant IEC/ISS.

TESTS (FOR DISC INSULATORS) :

The following tests shall be carried out on the insulator string and disc insulators.

TYPE TEST:

This shall mean those tests, which are to be carried out to prove the design, process of manufacture and general conformity of the material and product with the intents of this specification. These tests shall be conducted on a representative number of samples prior to commencement of commercial production. The Bidder shall indicate his schedule for carrying out these tests.

ACCEPTANCE TESTS:


This shall mean these tests, which are to be carried out on samples taken from each lot offered for pre-dispatch inspection for the purpose of acceptance of the lot.

ROUTINE TESTS:

This shall mean those tests, which are to be carried out on each insulator to check the requirements, which are likely to vary during production.

TESTS DURING MANUFACTURE:

Stage tests during manufacture shall mean those tests, which are to be carried out during the process of manufacture to ensure quality control such that the end product is of the designed quality conforming to the intent of this specification.

TEST VALUE:

For all type and acceptance tests the acceptance values shall be the value guaranteed by the bidder in the guaranteed technical particulars of the acceptance value specified in this specification of the relevant standard whichever is more stringent for that particular test.

TEST PROCEDURE AND SAMPLING NORMS:

The norms and procedure of sampling for the above tests shall be as per the relevant Indian

Standard or the internationally accepted standards. This will be discussed and mutually agreed to between the supplier and purchaser before placement of order. The standards and normal according to which these tests are to be carried out are listed against each test. Where a particular test is a specific requirement of this specification, the norms land procedure for the same shall be as mutually agreed between the supplier and the purchaser in the quality assurance programme.

TYPE, ROUTINE & ACCEPTANCE TESTS:

The following type test shall be conducted on a suitable number of individual unit components, materials or complete strings.

1.On complete insulator string with hardware fittings Standards BS:137(Part-I) IEC: 383

a) Power frequency voltage withstand test with corona control rings and under wet condition.

b) Impulse voltage withstand test under dry condition.

c) Mechanical strength test. As per this specification.

2. On Insulators:

a) Verification of dimensions. :IS: 731

b) Thermal mechanical performance test: : IEC:575

c) Power frequency voltage withstand and flashover i) dry ii) wet :BS:173 d) Impulse voltage withstand flashover test (dry) : IEC: 383

e) Visible discharge test (dry) : IS:731

All the type tests given under clause No.5.14 above shall be conducted on single suspension and Double Tension insulator string along with hardware fittings.


3. ACCEPTANCE TESTS: For insulator:

a) Visual examination : IS:731

b) Verification of dimensions. : IS:731

c) Temperature cycle test. : IS:731

d) Galvanizing test. : IS:731

e) Mechanical performance test. : IEC:575

f) Test on locking device for ball and socket coupling. :IEC-372

g) Eccentricity test.

h) Electro-mechanical strength test : As per this specification.

i) Puncture test. : IS:731

j) Porosity test. : IS:731

4. ROUTINE TESTS: For insulators:

a) Visual inspection. : IS:731

b) Mechanical routine test.

c) Electrical routine test. : IEC:383

ADDITIONAL TESTS:

The purchaser reserves the right for carrying out any other tests of a reasonable nature at the works of the supplier/ laboratory or at any other recognized laboratory/ research institute in addition to the above mentioned type, acceptance and routine tests at the cost of the purchaser to satisfy that the material complies with the intent of this specification.

CO-ORDINATION FOR TESTING:

For insulator strings, the supplier shall arrange to conduct testing of their disc insulators with the hardware fittings to be supplied to the purchaser by other suppliers. The supplier is also required to guarantee overall satisfactory performance of the disc insulator with the hardware fittings.

NOTE:

In respect of electrical tests on a complete string consisting of insulators and hardware guarantee of values of responsibility of testing shall be with hardware manufacturer of RIV corona and voltage distribution test and with insulator manufacturer for all other tests.

TEST CHARGES AND TEST SCHEDULE:

TYPE TEST:

The insulator offered shall be fully type tested as per this specification. In case the equipment of the type and design offered, has already been type tested in an independent test laboratory. The bidder shall furnish four sets of type test reports along with the offer. These tests must not have been conducted earlier than five years. The purchaser reserves the right to demand repetition of some or all type tests in the presence of purchasers‘ carrying representative. For this purpose the bidder may quote unit rates for carrying out each type test. These prices shall be taken into consideration for bid evaluation. For any


change in the design/type already type tested and the design/type offered against this specification, purchaser reserves the right to demand repetition of tests without any extra cost.

ACCEPTANCE AND ROUTINE TEST:

All acceptance and routine tests as stipulated herein shall be carried out by the supplier in the presence of purchaser‘s representative.

Immediately after finalization of the programme of type/ acceptance/ routine testing, the supplier shall give sufficient advance intimation to the purchaser to enable him to depute his representative for witnessing the tests.

For type tests involving tests on a complete insulator string with hardware fittings, the purchaser will advice the supplier of the hardware fittings to provide the necessary fittings to the place of the test.

In case of failure of the complete string in any type tests, the supplier whose product has failed in the tests shall get the tests repeated at his cost. In case of any dispute, assessment of the purchaser as to the items that has caused the failure in any of the type tests shall be final and binding.

VOLTAGE DISTRIBUTION TEST:

a) The voltage across each insulator unit shall be measured by sphere gap method. The result obtained shall be converted into percentage and proportionate correction be applied as to give a total of 100% distribution.

b) The complete insulator string along with its hardware fitting excluding arcing horn corona controlling/grading ring and suspension assembly/dead end assembly shall be subject to a load equal to 50% of the specified minimum ultimate tensile strength (UTS) which shall be increased already rate to 68% of the minimum UTS specified. The load shall be held for five minutes and then removed. After removal of the load, the string components shall not show any visual deformation and it shall be possible to disassemble them by hand,. Hand tools may be used to remove cotter pins and loosen the nuts initially. The string shall then be reassembled and loaded to 50% of UTS and the load shall be further increased at a steady rate till the specified minimum UTS and held for one minute. No fracture should occur during this period. The applied load shall then be increased until the failing loads reached and the value recorded.

VIBRATION TEST:

The suspension string shall be tested in suspension mode, and tension string in tension mode

itself in laboratory span of minimum 30 meters. In the case of suspensions string a load equal to

600 Kg. shall be applied along with the axis of the suspensions string by means of turn buckle. The insulators string along with hardware fittings and two sub conductors throughout the duration of the test vibration dampers shall not be used on the test span. Both the sub- conductors shall be vertically vibrated simultaneously at one of the resonance frequencies of the insulator string (more than 10Hz) by means of vibration inducing equipment. The amplitude of vibration at the antipode point nearest to the string shall be measured and the same shall not be less than 120.4 being the frequency of vibration. The insulator strings shall be vibrated for five million cycles then rotated by 90 deg and again vibrated for 5 million cycles without any failure, after the test, the disc insulators shall be examined for looseness of pins and cap or any crack in the cement. The hardware fittings shall be examined to fatigue fatter and mechanical strength test. There shall be no deterioration of properties of hardware components and disc insulators after the vibration test. The disc insulators shall be subjected to the following tests as per relevant standards.

Test. Percentage of disc to be tested


a)Temperature cycle test followed by 60

Mechanical performance test.

b)Puncture test (for porcelain insulator only) 40

INSPECTION:

i. Purchaser and its representative shall at all times be entitled to have access to the works and to all places of manufacturer where insulators are manufactured and the supplier shall afford all facilities to them for unrestricted inspection of the works, inspection of materials, inspection of manufacturing process of insulators and for conducting necessary tests as specified herein.

ii. The supplier shall keep the purchaser informed in advance of the time of starting and of progress of manufacture of insulators in its various stages so that arrangements could be made for inspection.

iii.No material shall be dispatched from its point of manufacture unless the materials has been satisfactorily inspected and tested.

iv. The acceptance of any quantity of insulators shall in no way relieve the supplier of his responsibility for meeting all the requirement of this specification and shall not prevent subsequent rejection, if such insulators are later found to be defective.

IDENTIFICATION MARKING:

a) Each unit of insulator shall be legibly and indelibly marked with the trade mark of the supplier, the year of manufacture, the guaranteed combined mechanical and electrical strength in kilo-Newton abbreviated by ‗KN‘ to facilitate easy identification and proper use.

b) The marking shall be on porcelain for porcelain insulators. The marking shall be printed and not impressed and the same shall be applied before firing.

QUALITY ASSURANCE PLAN:

The bidder here under shall invariably furnish following information along with his offer, failing which the offer shall be liable for rejection.

a. Statement giving list of important raw materials, names of sub-suppliers for the raw materials, list of standards according to which the raw material are tested, list of tests normally carried out on raw materials in presence of bidder‘s representative, copies of test certificates.

b. Information and copies of test certificates as in (i) above in respect of bought out materials.

c. List of manufacturing facilities available.

d. Level of automation achieved and lists of area where manual processing exists.

e. List of areas in manufacturing process, where stage inspections are normally carried out in quality control and details of such tests and inspection.

f. Special features provided in the equipment to make it maintenance free.

g. List of testing equipping available with the bidder for final testing of equipment specified and test plant limitation, if any, vis-à-vis the type, special, acceptance and routine tests specified in the relevant standards. These limitations shall be very clearly brought out in schedule of deviations from specified test requirements.

The supplier shall within 15 days of placement of order submit the following information to the owner.


List of raw material and the names of sub-suppliers selected from those furnished along with the offer.

CHEMICAL ANALYSIS OF ZINC USED FOR GALVANIZING.

Samples taken from the zinc ingot shall be chemically analyzed as per IS: 209. The purity of zinc shall not be less than 99.95%.

TESTS FOR FORGINGS:

The chemical analysis hardness tests and magnetic particle inspection for forgings will be as per the internationally recognized procedures for these tests. The sampling will be based on heat number and heat treatment batch. The details regarding test will be as discussed and mutually agreed to by the supplier and purchaser in quality assurance programme.

TESTS ON CASTING:

The chemical analysis mechanical and metallographic tests and magnetic particle inspection for castings will be as per the internationally recognized procedures for these tests. The samplings will be based on heat number and heat treatment batch. The details regarding test will be as discussed and mutually agreed to by the supplier and purchaser in quality assurance programme.

HYDRAULIC INTERNAL PRESSURE TEST ON SHELLS:

The test shall be earned out on 100% shells before assembly. The details regarding test will be as discussed and mutually agreed to by the suppliers and purchaser in Quality Assurance Programme.

THERMAL MECHANICAL PERFORMANCE TEST:

The thermal mechanical performance test shall be carried out on minimum 15 number of disc insulators units as per the procedure given in IEC 575. The performance of the insulator unit shall be determined by the same standard.

ECCENTRICITY TEST:

The insulator shall be vertically mounted on a future using dummy pin and socket. A vertical scale with horizontal slider shall be used for the axial run out. The pointer shall be positioned in contact with the bottom of the outermost petticoat of the disc. The disc insulators shall be rotated with reference to the fixture and the slider shall be allowed to move up and down on the scale but always maintaining contact with the bottom of the outer most petticoats. After one full rotation of the disc the maximum and minimum position the slider has reached on the scale can be found out. Difference between the above two readings shall satisfy the guaranteed value for axial run out.

Similarly using a horizontal scale with veridical slider the radial run out shall be measured. The slider shall be positioned on the scale to establish contact with the circumstance of the disc insulator and disc insulator rotated on its future always maintaining the contact. After one full rotation of the disc the maximum and minimum position the slider has reached on the scale can be found out. Difference between the above two readings shall satisfy the guaranteed value for axial run out.

CRACK DETECTION TEST:

Crack detection test shall be carried out on each ball and pin before assembly of disc unit. The supplier shall maintain complete record of having conducted such tests on each and every piece of ball pin The bidder shall furnish full details of the equipment available with him for crack test and also indicate the test procedure in detail.


DISC INSULATOR (B&S) Type: Bidder should offer 11KV/33 KV Disc Insulator (B & S type) suitable for overhead power line Conforming to IS:731/1971 (2nd Revision), (Amendments - 6), Reaffirmed – 1991 & Guaranteed Technical Particulars. Type test certificates from CPRI or accredited NABL laboratory should be furnished

GUARANTEED TECHNICAL PARTICULARS DISC INSULATOR B & S TYPE

Sl. No.

Description Unit 90KN. Bidder’s Offer

1. Manufacture’s Name & Address

To be specified by bidder

2. Type of Insulator Ball T Socket 3 Size of Ball & Socket 16B 4 Dimensions a) Disc Diameter mm 255 b) Unit spacing mm 145 c) Creepage distance of single

insulator mm 430

5 Electromechanical strength of single insulator

KN 90

6 Materials of Shell Porcelain 7 Dry one minute power 80 6 Wet one minute power

Kv(rms) 45

7 Dry power frequency flashover. Kv(rms) 85 8 Wet power frequency flashover. Kv(rms) 50 9 Dry impulse withstand positive

& negative. Kv

(Peak) 170

10 Impulse flashover 1.2 x 50 microsecond (Positive)

Kv (Peak)

125

11 Impulse flashover 1 x 50 microsecond (Negative)

Kv (Peak)

125

12 Power frequency puncture voltage

Kv 1.3 times the actual drive flashover voltage of the

13 High system voltage. Kv 36 14 Visible Discharge voltage. Kv 27 15 Weight/Unit. Kg. To be specified by

bidder To be specified by

bidder

16 Marking :-- Each insulator will be legibly marked to show the following :

(a) Name of the Purchaser :-- NESCO


(b) Name or trademark :-- (c) Month & year of manufacturing :-- (d) Minimum failing load. PACKING: -- All insulators shall be packed suitably for easy but rough handling &

acceptable for road transport. Where more than one insulator is packed in a crate, separator shall be fixed between the insulators to keep individual insulator in position without movement in the crate.



11 KV Disc insulator 45 KN (T&CType)

TECHNICAL SPECIFICATION FOR 11 KV 45 KN DISC INSULATORS

1. SCOPE : This specification covers the manufacture, testing and works supply and delivery of 11 KV Disc insulators. The Porcelain insulators shall conform to IS:731-1971ammended upto date. Insulators shall be of Tongue & Clevis type (T&C).Disc insulators made of glazed porcelain shall be used as insulators on dead ends or on suspension type lines of 11 KV and above. Tongue & Clevis type (T & C) disc insulators of mechanical strength not less than 45KN shall be used confirming to IS: 731/1971. These shall be mounted on metallic cross-arms with the help of suitable non-magnetic galvanised iron hardware fittings. Small fittings like spring washers, nuts etc may be electro-galvanised.

2. SERVICE CONDITIONS :

The insulators to be supplied against this specification shall be suitable for satisfactory continuous operation under the following tropical conditions.

2.1.1 Maximum ambient temperature (Degree C) … 50 2.1.2 Minimum ambient temperature (Degree C) … 3.5 2.1.3 Relative Humidity (%) … 10 to 100 2.1.4 Maximum Annual Rainfall (mm) … 1450 2.1.5. Maximum Wind pressure (kg/m.sq.) … 150 2.1.6 Maximum wind velocity (km/hour) … 45 2.1.7 Maximum altitude above mean sea level (meter) … 1000 2.1.8 Isoceraunic level (days/year) … 50 2.1.9 Seismic level (Horizontal acceleration) … 0.3 g


2.1.10 Moderately hot and humid tropical climate conductive to rust and fungus growth

3. System Particulars :

a) Nominal System Voltage

11 KV b) Corresponding highest system Voltage

c) Frequency d) Number of phase e) Neutral earthing f) Min. Impulse withstand voltage

12 KV 50 Hz with 3% tolerance 3 effectively grounded. 75 KV

4. Standards :

Unless otherwise specified elsewhere in the specifications insulators shall confirm to the latest

revisions of all relevant standards .

5. General Requirements

i) The Porcelain insulators shall generally conform to IS:731-1971 and any amendments up to date to the same .

ii) Conductors :

The Disc Insulators will be used on lines on which the conductors will be A.A.A. Conductor

of size up to 100 sq. mm. The insulators should withstand the conductor tension, the

reversible wind load as well as the high frequency vibrations due to wind.

iii) Type a) Insulator shall be suitable for both the suspension and strain type of load & shall be of Tongue and

Clevis type. The insulators shall conform to Type ‘B’ of IS:731-1971.

b) Diameter of porcelain disc insulator shall be 255mm . The center to center distance between Tongue and Clevis shall be 145mm.

c) Insulator Ends.

Disc Insulators shall have Tongue and Cleave ends. The security clips will have to be provided as per fig. 25 of I.S. 2486 (Part-2) 1989 ( amended up to date) REC Specification 3/1971(Revised 1993).

d) The colour of the units shall be brown for 45 KN Disc Insulators .

e) The number of units to be used both on suspension and tension strings shall be as given below :

Voltage Class Suspension Strings Tension Strings.

Single Double Single Double 33 3 3x2 3 3x2 22 2 2x2 2 2x2 11 1 1x2 1 1x2

iv). Electromechanical & Mechanical Strength :


The mechanical and electromechanical strength of the individual and the complete Disc shall be 45 KN.

v) Creepage Distances : The minimum creepage distance for each 11KV disc Insulator shall 320mm.

6.0 Tests :

Suitable number of individual units and complete string shall be subject to the following tests in accordance with IS:731/1971 with its latest amendments.

i) Type Tests :

Following Type test shall be carried out on porcelain insulators as specified in IS: 731 /971 amended up to date. 1. Visual Examination. 2. Verification of dimensions. 3. Visible Discharge Test. 4. Impulse voltage withstand test. 5. Impulse voltage flashover test. 6. Wet one Minute Power Frequency withstand test and West Flashover test. 7. Temperature Cycle test. 8. Electromechanical failing load test. 9. Power frequency puncture withstand test. 10. Porosity test. 11. Galvanizing test.

ii) Acceptance Tests :

The test samples after having withstood the routine test shall be subject to the following acceptance tests in order indicated below: 1. Verification of dimensions. 2. Temperature Cycle test. 3. Twenty four hour mechanical test. 4. Electromechanical failing load test. 5. Power Frequency puncture withstand test. 6. Porosity test. 7. Galvanizing test.

iii) Routine Tests:

1.Visual Examination 2. Mechanical test 3. Electrical test 4. Twenty four hours mechanical test 5. Electro mechanical failing load test

7 Test Certificate :

The tenderer shall furnish detailed type test reports of the offered Disc Insulators as per clause 6.1 of the Technical Specifications at the NABL approved laboratories to prove that the Disc Insulators offered meet the requirements of the specification. These Type Tests should have been carried out within five years prior to the date of opening of this tender. i) Their offered Disc Insulators are already fully type tested at


approved Laboratory CPRI/NABL within five years prior to the date of opening of this tender. ii) There is no change in the design of type tested Disc Insulators and those offers against

this tender. iii) Such tenderers complying (i) and (ii) above shall furnish an undertaking in the format

schedule.

The purchaser reserves right to demand repetition of some or all the Type Test in presence of purchaser’s representative at purchaser’s cost. For this purpose, the tenderer shall quote unit rates for carrying out each Type Test. However, such unit rates will not be considered for evaluation of the offer. In case the unit fails in the Type Tests, the complete supply shall be rejected.

8. Testing Facilities :

The tenderer must clearly indicate what testing facilities are available in the works of the manufacturer and whether facilities are adequate to carry out all Routine & acceptance Tests. These facilities should be available to Board's Engineers if deputed or carry out or witness the tests in the manufacturer works. If any test cannot be carried out at the manufacturer's work, the reasons should be clearly stated in the tender. The insulators shall be tested in accordance with the procedure detailed in IS-731/1971 amended up to date.

9. Material Quality and Workmanship :

The quality of porcelain and hardware in case of porcelain insulators and core & housing in case of polymeric insulators shall be of the highest grade and best workmanship such as is suitable and customary for extra high tension lines and shall conform to current IS or IEC (only in absence of the relevant I.S.S.). The porcelain shall be sound, free from defect, thoroughly vitrified and smoothly glazed and brown in colour.

Unless otherwise specified the glaze shall cover all exposed porcelain parts of the insulator.

Glazing shall be uniform and free from defects. Small and isolated defects in the insulator glaze of a total surface less than 0.5 sq.cm. will however be ignored. Deviation on this account may be supported by relevant IS.

10 Mechanical Design :

The design shall be such that stresses due to expansion and contraction in any part of insulator shall not lead to deterioration.

Cement used in manufacture of the insulators shall not cause fracture due to expansion or loosening due to contraction.

11. Drawings :

The tender shall be accompanied with the detailed drawings showing the dimensions of the individual Disc giving all the design dimensions of various component parts. The drawing for Insulators should clearly show the method of cementing the porcelain to the metal caps and balls. Generally it shall be as per IS.

12. Markings:


12.1 Each insulator shall be legibly and indelibly marked to show the following :

a) Name or trade mark of the manufacturer.

b) Voltage Type

c) Month and year of manufacturing.

d) Electromechanical strength in KN

e) Property of NESCO Utility.

12.2 The “W” clip shall be marked with/punched with the ball and socket sizes for which it is meant

e.g.16B,20 etc. 12.3 Marking on porcelain shall be printed and shall be applied before firing.

13 Packing :

All insulators shall be packed in crates or boxes suitable for rough handling. Packing shall be marked with the strength and KV rating.

GUARANTEED TECHNICAL PARTICULARS FOR 45 KN DISC. INSULATOR ( T&C TYPE)

Sl. No

Particulars

Specific Requirement

Bidders offer

1. Name of Manufacturer. & Address To be specified by the bidder

2. Location of type testing To be specified by the bidder

3 Applicable standard IS-731/1971 with latest amendment

4 Type of insulator T&C type Disc insulator

5 Nominal System Voltage 11 KV 6 Highest System voltage 12 KV 7 Visible discharge Test voltage (Minimum) 9 KV 8 Dry Impulse withstand voltage +(1.2/50 microsecond wave) 75 KV 9 Dry Impulse flashover voltage+(1.2/50 microsecond wave) 90 KV 10. Dry 1 min. power frequency withstand Voltage kV. 60 KV 11 Wet 1 min. power frequency withstand Voltage . 35 KV 12 1 min. power frequency flashover Voltage kV. (Dry) 65 KV 13. 1 min. power frequency flashover Voltage kV.(Wet) 45KV 14 Power frequency puncture voltage 105 KV 15 Mechanical Routine test load 18 KN 16 Mechanical impact strength 45 KN


17 Shattered strengths (Glass) .. KV 18 Electromechanical Failing Load 45 KN 19 Safe working load 18 KN 20 Minimum Failing Load 45 KN 21 Creepage Distance 320 mm 22 Type and Grade of Materials :

i) Insulators Porcelain ii) Cap Malleable Casting or S.G

iii) Pin Forged pin iv) Locking Split pin v) Cement Portland

23 Type of semi conducting Glaze Ceramic 24 Colour of Insulators Dark Brown 25 Weight of single disc. kg. 4 Kg(Approx.) 26 Number of Insulators per crate 4 nos./ 6 nos.

27 Cross weight of Loaded crate 20 – 30 Kg 28 Whether drawing showing dimensional details have

been furnished along with bid. To be enclosed by bidder

NB : Every insulator should bear the marking of Purchaser’s name/ Manufacturer’s name and ISI mark.

Bidders Signature with Seal

11KV H.W fittings (T&C Type) : 11 KV Hard Ware fittings Tongue & Clevis type ,confirming to REC Construction Standard C-2 and as per drawing. 33KV H.W fittings (B&S Type) : 33 KV Hard Ware fittings Ball and socket type ,confirming to IS: 2486 (Part-II) latest amendment and as per drawing.

T & C and B & S Hardware Fittings The hardware fittings for B & S and T & C Strain Disc Insulator. For use in 33 KV and 11 KV Overhead power lines shall comply IS:2486 (Part-I) 1971 and 2486 (Part-II) / 1974 and IS:2486 (Part-III) 1974 IS:12048 /1987 and REC Specification 24/84 or the latest revision thereof. All Forging and Casting shall be good finish and free from flaws and other defects. The edges on the outside of fittings such as at the Eye, Cleaves and Holes shall be rounded. All parts of different fittings, which provide for Inter-connection shall be made such that sufficient

clearance is provided at the Connection Point to ensure free movement & suspension of the Insulator string Assembly.All eye and cleaves shall be free in this manner but care shall be taken that too much clearance between Eye & Tongs of the cleaves is avoided. All ferrous fittings and parts other than those of Stainless steel shall be hot dip galvanized as

per ISS: 2633 / 1964.Small fittings like Spring washer , Nuts etc. may be Electro-galvanized as per IS-6745 / 72.The threads of nuts and topped holes when cut after


Galvanizing shall be well cited & grassed. (A) Ball & Socket type Hardware fittings(Conversional/ Performed ) for B & S type Strain Insulators The hardware fittings (Ball and Socket type) shall be suitable for fixing on 100 mmx50 mm channel cross arms and for accommodation of 55 mm² / 100 mm² Conductor.

The set shall complete with following components (i) Cross-arms straps with Bolts & Nuts, Brass split and Spring Washer. (ii) Two numbers forged cotter pins,Brass split pins,Plain washer. (iii) One number Ball Eye of malleable cast iron (iv) One number of socket eye complete with security clips made of Phosphor bronze made cut of alluminium alloys-A/6. (v) Halically formed Dead and Conductor grip having a Pre-fabricate loop to fit into the proved contour of the thimbles on one end and for application over the conductor at the other end for 55 mm²/100mm² conductors. (vi) Strain clamps shall be suitable for above ACSR / AAAC.The ultimate strength of clamp should not be less than 4500 Kg and Slipping strength shall not be less than 90% of these figures.

(B) Tongue & Clevics type Hardware Fittings (Conventional / ¼ Performed ) for T & C type Strain Insulators

The Hardware fittings ( Tongue & Clevis type) shall be suitable for fixing on 75 mmx40 mm Channel Cross Arm an accommodation 34mm²/55mm²/100mm² Conductors. The set shall comply of the following components :- (i) Cross arms straps (Dead & Straps) with Bolt (16mm) Nut and Spring Washer. (ii) Two Nos. forged cotter pints and spring washer to suit the tongue and the clevics. (iii) Formed helical fittings should be of suitable materials i.e all alloy aluminum steel

suitable for 34mm²/55mm²/100mm² ACSR/AAAC. (iv) Strain clamps shall be suitable for the above ACSR

conductor or AAAC.The ultimate strength of the clamp should not be less than 3000 Kg and slipping strength shall not be less than 90% of this figure.The clamp should be malleable cast iron/All alloy A-6.

Tests : String insulator fittings shall comply with the following tests as per IS: 2486 (Part.I)

Type Tests:

a) Visual examination test ii) Verification of dimensions iii) Slip strength test iv) Mechanical test v) Electrical resistance test vi) Heating cycle test vii) Galvanising test. Acceptance/ Routine Test : i)Verification of dimensions ii) Mechanical test iii) Galvanising test iv) Vidual examination test v) Routine mechanical test. Marking :


The caps and clamps shall have marked on them as trade mark & year of manufacturing. Packing :

All hardware fittings shall be packed in bags or boxes suitable for rough handling. Packing shall be marked with the strength and KV rating.

Guaranteed Technical Particulars :

The bidders are required to furnish the guaranteed technical particulars duly filed in the proforma along with the bid.

GUARANTEED TECHNICAL PARTICULARS FOR 11 KV H/W

FITTINGS ( T&C )

Sl.No. Description Specified Bidders Offer

1. Manufacturer Name & Address

To be specified by Bidder

2. Standard Specification to which Hard ware Fittings shall confirm.

IS: 2486 (Part-I,II &II)

3 Ultimate strength 3000 Kg (min) 4. Dimensions in accordance

with IS: 2486(Part-II)

5 Type of washer thickness

a) Spring 2.5 mm

b)Flat 2.5 mm

6. Type of Clamp size Tension Clamp suitable for Squiral/Weasel/ Rabbit

7. Galvanised conform to IS 2633 , IS: 4759-1996 & IS: 6747

8. Weight of Fittings ..

9. Tolerance in dimension if any

+ 5%

10. Manufacturer trade mark to be embossed on the sets

Specified by the Bidder

11. Specific drawing to be enclosed.

Enclosed

NB. All ferrous fittings and the parts other than those of stainless steel , shall be galvanized.

Bidder’s Signature with Seal


GUARANTEED TECHNICAL PARTICULARS FOR 33 KV H/W

FITTINGS ( B&S )


1. Manufacturer Name & Address

To be specified by Bidder

2. Standard Specification to which Hard ware Fittings shall confirm.

IS: 2486 (Part-I,II &II)

3 Ultimate strength 4500 Kg (min.)

4. Dimensions in accordance with

IS: 2486(Part-II)

5 Material used and reference to Standard:

i) Cross arm Strap G.I as per IS:1570

ii) Ball Eye Forged Steel IS:2004

iii) Socket Eye Malleable Cast Iron IS:

2108/1962

iv) Bolted type tension clamp & its keeper

Aluminium Alloy LM-6,

IS: 617

6. Galvanised conform to IS 2633 , IS: 4759-1996 &

IS: 6747

7. Weight of Fittings not less than 2.5 Kg.

8. Tolerance in dimension if any

+ 5%

9. Manufacturer trade mark to be embossed on the sets

Specified by the Bidder

10. Specific drawing to be enclosed.

Enclosed

NB. All ferrous fittings and the parts other than those of stainless steel , shall be galvanized.



33 KV GI Pin ) : 33 KV GI Pin conforming to IS 2486 (part –II)/74 and suitable for 33 KV Pin Insulator having stalk length of 300 mm & shank length 150 mm with minimum failing load of 10 KN & provision of double nuts & a spring washer. The threading shall good finish & with standard galvanization.

GUARANTEED TECHNICAL PARTICULARS FOR 33KV G.I PIN

Slno. Description Specified Bidder’s Offer 1 Manufacture Name & Address 2 Standard applicable specification IS 2486 3 Minimum failing load 10KN 4 Dimensions (mm) a) Length 450mm b) Shank length 150mm c) Stalk length 300mm 5 Type of Threads

6

Threads per inch 8-9 threads per inch

7 Type of galvanization of pin & nuts Hot Dip 8 Mass of Zinc (minimum) 690 gm/m2 9 Applicable specification IS 2633

10

No. of Nuts with each pin & its size To be submitted by the bidder

11

No. of spring washer with each pin & its size To be submitted by the bidder

12 Packing Details a) Type of packing Heasian Bag

b)

Weight of each pin approx.(with nut & washers)

c)

No. of pins in each packing (Kg)

15 Pcs

13

Tolerance in weight

±3%

14

I.S.I Certificate License number

16

Manufacture's Trade mark with each GI Pins

17

Drawing & Sample

To be submitted by bidder



11 KV GI Pin ) : 11 KV hot-dipped galvanizing Pin suitable for 11 KV pin insulator , confirming to REC Construction Standard. C- 1 and confirming to IS: 2486/Part-I/1971 & Part-II/1989, IS: 1363/1984, IS: 3063/1972, IS:2633/1972.

GUARANTEED TECHNICAL PARTICULARS FOR 11KV G.I PIN


1 Manufacturer Name & Address To be specified by Bidder

2 Type of Pin 11KV 3 Applicable International Standard IS:2486 (part-II) 4 Grade Steel HDG Steel 5 Steel Specification HDG Steel

6 Specification of Bolt & Nut As per ISS

7 Specification of Bolt Threads As per ISS 8 Mechanical falling load (MFL) 10 KN

9 Elongation at MFL As per ISS

10 Maximum deflection of Pin Top at MFL

1.5 mm

11 Galvanising Specification IS- 2633

12 Minimum weight of Steel deposited on steel surface

610 g/m²

13 Pin Length 315 mm

14 Shank Length 150 mm

15 Stalk Length 165 mm

16 Type of Thread As per ISS

17 Thread Length As per ISS

18 Drawing enclosed



11 KV 200 Amp 3 Pole/ 2 Pole AB Switch

Technical Specification 01.0 Scope: -

This specification covers manufacturing testing and supply of 11KV 200 Amps 50HZ Air Break switches for out door installation in horizontal configuration. The switches are suitable for operation under off load conditions only and are intended for use on Distribution Sub – stations and tapping sectionalizing points of 11 KV lines.

02.0 Description of the materials: -

The 11KV A.B. Switch sets shall confirm to the following parameters: -

a. Number of poles 3 b. Number of Post insulator per pole 2nos12KVpostinsulator. c. Nominal system voltage 11KV d. Highest system voltage 12KV e. Rated frequency 50Hz f. System earthling effectively earthed. g. Rated nominal current 200 amps h. Altitude of installation Not exceeding1000M

The post insulators used in the A.B. Switches shall have the following ratings :-

a. Power frequency withstand voltage (dry) 35KV (RMS) b. Power frequency withstand voltage(wet) 35KV (RMS) c. Implies withstand voltage(dry) 75KV d. Power frequency puncture withstand 1.3

03.0 Standards: -

The AB Switch Set shall conform to the following standards: -

a. IS-9920 (Part-I to V) b. IS-2544/1973 (for porcelain post insulators) c. IS-2633, (for galvanization of ferrous parts.) or its latest amendments if any.

04.0 Insulator make: -

12KV post insulators complete with post and cap duly cemented to be used in the AB Switch Set conforming to IS-2544/1973.

The bidder shall furnish the type test certificate of the post insulators from their manufacturer for reference and scrutiny. The bidder shall mention make, type of insulation materials, metal fittings, Creepage distance, protected Creepage distance, tensile Strength, compressing strength, torsion strength and cantilever strength.

05.0 Climatic condition: -

The A.B. Switch set shall be suitable for operation under the following climatic conditions.


a. Maximum ambient air temperature 45 o C b. Maximum daily average air temperature 35 o C c. Maximum yearly average ambient air temperature 30 o C d. Maximum temperature attainably by a body e. Exposed to the Sum. 50 o C f. Minimum ambient air temperature 0 o C g. Maximum relative humidity 100% h. Minimum number of rainy days per annum 70 i. Average number of rainy days per annum 120 j. Average annual rain fall 150cm. k. Number of months of tropical monsoon conditions 4 l. Maximum wind pressure 260Kg./mm2 m. Degree of exposure to atmospheric pollution normally n. Atmosphere. Polluted.

06.0 Other technical details: -

06.01 General: - The 11KV A.B. Switch Set shall be the gang operated rotating single air break type having 2

post insulators per phase. The operating mechanism shall be suitable for manual operation from the ground level and shall be so designed that all the three phases shall open or close simultaneously. The Switches shall be robust in construction, easy in operation and shall be protected against over travel or staining that might adversely affect any of its parts. The required base M.S. Channel (hot dip galvanized) phase coupling rod, operation rod with intermediate guide braided with flexible electrolytic copper, tail piece of required current carrying capacity and operation mechanism with ‘ON’ & ‘OFF’ positions shall be provided. The operation rod shall be medium gage of 32mm diameter nominal bore G.I. pipe single length 6 meters. The phase coupling rod for gang operation shall be of medium gauge 25mm dia &2100 mm length nominal bore G.I. pipe. The Rating post insulators shall be provide with suitable bearing mounted on a base channel with 8mm dia thrust collar and 6mm split pin made out of stainless steel. The operating down rod shall be coupled to the spindle (minimum dia – 32mm) for gang operation through another suitable bearing by two numbers 10mm dia stainless steel bolts with double nuts. All the bearings shall be provided with grease nipple. All metal (ferrous) parts shall be galvanized an polished. The pipe shall be galvanized in accordance with IS-4736/1968.The post insulators should be fixed with the base channel using Galvanized Nuts and Bolts.

06.02. Mounting:- The A.B. Switches shall be suitable for horizontal mounting in double pole sub-station structures. MS Galvanized base Channel & base support channel should be of min. size 75x40x6 mm.

06.03. Switching Blades: - It shall be made out of electricity copper with silver plated. The approximate size shall be 220mm X 35X 6mm. The Switch shall have such a spring mechanism so as to ensure that the speed of the opening of contact is independent of speed of manual operation.

06.04 Fixed Contacts: - The Fixed Jaw type female contacts o f s ize (70x35x6) mm shall be made of

electrolytic copper (minimum 95% copper composition) duly silver coated controlled by phosphorous bronze high pressure spring housed in robust G.I. Cover. It is essential that provision shall be made in fixed female contracts to take the shock arising from the closing of move contract blade without the same being transmitted to the post insulator. The arrangement made in this regard shall be specifically shown in the drawing.

06.05 Arcing Horn: - As the switches are generally meant for isolating transmission line and distribution

transformers, suitable arcing horns shall be provided for breaking the charging current horn shall be made of 8 mm dia G.I. Rod with spring assisted operation.

06.06 Terminal Connectors: - Terminal connectors shall be robust in design. The size of fixed connector shall be (65 X 35 X 6 mm) and size of movable connector shall be of (65 X 35) X (65 X 35) X 6mm of copper casting with uniform machine finishing duly silver plated made out of minimum 95% copper composition with 2 nos. 12mm dia holes provided with suitable brass bolts and double nuts, flat washers & 2nos.


bimetallic solder less sockets suitable up to 55 mm2 conductor.

06.07Spacing: - The minimum clearance between phases to the switch shall be 760mm. The operation down rod shall be at a transverse distance of 300mm from the outer limb of the switch. The centre spacing between two post insulators of the same phase shall be 380 mm. In the open position of the A.B. switches the moving blade shall rotate through 90 o. This shall be exhibited in the drawing.

06.08 Sample, Drawing & Literatures: - A copy of drawings of 11KV 200 Amps. A.B. Switch shall be furnished along with the tender.

06.09 The details of construction and materials of different parts of the A.B. Switch shall clearly be indicate in the

tender and illustrative pamphlet / literature for the same shall be submitted along with the tender.

07.0 TEST & TEST CERTIFICATE: -

07.01 Type Test: - Certificate for the following type tests conducted on a prototype set of A.B. Switch in a NABL approved test house/CPRI shall have to be submitted along with offer.

Dielectric Test (impulse and one minute were power frequency withstand voltage test.)

• Temperature rise test (for contracts and terminals) • Shorts Time current and peak withstand current test. • Mainly active load breaking capacity test. • Transformer off-load breaking capacity test. • Line charging breaking capacity test. • Cable charging breaking test. • Operation and mechanical endurance test. • Mechanical strength test for post insulator, as per IS-2444/1937 shall be furnished. • Test for galvanization of metal (ferrous) parts.

07.02 Routine /Acceptance Test: - The inspection may be carried out by the Purchaser at any stage of manufacture. The successful bidder shall grant free access to the Purchaser’s representative at a reasonable time when the work is in progress. The following routine tests shall have to be conducted on each set and results are to be furnished for consideration of deputing inspecting officer for inspection and conduction testing of the materials at the works of the manufacturer. the supplier shall give fifteen days advance intimation to the Purchaser to enable him to depute his representative for witnessing the tests.

1. Power frequency voltage dry test. 2. Measurement of resistance of main circuit. 3. Tests to prove satisfactory operation. 4. Dimension Check 5. Galvanization test. 6. Operational test.

08.00 Guaranteed Technical Particulars: -

The bidder shall furnish the guaranteed technical particular duly filled in the format along with the tender.

09.0 Completeness of Equipment: -

All fittings, accessories of apparatus which may not have been specifically mentioned in this specification but which are usual or necessary in equipment of similar plat shall be deemed to be included in the specification and shall be supplied by the Tender without extra charge. All plant and equipment shall be completed in all details whether such details are mentioned in the specification or not.


11 KV 200 Amp 2 / 3 Pole AB Switch

Guaranteed Technical Particulars

Sl. No

Particulars

Requirement

Bidders offer

2 pole 3 pole

1 Maker’s name & Address To be specified by the bidder

2 Type of Switch Rotating Type 3 Suitable for mounting Horizontal only 4 No. of Breakers per phase Single Break

5 No. of Post Insulators per phase

2nos. of 12KV Post Insulators as per IS:2544/73 per phase

6 (a)

Post Insulators Maker’s Name & Country of Manufacture of Post Insulator

To be specified by the bidder as per CPRI Test Report

(b) Type of cementing Original Cementing. The insulator to be cemented with MCI (Hot dip galvanised /Al Alloy cap and MCI/Forged steel hot deep galvanized pedestral) as per IS: 2544/1973

(c) Power frequency withstand voltage (Dry)

35 KV RMS

(d) One minute Power frequency withstand voltage (wet)

35 KV RMS

(e) Visible discharge voltage 9KV RMS

(f) Dry flash over voltage 85 KV

(g) Power frequency puncture withstand voltage

1.3 times of actual dry flash over voltage

(h) Creapage distance 320 mm minimum (ISS-2544/1973 & relevant IEC)

(7) Impulse withstand voltage for positive & negative polarity (1.2/50 micro second wave)

(a) Across the isolating distance

85KV Peak

(b) To earth & between poles 75KV Peak


8 Rated one minute Power frequency withstand voltage

(a) Across the Isolating distance

32KV(RMS)

(b) To earth & between poles 28KV(RMS)

9(a) Rated voltage nominal/ maximum

11/12KV

(b) Rated normal current and rated frequency

200 Amps. 50hz

10 Rated short-circuit making capacity

25KA (Peak)

11 Rated Short-time current 10KA

12 Rated peak withstand current 40KA

13 Rated mainly active load breaking capacity

200 Amp.(RMS)

14 Rated Transformer off load breaking capacity

6.3 Amp.(RMS)

15 Rated line charging breaking capacity

2.5 Amp(RMS)

16 Minimum clearance between adjacent phase

(a) Switch closed (center to center)

760mm

(b) Switch opened (Center of post insulator to the edge of the blade)

380mm

17 Temperature rise The Temperature rise should not exceed the maximum limit to 65oC at an ambient temperature not exceeding 40oC

650C

Copper contacts silver faced terminal of switch intended to be conducted to external conductor by bolts or screws at an ambient temperature should not exceed.

50oC

18 Vertical clearance from top of insulator cap to mounting channel.

254 mm


19 Type of contact a) Self aligned high pressure jaw type fixed contacts of electrolytic copper of size 70 mm x 35mm x 6 mm duly silver plated .Each contact should be riveted with three nos. copper rivets with a bunch ( minimum 3 mm thick) of copper strips /foil each may vary from 0.15 mm to 0.25 mm to and total thickness of copper foil per jaw should be 6 mm . Jaw assembles are to be bolted through brass bolts and nuts with spring washer.

b) Solid rectangular blade type moving contact of electrolytic copper of size 35 mm X 6 mm and length 220 mm duly silver plated ensuring a minimum deposit of silver 10 micron on copper contacts or as may be

prescribed under relevant ISS / IEC .

c) Pressure springs are to be used in each jaw contacts should be phosphorous bronze having 8nos. of turns X28mm heights X14.4mm diameter with 14

SWG wire .

17 Connectors:- Terminal connectors for both movable and fixed should be of copper flat of same size similar to that of moving contact blades (minimum 95% copper composition). The fixed connector shall of size 65 mm x 35 mm x 6 mm and the size of movable connector shall be size (65 X 35) X (65 X 35) X 6mm with machine finishing duly silver plated with 2 nos. 12mm dia holes provided with suitable brass bolts and double nuts, flat washers & 2nos. bimetallic solder less sockets suitable upto 55 mm² conductor.

18 Moving contact supporting angle

Moving contact is to be supported by G.I angle of size 45x45x5 mm on each phase and the moving contact are to be bolted through 2 nos. stainless steel bolts and nuts with suitable stainless steel flat and spring washers.


19 Galvanization

a) Iron parts shall be ho t dip galvanized as per IS-2633/1972.(Latest Amendment) , IS :2629/1985 (1st. Revision),

b) The pipe shall be galvanized as per IS-4736/1968.(Latest Amendment)

20 (a)

Phase Coupling Rod 25mm nominal bore G.I. Pipe (Medium gause)

(b) Operating Rod ISI mark 32mm nominal bore G.I. Pipe (Medium gause) 6 mtr. long

Normal Outside Dia. in mm

Wall thickness

Max. Min. 25 mm 34.2 33.3 3.25 32 mm 49.9 42 3.25

(c) Arcing Horn 8 mm dia G.I. rod with spring assisted operation.

(d) Force of fixed contact spring 50lbs to 75 lbs

(f) Bearings 4 nos. self lubricated bearing to be provided with grease nipple including 4th bearing being a axial thrust bearing.

(g) Locking Arrangement Pad Lock and key arrangement at both “ON & OFF” position..

(h) Earth terminal Provided at base channel at opposite ends.

(i) Copper braided flexible tapes

320mm long 2no. tin coated copper braided flexible tape both end seated with cupper sheets duly punched for fixing having minimum weight of 450 grams per meter without sockets.

(j) Quick break device Lever mechanism

(k) ‘T’ connector The ‘T’ connector provided on the channel having ‘Moving Contact’ shall be of G.I Nut & Bolt at the bottom end to facilitate replacement of this unit only during requirement and avoid entire change of the arm.


l) I-Bolt The ‘I-Bolt” shall be longer with 75 mm thread.

21 Supporting Channel 75mmx40mmx 6mm M.S.Channel. (Hot dip galvanized)

22 Weight of each pole 20 Kg (Approximately) ( to be specified by bidder)

23 Detailed drawing submitted ? To be provided by bidders

N.B i) Ferrous parts shall be duly galvanized as per IS :2629/1985 (1st. Revision), (Amendment-2) and non-ferrous parts shall be silver plated.

ii) The G.I pipes and rods shall be galvanized as per IS:4736/1968 (1st. Revision), (Amendment-1) for hot-dipped zinc coating on M.S. Tube.

iii) Certificate from a Government approved laboratory regarding composition of copper in electrolytic copper casting of materials should be submitted during inspection of materials at the cost of tenderer.

iv) Items not covered in the G.T.P, but relevant in Design, manufacturing, quality control & testing of materials shall be governed by the relevant IS with latest Amendment.


11 KV 200 Amp 3 Pole HG Fuse Technical Specifications

1. SCOPE:- This specification covers the manufacture, testing and supply of 11

3 pole 200A H.G. Fuse Sets.

2. (a) The 11 KV H.G. Fuses shall be suitable for out door operation in horizontal configuration under the climatic conditions specified. It shall be of the following ratings:-

1 Number of Poles 3 2 No.of Insulator per Pole 2 nos. 12 KV post Insulators 3 Nominal system Voltage 11 KV 4 Highest System of Voltage 12 KV 5 Rated frequency 50 Hz 6 System Frequency Effectively earthed 7 Rated normal current 200 Amps 8 Altitudes of installation Not exceeding 1000 M.

(b) The post insulator used in the H.G. Fuse set shall have the following ratings :-

1 Power frequency withstand voltage (dry) 33 KV (RMS) 2 Power frequency withstand voltage (wet) 35 KV (RMS) 3 Impulse withstand voltage (dry) 75 KV (Peak)


4 Power frequency withstand voltage 1.3 times the actual dry flashover voltage of the unit

3. STANDARDS :-

The H.G. Fuse set shall confirm to the following standards. IS- 9385-1980 ( for high voltage expulsion fuses and similar fuses). IS- 2544-1973 ( for porecelain post insulators or its latest amendments if any.). IS- 2633-1979 ( for Galvanisation of ferrous parts).

4. INSULATOR MAKE :- 12 KV post insulator complete with pedestal cap duly cemented to be used in 11 KV H.G. Fuse sets confirming to IS-2544/1973.

5. TECHNICAL DETAILS :- The H.G. Fuses shall have adjustable arcing horns made

of solid copper rod having 7.62 mm dia. The horns shall be fitted with screwing devices with flynuts for fixing and tightening the fuse wire. It shall have robust terminal connectors of size 80 mm x 50 mm x 6 mm made of copper casting (95 % minimum copper composition) duly silver plated with two numbers of 12 mm dia brass bolts and double nuts with flat brass washers. The connectors should be capable of connecting crimpable conductor upto 80 Sq. mm size( ACSR/ Alloy) with bimetallic solderless sockets. The H.G Fuse Set shall suitable for horizontal mounting on sub-station structures. The minimum clearance between the adjacent phases of the fuse set shall be 760 mm and the centre to centre (distance between two post insulators of the same phase) shall be 410 mm. All metal (ferrous) parts shall be galvanized and polished. Only 12 KV post insulator ( orginal cemented and not pin insulators shall be used for the H.G. Fuse Set.

6. CLIMATIC CONDITIONS :- The H.G. fuse set shall be suitable for operation under the following climatic conditions.:-

1 Maximum ambient air temperature 450 C 2 Maximum daily average air temperature 350 C

3

Maximum yearly average ambient air temperature

300 C 4 Maximum temperature attainable by a body

exposed to the sun. 500 C

5 Minimum ambient air temperature 00 C 6 Maximum relative humidity 100% 7 Average number of thunderstorm days per annum 70 days 8 Average number of rainy days per annum 120 9 Average annual rain fall. 150CM 10 Number of months of tropical monsoon conditions 4 11 Maximum wind pressure 260 Kg/mm 12 Degree of exposure to atmospheric pollution. Normally polluted

atmosphere.

7 Type Test :-

Certificate for the following type tests conducted on a prototype set of HG Fuse in a NABL approved test house/CPRI shall have to be submitted along with offer.

i) Dielectric test (impulse & one minute wet power frequency withstand voltage test.)


ii) Temperature rise test ( for terminals) iii) Mechanical strength test for the post of insulator as per IS-2544/1973 iv) Test for galvanization of metal (ferrous) parts.

8. ROUTINE/ACEPTANCE TESTS :-

The inspection may be carried out by the Purchaser at any stage of manufacture. The successful bidder shall grant free access to the Purchaser’s representative at a reasonable time when the work is in progress. The following routine tests shall have to be conducted on each set and results are to be furnished for consideration of deputing inspecting officer for inspection and conduction testing of the materials at the works of the manufacturer. the supplier shall give fifteen days advance intimation to the Purchaser to enable him to depute his representative for witnessing the tests.

i) Power frequency voltage dry test ii) Dimension Check iii) Galvanisation test.

9. Guaranteed Technical Particulars :

The bidders are required to furnish the guaranteed technical particulars duly filed in the proforma along with the bid.

10. Completeness of Equipment :

Any fittings accessories or apparatus which may not have been specifically mentioned in this specification but which are usually necessary in equipment of similar plant shall be deemed to be included in the specification and shall be supplied by the bidder without extra charge. All plant and equipment shall be complete in all details whether such details are mentioned in the specification or not.

11. Inspection :

Routine and acceptance test shall be conducted at the place of manufacturer. The bidders are requested to furnish details of equipments which will be used for testing along with the bid. The bids of these manufacturers who do not have adequate testing facilities for conducting routine and acceptance test are liable for cancellation. The successful bidder has to furnish routine test certificate and guarantee certificate for each consignment of materials to be inspected at the time of offer of materials for inspection.


GUARANTEED TECHNICAL PARTICULARS OF 11 KV 200Amp. HG Fuse ( 2 / 3 pole)

Sl. No

Particulars

Requirement

Bidders offer

11 KV 200 Amps.2/ 3 pole H.G Fuse.

2 Pole 3 Pole

1 Maker’s name & Address To be specified by the bidder 2 Operating voltage 11 KV 3 No. of Post Insulators per

phase 2 nos. of 12 KV Post Insulators per phase as per ISS:2544/1973

4 Rated normal current & normal frequency

200 Amp., 50 Hz

5 Vertical clearance from the top of insulator to mounting channel

254 mm (minimum)

6 Height of the riser for carrying the horn.

150 mm from the cap top of insulator

7 (a)

Post Insulators : Maker’s Name & Country of Manufacture of Post Insulator

To be specified by the bidder ( as per CPRI Test Report).

(b) Type of cementing Original Cementing only as per IS: 2544/1973 & relevant IEC.

(c) 1 minute Power frequency withstand voltage (Dry)

35KV RMS

(d) 1 minute Power frequency withstand

35KV RMS

(e) Visible discharge voltage 9KV RMS (f) Dry flash over voltage 85 KV RMS (g) Power frequency puncture

withstand voltage 1.3 times of actual dry flash over voltage (110 KV) .

(h) Creapage distance 320 mm (minimum). Actual creepage distance for which type test has been conducted is to be supplied.

8. Impulse withstand voltage for positive & negative polarity (1.2/50 micro second wave)

(a) Across the isolating distance 85KV (Peak) (b) To earth & between poles 75KV (Peak) 9. One minute Power frequency

withstand voltage

(a) Across the Isolating distance 32KV(RMS) (b) To earth & between poles 28KV(RMS)


10 Details of Arcing Horn 1 SWG (7.62 mm) dia. solid copper rod silver plated provided with screwing arrangement on the fuse carrier made of copper casting for fixing fuse wire (Total length -635 mm). All the bolts, Nuts and washers should be made out of Brass.

11 Riser Unit (150 mm height total)

a) Riser cum Connector made out of copper casting (with minimum 95% copper composition having riser size (80 mm height x30mm width x8 mm thickness) and connector of size (80 mmx50mmx 8mm) duly silver plated and machine finishing provided with 2 nios.12 mm dia. brass bolts and double brass nuts with flat brass washers and 2 nos. solderless bimetallic socket per each connector suitable upto 80 mm²conductor.

b) 100 mm height G.I Riser made of 19 mm nominal bore medium gauge G.I pipe welded with 2 nos. of G.I flat of 30mmx5mm of both ends fixed with 10mm dia. stainless steel bolts and nuts with flat & stainless steel spring washer.

13. Galvanization a) All ferrous parts shall be hot- dipped Galvanized as per IS.2633/1972 (Latest Amendment) , IS :2629/1985 (1st. Revision),& all non-ferrous parts shouldbe duly electroplated with silver.

14 Supporting Channel 75mmx40mmx6mm M.S.Channel. (Hot dip galvanized)

15 Weight of each pole 16 Kg (Approx.)To be specified by the Bidder

16 Detailed drawing submitted ? To be provided by bidders N.B i) Ferrous parts shall be duly galvanized as per IS :2629/1985(1st. Revision),

(Amendment-2) and non-ferrous parts shall be silver plated. ii) Certificate from a Government approved laboratory(NABL accredited) regarding

composition of copper in electrolytic copper casting of materials should be submitted during inspection of materials at the cost of Bidder.

iii) Type Test Certificate : The type test certificate , conducted within five years , preceding to date of opening of the tender from Govt. testing laboratory (NABL accredited / CPRI) shall be furnished.



11KV (LIGHTNING ARRESTERS)

TECHNICAL SPECIFICATION FOR 9 KV 10 KA DISTRIBUTION CLASS HEAVY DUTY SURGE ARRESTERS (LIGHTNING ARRESTERS)

1.0 SCOPE:

1.1 This specification provides for the design, engineering, manufacture, assembly, stage testing,

inspection and testing before despatch, packing, forwarding and delivery of Metal Oxide (gapless) Surge Arresters complete with accessories 11 KV system as specified hereunder.

1.2 It is not the intent to specify completely herein all the details of design and construction of Surge

Arresters, However, Surge Arresters shall conform in all respects to the high standard of design and workmanship and be capable of performing in continuous commercial operation up to Bidder's guarantee in a manner acceptable to Purchaser, who will interpret the meanings of drawings and specifications and shall have the power to reject any work or material which in his judgment are not in accordance therewith. The Arresters offered shall be complete with all parts, necessary for their effective and trouble free operation. Such components shall be deemed to be within the scope of supply, irrespective of whether they are specifically brought out in the commercial order or not.

2.0 STANDARDS:

2.1 The Surge Arresters shall conform to the latest editions and amendments available at the time of

supply, of the standards listed hereunder:

S. No.

Standard Ref No.

Title

1. IEC 99-4 Specification Part. 4 for Surge Arresters without gap for AC system.

2 IS:3070 (Part-III)

Specification for Lightning Arresters for alternating current System

3 IS:2629 Recommended practice for hot dip galvanising of iron and steel.

4 IS:2633 Method for testing uniformity of coating on Zinc coated articles.

5 IS:5621 Specification for large hollow porcelain for use in electrical installation.

6 IS:2147 Degree of protection provided by enclosures for low voltage switchgear and control gear.

7. Indian Electricity Rules 1956.

Note:

i) For the purpose of this specification all technical terms used hereinafter shall have the meaning as per

IEC specification.


ii) For the parameters of the Arrester which are not specified in IEC specification for Surge Arresters, the provisions of ISS 3070 (Part.III) shall be applicable.

2.2 Surge Arresters meeting with the requirements of other authoritative standards, which ensure equal or

better quality than the standards mentioned above shall also be acceptable. Where the equipment offered by the Bidder conforms to other standards, salient points of difference between the standards adopted and the specified standards shall be clearly brought out in the offer. Four (4) copies of the reference standards in English language shall be furnished along with the offer.

3.0. CLIMATIC CONDITIONS:

3.1 The Surge Arresters and accessories shall be suitable for continuous satisfactory operation under

climatic conditions listed below.

1. Maximum ambient Air 50 °C Temperature in shade (deg.C).

2. Minimum Ambient Air (-) 5 °C Temperature in

shade(deg.C).

3. Maximum daily average ambient air temperature 40°C

4. Maximum relative humidity(%) 100%

5. Height above mean sea level 1000M

6. Maximum wind pressure 260 Kg m²

7. Average No. of thunder Storm 70 days. Days / annum.

8. Average annual rainfall (mm) 1500 mm

9. Average No. of months of 4 tropical monsoon condition p.a.

All the electrical devices shall be given tropical and fungicidal treatment to enable their satisfactory operation in the above climatic conditions.

4.0 PRINCIPAL PARAMETERS:

The Surge Arresters offered under this specification shall conform to the parameters given below.

S. No Particulars System parameters

for 9 KV Distribution type

1 Nominal system voltage (kv rms) 11 2 Highest system voltage (kv rms) 12 3 1.2/50 microsecond impulse voltage with stand level


a Transformer and reactors (kvp) 75 b Other equipment and lines (kvp) 75 4 Minimum prospective symmetrical fault

current for 1 second at Arrester location (KA rms)

10

5 Anticipated levels of temporary over voltage and its duration.

a Voltage(p.u.) 1.5 b Duration(Seconds) 1/10 6 System frequency(Hz) 50 + / - 1.5

7 Neutral Grounding Effectively earthed

8 Number of Phases Three Note 1. 1 p.u. = 12 x √2KV

peak /√3

5.0 GENERAL TECHNICAL REQUIREMENTS:

5.1 The Surge Arresters shall conform to the technical requirements as per Annexure-A.

5.2 The energy handling capability of each rating of Arrester offered, supported by calculations, shall be

furnished in the offer. 5.3.1 The Station Type Surge Arresters shall be fitted with pressure relief devices and arc diverting

ports and shall be tested as per the requirements of IEC specification for minimum prospective symmetrical fault current as specified in Annexure-A.

5.3.2 The grading ring on each complete Arrester for proper stress distribution shall be provided if required for

attaining all the relevant technical parameters. 5.4 PROTECTIVE LEVELS:

The basic insulation levels and switching impulse withstand levels of the lines and equipment to be protected have been specified in clause 4.0, "Principal Parameters".

The protective characteristics of the Arresters offered shall be clearly specified in the schedule of guaranteed technical particulars.

5.6 GENERAL REQUIREMENTS:

5.6.1 The materials and components not specifically stated in this specification but which are necessary

for satisfactory operation of the equipment are deemed to be included in the scope of supply unless specifically excluded.

5.6.2 Unless otherwise brought out separately by the Bidder in the schedule of deviations the Surge Arresters

offered shall conform to the specification scrupulously. All deviations from the specification shall be brought out in the schedule of deviations. The discrepancies between the specification and the catalogues or literature submitted as part of the offer shall not be considered as valid deviations unless specifically brought out in the schedule of deviations.


5.6.3 Any deviation which has not been specifically brought out in the schedule of deviations of the Bid

Proposal Sheets, shall not be given effect to. The deviations brought out in the schedule shall be supported by authentic documents, standards and other references.

5.6.4. Each individual unit of Surge Arresters shall be hermetically sealed and fully protected against ingress of

moisture. The hermetic seal shall be effective for the entire life time of the Arrester and under the service conditions as specified. The Bidder shall furnish sectional view of the Arrester, showing details of sealing employed.

5.6.5 The bidder shall furnish in the offer, a sectional view of pressure relief device employed in the Station type

Surge Arresters offered. 5.6.6 The Surge Arresters shall be suitable for hot line washing.

5.7 Construction: 5.7.1 All the units of Arresters of same rating shall be interchangeable without adversely affecting the

performance. 5.7.2 The Surge Arresters shall be outdoor and suitable for pedestal/ clamp type mounting.

5.7.3 All the necessary flanges, bolts, nuts, clamps etc., required for assembly of complete Arrester with

accessories and mounting on support structure to be supplied by the Purchaser shall be included in Bidder's scope of supply.

5.7.4 The drilling details for mounting the Arrester on Purchaser's support shall be supplied by the Supplier.

5.7.5 The minimum permissible separation between the Surge Arrester and any earthed object shall be indicated by

the Bidder in his offer. 5.8. PORCELAIN / POLYMERIC HOUSING:

5.8.1 The housing may be of Porcelain or Polymeric.

5.8.2 Where the bidders are quoting for Surge Arresters with Porcelain Housing, all porcelain housings shall be

free from lamination cavities or other flaws affecting the maximum level of mechanical and electrical strengths.

5.8.3 The porcelain shall be well vitrified and nonporous.

5.8.4 The creepage distance of the Arrester housing shall be as per Annexure-A.

5.8.5 The porcelain petticoat shall be preferably of self cleaning type (Aerofoil design).

The details of the porcelain housing such as height, angle of inclination, shape of petticoats, gap between the petticoats, diameter (ID and OD) etc., shall be indicated by the Bidder in his offer in the form of a detailed drawing.

5.8.6 The Arrester housing shall conform to the requirements of IEC specification. 5.9. GALVANISATION, NICKEL PLATING ETC.:

5.9.1. All ferrous parts exposed to atmosphere shall be hot dip galvanised as per IS:2629 as amended from time


to time. Tinned copper / brass lugs shall be used for internal wiring. Screws used for electrical connections shall be either made of brass or nickel plated.

5.9.2. Ground terminal pads and name plate brackets shall be hot dip galvanised.

5.9.3 The material shall be galvanised only after completing all shop operations.

5.10. ACCESSORIES AND FITTINGS:

5.10.1 All necessary accessories and earthing connection leads shall be in the Bidder's scope of supply.

5.10.2 Terminal connector conforming to IS: 5561 shall be supplied along with the arrester.

5.11. The grounding terminal shall be suitable for accommodating Purchaser's grounding connection to

steel earth mat. 5.12. Name Plate:

The arrester shall be provided with non-corrosive legible name plate indelibly marked with the following information:

1. Purchaser’s Name : NESCO 2. Order No.: 3. Manufacturer's name, address, trade mark and identification no. of the Arrester being

supplied. 4. Rated Voltage. 5. Maximum continuous operating voltage. 6. Type. 7. Rated Frequency. 8. Nominal discharge current. 9. Line discharge class. 10. Pressure relief current in kA rms. 11. B.I.L. of the equipment to be protected. 12. Year of manufacture. 13. Date of despatch. 14. Date of Expiry of Warranty.

6.0. TESTS:

6.1 TEST BEFORE DESPATCH:

The Surge Arrester of various rating and accessories shall be subjected at maker's works before despatch, to the following tests as per relevant standards.

A) ROUTINE TEST ON EACH UNIT AS PER RELEVANT STANDARDS: 1. Measurement of reference voltage. 2. Residual voltage test. 3. Satisfactory absence from partial discharges and contact noises. 4. For arrester units with sealed housing leakage check shall be made on each unit. 5. Current distribution test for multi Column arrester.

6.2 TYPE TESTS:

6.2.1 The bidder shall furnish valid and authenticated type test reports from a Govt. approved / Govt. recognized /

NABL Accredited laboratory of similar rating and design of tendered material along with detailed


dimensional drawing duly signed & verified by testing agency also showing size & numbers of blocks dimensions contained in the housing along with bid as per requirement of the Tender Specification. Such type test certificates should not be older than 5 years as on the date of bid opening. For this purpose date of conducting type test will be considered. The type test certificates shall be furnished either in original or copy duly attested by notary.

The bidder should furnish documentary evidence in support of the laboratory whose type test have

been furnished, that the said laboratory is a Govt. / a Govt. approved / a Govt. recognized / NABL accredited laboratory / ILAC accredited (in case of foreign laboratory).

The bids of only those bidders shall be considered to be meeting the type test criteria who furnishes

complete type test certificate with the bid as per above provision. 6.2.2: Following type tests shall be conducted on one unit of each rating as per relevant standard.

1. Insulation withstand test. 2. Residual voltage test. 3. Bending test on arrester housing assembly. 4. Long duration current impulse withstand test. 5. Operating duty test. 6. Pressure relief test (Only for station type) 7. Test of arrester disconnectors (For 9 KV Feeder Type) 8. Artificial pollution test on porcelain. 9. Partial discharge test. 10. Housed arresters.

a) Temperature cycle test. b) Porosity test.

11. Galvanising test on exposed ferrous metal parts. 12. Any other type test which are not specified above but covered as per amendment/latest edition of relevant IS/IEC.

6.3 TEST ON BOUGHT OUT ITEMS:

Tests are not required to be performed on bought out equipments/items like, Terminal connector etc. at the works of manufacturer. Furnishing Test Certificate of bought out items from the original equipment manufacturers shall be deemed to be satisfactory evidence. Inspection of the tests at Sub- contractors works will be arranged by the supplier whenever required.

6.4 ROUTINE/ACCEPTANCE TESTS:

The following tests shall be got conducted in presence of purchaser's representative, as per stipulation of the relevant standards. Acceptance tests whenever possible shall be conducted on the complete arrester unit. No. of samples to be selected for acceptance tests shall be nearest lower whole number to the cube root of the number of arresters to be supplied.

1. Measurement of power frequency reference voltage on the complete arrester at the reference current

measured at the bottom of the arrester. 2. Lightning Impulse residual voltage. 3. Partial discharge test. 4. Visual inspection & verification of dimension. 5. Special thermal stability test. 6. Galvanising test on Ferrous metal parts.


7. Any other tests as per IS. 6.5 TOLERANCE ON TEST RESULTS:

As per relevant standards/specifications. 6.6. CHECKING AT STORES (TEST AT CTL):

One out of every 50 nos. Surge Arresters will be selected for checking at Store for visual, dimensional, weight, marking etc. as per relevant ISS/GTP/approved drawing.

7.0 INSPECTION:

All the tests (as mentioned at Clause 6.4) and Inspection shall be made at the place of manufacturer unless otherwise especially agreed upon by the bidder and purchaser at the time of purchase. The bidder shall afford the inspection officer(s) representing the purchaser all reasonable facilities without charges, to satisfy him that the material is being supplied in accordance with this specification. The purchaser has the right to have the tests carried out at his own cost by an independent agency whenever there is a dispute regarding the quality of supply.

The Inspection may be carried out by the purchaser at any stage of manufacture/before despatch as per relevant standard.

Inspection and acceptance of any material under the specification by the purchaser, shall not relieve the bidder of his obligation of furnishing material in accordance with the specification and shall not prevent subsequent rejection if the material is found to be defective. The Bidder shall keep the purchaser informed in advance, about manufacturing programe so that arrangements can be made for inspection.

The purchaser reserves the right to insist for witnessing the acceptance/routine testing of the bought out items.

GUARANTEED TECHNICAL PARTICULARS FOR METAL OXIDE (GAPLESS) SURGE ARRESTERS

S. No.

Particulars Requirement of parameters

Bidder’s offer

1 Name of Manufacturer. & Address To be specified by the bidder

2 Location of type testing To be specified by 3 Applicable standard IS:3070 (Part-III) or

the latest version thereof

4 Rated arrester voltage (KV) 9

5 Maximum continuous operating voltage (MCOV) KV (rms)

10

6 Installation Outdoor 7 Class Distribution Class

8 Type of construction Single column, single phase

9 Nominal discharge current corresponding to 8 / 20 micro second wave shape (KA peak)

10

10 Type of mounting Pedestal


11 Connection (between phase to earth) / (between phase to phase)

Phase to Earth

12 Line discharge class 2 13 Ratio of switching impulse residual

voltage to rated voltage of arrester

As per provision of IEC – 99 – 4 (latest amended)

14 Minimum prospective symmetrical fault current for pressure relief test (KA rms)

40

15 a)

Terminal connector suitable for the conductor

upto 100 mm² single

b) Take off For both vertical & horizontal

16 Voltage (corona extinction) (KV rms) Rated voltage of arrester

17 Partial discharge As per provision of IEC – 99 – 4 (latest amended)

18 Whether insulating base and discharge counter with milli ammeter are required

No

19 Minimum creepage distance of arrester housing

300 mm

20 Drawing To be submitted by bidder



GUARANTEED TECHNICAL PARTICULARS FOR LT GUY STRAIN

INSULATOR (TYPE_A)

Sl.

Particulars Requirement Bidder’s offer 1 Name of Manufacturer. & Address To be specified by

the bidder

2 Location of type testing To be specified by the bidder

3 Applicable standard IS: 5300-1969 or the latest version thereof

4 Nominal System Voltage 400/230 V

5 Highest System voltage 440/250 V

6 Length 90 mm

7 Diameter 65 mm

8 Cable hole diameter 16 ± 1.5

9 1min. power frequency withstand Voltage (Dry)

18 KV (rms)

10 1min. power frequency withstand Voltage (Wet)

8 KV

11 Minimum failing load 44 KN

12 Minimum creepage distance 41 mm

13 Drawing To be submitted

by bidder


NB- Every insulator should bear the marking of manufacturer’s name andISI mark

Name & Signature of Agency with seal


GUARANTEED TECHNICAL PARTICULARS FOR 11 KV GUY STRAIN INSULATOR (TYPE_C)

Sl.

No.

Particulars Requirement Bidder’s offer

1 Name of Manufacturer. & Address To be specified by the bidder

2 Location of type testing To be specified by the bidder

3 Applicable standard IS: 5300-1969 or the latest version thereof

4 Nominal System Voltage 11 KV

5 Highest System voltage 12 KV

6 Length 140 mm

7 Diameter 85mm

8 Cable hole diameter 25 ± 1.5

9 1min. power frequency withstand Voltage (Dry)

27 KV (rms)

10 1min. power frequency withstand Voltage (Wet)

13 KV

11 Minimum failing load 88 KN

12 Minimum creepage distance 57 mm

13 Drawing To be submitted

by bidder


NB- Every insulator should bear the marking of manufacturer’s name and ISI mark



GURANTEED TECHNICAL PARTICULARS OF LT STAY SETS

Sl No.

Item

Description

Specified Parameters

Material

Bidder’s

offer Section Tolerances

Fabrication Tolerances

Manufacture’s Name & Address

To be specified by the bidders

1. Anchor Plate

6mm thick +2.5%-5%

200x200mm+1% GS Plate 6 mm thick

2. Anchor Rod

16mm dia +5%- 3%

Length 1800mm + 0.5%

GS Round 16mm dia

Rounded Eye 40 mm inside dia +3% Threading 40mm+ 11%-5%

GS Round 16mm dia

3. Turn Buckle Bow

16mm dia +5%-3%

995mm+1% GS Round 16mm dia.

Length180mm +1%

GS Angle 50x50x6 mm

4. Eye Bolt Rod

16mm dia +5%-3%

Length 450mm + 1%

GS Round 16 mm dia

Threading 300mm +1% Round Eye 40mm inside dia+3%

5 Galvanisatio n thickness

All galvanization shall be carried out in accordance with IS: 2629 . The weight of Zinc deposited shall be in accordance with IS: 2629 and shall not less than 0.61 kg/m² with a minimum thickness of 86 microns for items of thickness more than 5 mm, 0.46kg/m²(64 microns) for items of thickness between 2 mm & 5 mm& 0.33kg/m²(47 microns) for items less than 2 mm thickness.

a Anchor Plate

b Anchor Rod

c TurnBuckle Bow

d Eye Bolt Rod

6 Thimble 2 nos. to be made of 1.5 mm thick G.S Sheet into a size 75x22x40 mm & shape as per standard.

7

Hexagonal Nut

One G.S Hexagonal Nut confirming to IS:1363 & 1367 with one square washer of size 50x50x6 mm (G.S) along with Anchor Rod.

8 Two G.S Hexagonal Nuts of suitable size along with Eye Bolt Rod.



GURANTEED TECHNICAL PARTICULARS OF 11KV HT STAY SETS

Sl No.

Item

Description


Material

Bidder’s offer

Section Tolerances



To be specified by the bidder

1 Anchor Plate

8 mm thick +2.5%-5%


2 Anchor Rod

18 mm dia +5%- 3%


GS Round 18mm dia


GS Round 18mm dia

3. Turn Buckle Bow

18mm dia +5%-3%


Length200mm +1%

GS Channel 100x50x4.7mm

4. Eye Bolt Rod

18 mm dia +5%-3%

Length 450mm + 1%

GS Round 18 mm dia




a Anchor Plate

b Anchor Rod

c TurnBuckle Bow

d Eye Bolt Rod


7

Hexagonal Nut





GURANTEED TECHNICAL PARTICULARS OF 33 KV HT STAY SETS

Sl No.

Item

Description


Material

Bidder’s offer

Section Tolerances



To be specified by the bidder

1 Anchor Plate

8 mm thick +2.5%-5%


2 Anchor Rod

20 mm dia +5%- 3%


GS Round 18mm dia


GS Round 18mm dia

3. Turn Buckle Bow

20 mm dia +5%-3%


Length200mm +1%

GS Channel 100x50x4.7mm

4. Eye Bolt Rod

20 mm dia +5%-3%

Length 450mm + 1%

GS Round 18 mm dia




a Anchor Plate

b Anchor Rod

c TurnBuckle Bow

d Eye Bolt Rod


7

Hexagonal Nut





GURANTEED TECHNICAL PARTICULARS STAY WIRE (7/8 SWG)

Sl. No.

Description Specified Bidder’s offer

1. Manufacturer’s name & address To be specified by the Bidder

2 Nominal diameter of wire in mm 4.0 3 Tolerance in diameter in mm + 2.5% 4 Minimum breaking load in Kg 5960.26 5 Tensile strength Kgf/mm² 71.40 6 Overall diameter of stranded wire in mm 12.0 7 Sectional Area (in mm².) 113.14 8 Coating Test a Type of zinc coating whether heavy or light Heavy b Weight of coating in g/m² 476

9 a Length of wire in each coil in mtr. 117

b Tolerance + 5% 10 No. of dips the coating is able to withstand

as 18 ± 20ºC 3 dip in min.

11 Adhesion Test (Wrap Test at 1 turn per second coiling while stress not exceeding % nominal tensile strength)

a Min. complete turn of wrap To be specified by bidder

b Dia of mandrel on which wrapped - do - 12 Bend Test a Angle - do - b Dia round a format to be bent - do -

13 Freedom from defect - do - 14 Chemical composition the MS Wire used

shall not exceed

a Sulphur 0.060% - do - b Phosphorous 0.065% - do -

15 a Weight of each coil in Kg 70 to 100

b Tolerance + 5%

16 a Weight of wire in Kg/Km 750 b Tolerance + 5%

17 Standard according to which the solid wire is manufactured and tested

ISS: 2141/1992 & ISS: 4826/1979




Sl. No.











shall not exceed



b Tolerance + 5%



ISS: 2141/1992 & ISS: 4826/1979



Guaranteed Technical Particulars for No. 6 G.I. wire

Sl. No.

GENERAL TECHNICAL PARTICULARS Guaranteed

Value Bidders Offer

Manufacturer’s Name & Address 1 Nominal diameter of wire in mm 4.88 mm 2 Tolerance in diameter in mm + 2.5% 3 Sectional Area (in Sq. mm.) 18.7038 4 Tensile strength of wire in N/mm²/ MPa 550-900 5 Minimum breaking load (KN) 9 6 Variety Hard/Soft Soft 7 Type of Galvanizing Hot dip

heavy coating

8 Weight of Zinc coating (Gms/Sq. Mtr.) 290 9 No. of dips the coating is able to withstand as 18 ± 20ºC 3 dip in Min



i) Min. complete turn of wrap do ii) Dia of mandrel on which wrapped do

11 Bend Test do i) Angle do ii) Dia round a format to be bent do

12 Freedom from defect do 13 Chemical composition the MS Wire used shall not

exceed do

i) Sulphur 0.060% do ii) Phosphorous 0.065% do

14 Weight of wire in Kg/Km 148

15 Tolerance in wt. + 5%


IS: 280/1978 , IS: 4826/1979 , IS: 7887/1975



Guaranteed Technical Particulars for No. 8 G.I. wire

Sl. No.

GENERAL TECHNICAL PARTICULARS Guaranteed

Value Bidders Offer

Manufacturer’s Name & Address 1 Nominal diameter of wire in mm 4.06 mm 2 Tolerance in diameter in mm + 2.5% 3 Sectional Area (in Sq. mm.) 12.9462 4 Tensile strength of wire in N/mm²/ MPa 550-900 5 Minimum breaking load (KN) 8.79 6 Variety Hard/Soft Soft 7 Type of Galvanizing Hot dip

heavy coating

8 Weight of Zinc coating (Gms/Sq. Mtr.) 290 9 No. of dips the coating is able to withstand as 18 ± 20ºC 3 dip in Min



ii) Min. complete turn of wrap do ii) Dia of mandrel on which wrapped do

11 Bend Test do iii) Angle do iv) Dia round a format to be bent do

12 Freedom from defect do 13 Chemical composition the MS Wire used shall

not do

iii) Sulphur 0.060% do iv) Phosphorous 0.065% do

14 Weight of wire in Kg/Km 103

15 Tolerance in wt. + 5%


IS: 280/1978 , IS: 4826/1979 , IS: 7887/1975



40mm dia GI Earthing Device: 1. Scope :-

This specification provides for design, manufacturing, testing before dispatch, supply & delivery of Earthing Device (Heavy Duty) (for use in Sub-station earthing).

2. APPLICABLE STANDARDS :-

The Earthing Device must be made out of 40 mm nominal Bore & 3.2 mm (Medium Gauge- No minus Tolerance allowed) wall thickness Hot Dip G.I. Pipe (as per IS ;- 1239,m Part-1, 1990 & REC construction Standard –J-2) , ISI marked of reputed Make & 2.5 mtrs length tapered finished smooth at one end for a length of 75 mm & Clamp at the other end.

Staggered drills hole of 12 mm Dia of interval of 150mm shall be made before galvanization.

The GI Earthing Clamp/ Strip (C- Clamp Type) is to be of 50mm width, 6mm thickness & flange length of 65 mm in each side. This should be suitable for termination of 4 nos of GI Flat earth electrodes. The Clamp/ Strip & Earthing pipe after fabrication will be hot dip galvanized confirming to IS: 2629/85 with latest amendments. The clamp shall have two holes in both sides suitable for 5/8 x 2” Bolt & provided with two GI bolts& Nuts in each side of 12mm dia 50mm long half threaded with spring washer as per IS: 3043/1982.The galvanization tests are to be conducted as per IS: 2633/72 & IS: 6745/72 & its latest amendments.

Guaranteed Technical Particulars of Earthing Device (To be submitted along with Offer)

Particu

Bidder’s Offer

1. Location of Factory or Place of Manufacture

2. Maker’s Name, Address & Country

3. Size of

a Pipe

b Earthing Strips

4. Length

5. Thickness of Pipe

6. Galvanization Process

7. Galvanization thickness

a For Earthing device

b For Connecting Flat

8. Galavanization tests to be conducted as per ISS

9. Any other Particulars ( like details of Clamp/ G.I. Bolts)

10. Details of Drawings submitted



16 mm dia. Hexagonal Bolts & Nuts and Washer (GI) 16 mm diameter GI Nuts and Bolts black hexagonal As per IS: 1387 (Part-II) Gr.-4/4.6 of following size. Washers shall be round of thickness 1.5 mm suitable for 16 mm dia. bolts.

Specification finished products:

1. The bolts & Nuts shall be ISI Marked Mild Steel of Black Grade “B” and shall be round with hexagonal head.

(i) The Bolts and Nuts shall be manufactured by Hot/Cold forging process neatly and cleanly finished

and shall have metric threads as per IS : 4218/1967 with its latest amendments.

(ii) The dimensions of the bolts & nuts and tolerances should conform to IS: 1363 with their latest amendments in all respect. The eccentricity and angular errors of various elements shall be within specified limits as per IS: 1367/1967 with its latest amendments the bolts & nuts shall be free from forging and threading defects such as cuts, spats. burns, bulging taper eccentricity, loose fill etc. which may affect their serviceability.

(iii) The colt heads and nuts shall be chamfered on one face only and other face shall be machined made.

(iv) Mechanical property requirement of tester shall conform to IS: 1367 (Part-III) 1979 property class 4.6 for bolts & property class-5 for nuts as per IS: 1367 (Part VI) —1980.

(v) The bolts & nuts shall be supplied in well-cleaned conditions and suitably protected against corrosion in individual bags of 50 Kgs.

ACCEPTANCE TESTS:

The bidder should furnish test certificate from recognized Govt. Laboratory ( NABL accredited) giving the results of tests as per IS: 1367 (Part-Ill) —1979 & IS: 1367 (Part-VI) 1980 The test certificate shall be in respect of the following for all sizes of both bolts & nuts as applicable given below:-

i) Dimensional particulars (Sampling Ifl accordance with IS: 2614 for both bolts & nuts (Tolerance as per drawing).

ii) Tensile strength test on full size (for bolts minimum 400 NI Sq.mm and for Nuts Proof

Stress test Mm 610 N/Sq. mm).

iii) Power load test on full size bolts and M-12-51400 N for 15 Sec.

iv) Head soundness tests for bolts (no fracture).

v) Brinell hardness tests or Rockwell Hardness or Vickers’s Hardness tests for bolts min- 114 &max. 209 or mm. 67 & max. 95 or mm. 120 & max. 220 respectively. For nuts Vickers’s Hardness mm. 130 & max. 302.

Markings: On the bolt head, there shall be identification marking of the manufacturer as well as property class ‘4.6”. If possible property class “5” shall be marked on Nuts also. Further ‘ISI’ mark shall be marked on Gunny Bags for proper identification.


EARTHING COIL :

EARHTING COIL TECHNICAL SPECIFICATION

SCOPE :

The specification covers design, manufacture, testing and dispatch to the owner’s stores of Earthing Coils for use in earthing of the HT & LT poles.

GENERAL REQUIREMENTS :

Earthing coils shall be fabricated from soft GI Wire Hot Dip Galvanized. The Hot Dip galvanized wire shall have clean surface and shall be free from paint enamel or any other poor conducting material. The coil shall be made as per REC constructions standard. The Hot Dip galvanizing shall conform to IS: 2629/1966, 2633/1972 and 4826/1969 with latest amendments.

TESTS :

Galvanizing Tests Minimum Mass of Zinc On GI Wire used 280 cm/m²

After Coiling-266 gm/m².The certificate from recognized laboratory shall be submitted towards mas of zinc.

Dip Test

Dip test shall stand 3 dips of 1 minute and one dip of ½ minute before coiling and 4 dips of 1 minute after coiling as per IS: 4826/1979 Adhesion Test

As per ISS 4826 – 1979 DIMENSIONAL REQUIREMENT

i) Nominal dia of GI Wire -4 mm (Tolerance±2.5%)

ii) Minimum no. of turns – 115 Nos.

iii) External dia of Coil (Min) – 50 mm

iv) Length of Coil (Min) – 460 mm

v) Free length of GI Wire at one end coil (Min.) – 2500 mm

vi) The turns should be closely bound. Weight of one finished Earthing Coils (min.) – 1.850 Kg.


Guaranteed Technical Particulars of Coil Earth

Sl. No.

GENERAL TECHNICAL PARTICULARS

Bidder’s Offer

1 Nominal diameter of wire 2 No. of turns 3 External dia of Coil 4 Length of Coil 5 Mass of Zinc 6 Total weight of Coil 7 Whether drawing enclosed (yes)


100x50x6mm MS Channel 75x40x5 mm MS Channel 50x50x6 mm Angle

Technical Specifications :

Clause No.

TECHNICAL SPECIFICATIONS OF MILD STEEL CHANNEL & ANGLE

1.0 SCOPE This specification covers design, manufacture, testing and dispatch to owner’s stores of M.S. Channel & Angle for use in structures in distribution system.

2.0 APPLICABLE STANDARD Materials shall conform to the latest applicable Indian standards. In case bidders offer steel section and supports conforming to any other international specifications which shall be equivalent or better than IS, the same is also acceptable.

S.No. Standard No. Title 1 IS: 2062 Grade ‘A’Quality Specification for M.S.Angles, M.S.Channel 2 IS: 2062 Chemical and Physical composition

of material 3 IS: 1852 Rolling and Cutting Tolerances for Hot

Rolled Steel products


3.0 3.1

GENERAL REQUIREMENTS Raw material

The Steel Sections shall be re-rolled from the BILLETS/INGOTS of tested quality as per latest version of IS: 2830 or to any equivalent International Standard and shall be arranged by the bidder from their own sources. The Chemical composition and Physical properties of the finished material shall be as per the equivalent standards.

3.2 3.3

3.4 3.5 3.6 3.7

Length The GS Flat to be supplied shall be in 5.5 meters length.

Weightment

The weighnment of GS Flat shall be witnessed by the consignee at the time of taking delivery. The weight recorded in the material receipt certificate issued by the consignees shall be final.

Chemical Composition and Physical Properties of M.S. Angles, M.S. Channels, and M.S.Flat conforming to IS: Conforming to IS:2062/84 Chemical Composition

Chemical composition For Fe 410 WA Grade

1 C - 0.23% MAX 2 Mn - 1.5% MAX 3 S - 0.050% MAX 4 P - 0.050% MAX 5 SI - 0.40% MAX 6 CE

(Carbon Equivalent)- 0.42% MAX Mechanical Properties

1. Tensile strength Kgf/mm²⎯ - 410 2. Yield stress Min. for thickness/diameter

< 20 mm - 26 Kgf/mm² OR 250 N/ mm² 20-40 mm - 24 Kgf/mm² OR 240 N/ mm² > 40 mm - 23 Kgf/mm² OR 230 N/ mm²

3. Elongation % - 23% 4. Bend Test (Internal Dia) - Min-3t

(t – is the thickness of the material) Tolerance

Variation in ordered quantity for any destination and overall ordered quantity be only to the extent of ±2%. Rolling and weight tolerances shall be as per version of IS: 1852 or to any equivalent International Standard.


4.0

5.0 6.0

TEST Steel Section shall be tested in IS approved Laboratory or Standard Laboratory the Bidder country having all facilities available for conducting all the test prescribed in relevant IS or IEC or to any equivalent International Standard or any recognized and reputable International Laboratory or Institutions.

The bidders are required to specifically indicate that;

i) They hold valid IS (or equivalent IEC) License. ii) Steel Section offered are bearing requisite IS certification or equivalent

marks. The bidders are required to submit a copy of the valid IS (or equivalent IEC) License clearly indicating size and range of product against respective ISS or any equivalent International Standards along with their offer. MARKING

It is desirable that the bidder should put his identification marks on the finished material. The mark shall be in “legible English letter” given with marking dies of minimum 18 mm size. INSPECTION AND TEST CERTIFICATES

The material to be supplied will be subject to inspection and approval by the purchaser’s representative before dispatch and/or on arrival at the destination. Inspection before dispatch shall not however, relieve the bidder of his responsibility to supply the Steel Sections strictly in accordance with the specification.

TECHINICAL SPECIFICATIONS LT XLPE AB CABLE

Part-I 1. SCOPE:

This specification covers the design, manufacturing, testing, supply, delivery and performance

requirements of LV overhead ISI marked Aerial Bunched Cable (ABC) of different sizes

indicated in our Schedule of Requirements for use in the LV network of NESCO.

The materials offered shall have been successfully type tested and the design shall have been in

satisfactory operation for a period of not less than two years on the date of bid opening.

Compliance shall be demonstrated by submitting with the bid (i) authenticated copies of the type

test reports and (ii) performance certificates from the users.


However where the bidder offers similar but not identical material but higher size to that which

has been type tested, the difference shall be stated in Test Certificate Schedule. The purchaser

shall adjudge whether to accept or reject the offered material and type test data presented.

The scope of supply includes the provision of type tests. Rates for type tests shall be given in the

appropriate price schedule of the bidding document and shall be considered for evaluation. The

purchaser reserves the right to waive type tests as indicated in the section on Quality Assurance,

Inspection and Testing in this specification.

The Aerial Bunched Cable shall conform in all respects to highest standards of engineering,

design, workmanship, this specification and the latest revisions of relevant standards at the time

of offer and the Purchaser shall have the power to reject any work or material, which, in his

judgment is not in full accordance therewith.

2. STANDARDS:

Except where modified by this specification, the Aerial Bunched Cable shall be designed,

manufactured and tested in accordance with the latest editions of the following standards.

IES/ISO Indian Standard Material

IEC: 1089 IS: 398/1994 Round wire concentric lay

Overhead electrical

Stranded Conductors.

IS: 398(Part-4)/1994 All Aluminum Alloy

Conductors, Quality

ISO: 9000 Management Systems.

IS: 8130/1984 Conductors for insulated

Electric cables.

IS: 10810/1984 Method of Tests for cables.

IEC: 502 IS:7098/1998 XLPE Insulated PVC.

Sheathed power cables.

IS:14255/1995 Aerial Bunched Cables for

working voltage up to and

including 1100 volts.


The Bidder may propose alternative standards, provided it is demonstrated that they give a

degree of quality and performance equivalent to or better than the referenced standards. The

purchaser shall adjudge whether to accept or reject any standards.

The Bidder shall furnish a copy of the alternative standard proposed along with his bid. If the

alternative standard is in a language other than English, an English translation shall be submitted

with the standard.

In case of conflict the order of the precedence shall be (1) IEC or ISO standards, (2) Indian

Standards, (3) Other alternative standards. This list is not to be considered exhaustive and

reference to a particular standard or recommendation in this specification does not relieve the

Contractor or the necessity of providing the goods complying with other relevant standards or

recommendation.

3.0 SERVICE CONDITIONS:

The service conditions shall be as follows:

Maximum altitude above sea level 500m

Maximum ambient air temperature 500C

Maximum daily average ambient air temperature 350C

Maximum ambient air temperature 50C

Maximum temperature attainable by an object exposed to sun 600C

Maximum yearly weighted average ambient temperature 320C

Maximum relative humidity 100%

Average number of thunderstorm days per annum 70

Average number of rainy days per annum 120

Average annual rainfall 150cm

Wind pressure as per IS:5613(Part-I/Sec.I) 1985

Wind Zones IS:5613 Part-I/Sec-I

Light Medium Heavy

Terrain Category 100 Kg/m2 150 Kg/m2 200 Kg/m2

Environmentally, the region where the work will take place includes coastal areas, subject to

high relative humidity, which can give rise to condensation. Onshore winds will frequently be

salt laden. On occasions, the combination of salt and condensation may create pollution

conditions for outdoor insulators.


Therefore, outdoor material shall be designed and protected for use in exposed, heavily polluted

salty corrosive and humid coastal atmosphere.

4. SYSTEM CONDITIONS:

The materials shall be suitable for installation in supply systems of the following characteristics.

Frequency 50Hz

Nominal System Voltage 400/230V

Maximum System Voltage LV System 440/250 V

Minimum LV Voltage 370 V

Power frequency one minute withstand 2KV (set & dry)

Neutral Earthing arrangement LV System Solidly earthed

Part-2: TECHNICAL

5.0 GENERAL/ TECHNICAL

The design of Aerial Bunched Cable offered shall comprise a compacted, standard, hard drawn

H2 / H4 grade aluminum phase conductor as applicable under IS-8130 / 84 with cross linked

polyethylene (XLPE) insulation 0.65 to 1.1. KV class, having of carbon black content 2.5% ±

0.5%.

The sizes and number of cores required are: ( 3x50+1x35+1x16) mm² And (3x95+1x70+1x16) mm² The type of Bunched Cables shall be three phase and street lighting insulated bundled. All

Aluminum Conductors combined with a neutral and catenaries (bare) which shall be of heat

treated aluminum magnesium silicon alloy wires containing approximately 0.5% each of

magnesium and silicon respectively. The catenaries must have an ultimate tensile stress of not

less than that specified in the table of technical requirements.

The Bidder shall specify the standard to which this bundle shall be manufactured.

The conductor bundle offered shall be designed to meet the requirements set out in this

specification taking note of safety factors pertaining to conductor or catenary tensioning and

NESCO specification: General Technical Requirements for LV overhead lines.

However, a bid of Aerial Bunched Cables shall not be considered, unless it is accompanied by a

list of all special tools and equipments necessary to complete the installation.

6.0 CONDUCTORS:


(a) The phase & street light conductors shall be of multi-stranded aluminum of compacted

circular cross section. The aluminum shall comply with IS 8130:1984. The messenger

conductor shall be of multi-stranded Aluminum Alloy conforming to IS 398 (Part 4) – 1994.

In addition to meeting all requirement of relevant ISS the LT XLPE AB Cables supplied

shall satisfy following general requirements.

FOR PHASE AND STREET LIGHT CONDUCTORS

Sl. No.

Specified Cross

Sectional Area

(mm2)

No. of Stran

ds

Minimu m Dia Of

each strand in

mm

Minimum. Over all dia. Of conducting

part of the compacted

conductor. (mm)

Maxm. D.C Registance at 20

degree centigrade.( Ohm

/ Km)

Nominal Insulation thickness

(mm)

1 16 7 1.75 5.25 AS per

ISS/GTP

1.2 2 25 7 2.14 6.42 1.2 3 35 7 2.54 7.6 1.2 4 50 7 3.05 9.15 1.5 5 70 19 2.18 10.9 1.5 6 95 19 2.54 12.7 1.5

FOR MESSANGER CONDUCTORS

Sl. No.

Phase Conductor Size of the

LT AB Cable in

mm2

Specified Cross

Sectional Area of the Messanger Conductor

(mm2)

No. of Strands

Nominal dia Of each

strand

Appx. Over all dia. Of

conducting part of the compacted conductor.

(mm)

Maxm. D.C Resistance of

the messenger at

20 degree centigrade.( Ohm / Km)

Appx. Mass ( Kg / Km.) for

the messanger

1 16 25 7 2.14 5.2 AS PER ISS/GTP

65 2 50 35 7 2.54 7.6 95 3 70 50 7 3.05 9.15 136 4 95 70 7 3.6 10.8 191.8

6.0 (b) The bidder must take required precaution to ensure that the average diameter of each strand of

conductor shall be ascertained through physical measurement of dimensions of finished cables at

ambient temperature during pre-dispatch inspection or / and verification at NESCO Store by

consignee and the value so obtained shall have a tolerance limit with reference to the nominal

diameter of each strand of conductor as stated in the tables above.


7.0 TOLERANCES:

The measurement of strand diameter of the finished AB Cable shall not be less 0.03mm for

strands up to and including 3.00mm diameter. For strands above that size, measurement of strand

diameter shall not be less than 1% of the nominal strand diameter.

For the purpose of checking compliance with the above requirement, the diameter shall be

determined by two measurements at right angles taken at the same cross section. The physical

measurement of strands shall be conducted after opening the strands of a finished AB Cable

offered for inspection.

8.0 SPLICES IN WIRES:

Splices in Wires shall generally comply with requirements of IEC 1089.

The aluminum alloy rods may be spliced by cold pressure but welding before drawing provided

the manufacturer can guarantee that the splice can develop 90% of the tensile strength of the un


sliced rod. Wires which break during stranding may be sliced by cold pressure butt-welding

provided that:

No two splices in the completed conductor occur within 15m of each other and no two splices in

any individual wire are less than 150m apart.

The splice shall be done with high skilled workmanship. The finished splice shall be smooth and

at no point shall the cross sectional area be less than that of the un sliced wire.

Splicing of the alloy wires on the stranding machine in order to utilize lengths of wires on reels

shall not be permitted. 9.0 STRANDING AND CORE LAY:

The conductor cores shall be stranded and the direction of lay must be as defined in IEC: 1089.

10.0 INSULATION:

The Aerial Bunched Cables shall be insulated for a voltage class of 0.65/1.1 KV and shall be

capable of operating permanently at 1.2KV.

The insulation wall thickness shall be determined in accordance with Table-4 (Clause-7.2 and

Clause 7.3) of IS: 14255/1995.

The insulating material shall be black and suitable to resist ultra violet radiation, salt laden

sprays, chemical pollution, ageing effects, abrasion and mechanical shocks and mechanical and

electrical stress at temperature up to 90˚C in normal operation and 2500C under short circuit conditions per IEC: 502/1994.

The carbon black content in the XLPE insulation shall be 2.5% ± 0.5%

11.0 PHASE IDENTIFICATION:

The individual insulated conductors within a bundle shall be identified by means of longitudinal

projections.

The three phase conductors shall be marked by one, two or three longitudinal projections,

indicating the R,Y,B phases.respectively.

The projections shall have the following dimensions.


The distance between the tips of two adjacent projections, where there is more than one,

shall be between 1.0 and 1.5.

The width of the projection at the base shall be 1.0mm; and

The height of the projections shall be 0.5mm. 12.0 INSULATION MARKINGS:

Each individual conductor comprising a bundle shall have the range of non-erasable distinct

markings listed below legibly printed on the insulation surface at one meter intervals. The

embossing should be very clear & easily visible to naked eye.

ISI Mark, IS 14255-95, Manufacturer‟s B.I.S License No. legibly embossed on the insulation.

Name of the Purchaser.

P.O No. & Date

Manufacturer’s trademark identification for example “UCXLPE50”

Year of manufacture: last two digits are sufficient:

Designation of conductor type

Size: for example “3x50”/3x95

Shape of conductor.

Rated voltage class: 0.65/1.1KV

Back up conductor identification: conductors with one, two and three projections shall be

marked R, Y and B respectively. The conductor with no projection shall be marked N and

The height of the printed lettering shall be not less than 20% of the overall diameter of

the conductor

13.0 TWIST:

The direction of lay of the conductors comprising the bundle shall be left-handed and the lay

ration shall comply with IEC: 1089.

With a bare catenaries configuration the insulated phase cables together with the street lighting

cores shall be twisted round the neutral catenaries to form the ABC. This cable bundle is then

strung directly onto the distribution poles supported by the catenaries with standard approved

hardware. 14.0 CABLE DRUM LENGTH:

The cable shall be supplied in 500m or 1000 m Drum Lengths as the case may be for different


sizes of LT XLPE AB Cable.

15.0 TESTS:

15.1 General

Where not specified, all tests and test results shall conform to the requirements of IEC 502/1994

or IS 7098 (Part-I) 1998, IS 10810/1984, IS: 398(Part-IV) and IS: 14255/1955.

Unless expressly stated otherwise, the ambient temperature for routine tests as well as voltage

tests shall be 20 + 150C and for all other tests be 20 + 150C.

The frequency of the alternating test voltage shall be 49 Hz to 51Hz. The voltage wave form

should be sinusoidal.

15.2 Type Tests

The test sample shall be 10m to 15m in length. All cores of the bundles shall be tested.

Insulation resistance at ambient temperature.

Insulation resistance at operating temperature.

AC voltage test.

The insulation resistance test at ambient temperature shall be carried out in a water bath at ambient

temperature.

The insulation resistance test at a operating temperature shall be conducted in a water bath at

900C.

The longitudinal projections used for phase identification shall be ignored. The results of this test shall

be used to calculate the volume receptivity and the results conform to the requirements of IEC:

502/1994 or IS 10810 (Part-43).

The AC voltage test shall be carried out by applying 1.95KV (3U0) for four hours to the sample, which

shall be submerged in a water bath at ambient temperature, having been steeped for a period not

less than one hour. The test shall only be deemed to have been passed if no breakdown occurs.

Furthermore, the following non-electrical type tests shall also be carried out:

Insulation wall thickness: the longitudinal projections used for phase 1 identifications shall


be ignored as per IS 10810 (Part-6);

Ageing test, consisting of an evaluation of the retention of the mechanical properties of the

insulation after ageing.

Wrapping test: as per IS 10810 (Part-3);

Tests for bleeding and blooming of pigment as per IS 10810 (Part-9)

Thermal expansion of insulation.

Measurement of carbon black content as per IS 10810 (Part-32).

Water absorption by the XLPE insulation, shrinking of the XLPE insulation.

Tensile test: adhesion between conductor and insulation.

The adhesion test requires a tensile testing machine. A sample of at least 300mm length shall be

selected and straightened out. The insulation shall be removed for a length of 150mm. The

insulated end shall be held in the upper grip head and the bare conductor on the lower grip head.

Tension shall be applied at a speed of 500mm/ min until the conductor first begins to slide within the

insulation. The test shall have been passed if the conductor and insulation combination can stand

75N/mm2 without slippage occurring.

The neutral conductor/catenaries shall be type tested in accordance with the requirements of IS

398 (Part-IV) 1994. 15.3 Routine Tests

The following measurement or tests shall be carried out on all drums and coils of Bunched cable:

Conductor resistance

Voltage test.

The conductor to be tested for conductor resistance shall be stored for at least 12 hours in a room

at particular constant temperature. If it cannot be established that the conductors have reached

the room temperature, the test should be postponed for a period of further 12 hours.

Alternatively, the test can be carried out on short sample after remaining one hour in a

temperature controlled water bath. The test shall be carried out and the conversion factors used to

convert the resistance value to a base of 2000C and one Km. The DC resistance of each

conductor shall not exceed the appropriate maximum values specified in IEC:228/IS:6474.

The voltage test shall be conducted by applying to each core 3.5KV AC (2.5 U0 plus 2 KV) or

8.4 KV DC for 5 minutes with the specimen lying in a water bath at ambient temperature. The

conductor shall pass the test if no electrical breakdown occurs.


15.4 Acceptance Tests

The following sample check, measurements and test shall be carried out in addition to the

Acceptance Tests as per IS 14255 – 1955, IS : 398 ( Part – IV ) 1994, IS 8130 / 1984

Measurement of insulation wall thickness;

Measurement of diameter of each strand, overall outside dia & Cross Sectional Area of the conducting Part out of the finished product during pre-dispatch inspection.

Thermal expansion test;

Check of physical characteristics Tensile strength of individual wires of conductor.

High Voltage Test on drums immersed in water(apply voltage 3.5 KV AC for 5 min)

These tests should be carried out on one length form each production batch of the same sample.

The thickness of the insulation wall shall be measured on a piece removed from each end of the

sample length. If either means or minimum values are not met, two further samples shall be

removed at 0.5m form the end corresponding to the failed specimen. If these samples do not

satisfy the mean and minimum thickness requirements, the test shall be deemed to have been

failed.

The longitudinal projections used for phase identifications shall be ignored. The thermal expansion test need only be carried out on one core. In relation to the tensile test, the tensile strength of the aluminum wires before stranding and that of the finished conductor shall comply with IEC: 1089.

15.5 Test on the Catenary (messenger) Conductor

Breaking load, elongation and resistance tests shall be completed on the aluminum alloy

catenaries conductor in accordance with the requirements of IS:398 (Part-IV)/1994 or IEC:1089.

15.6 Bending Test on a complete cable

This test shall be performed on a sample of completed cable. The sample shall be bent around a test mandrel at room temperature for at least on turn. It shall then be unwound and the process

shall be repeated after turning the cable sample around its axis by 1800. This process shall be

repeated twice more. There shall be no signs of breaking or cracking of the cable insulation

during this test.

The diameter of the mandrel shall be: 10 (D+d)

Where D = Actual diameter of the cable (mm)

d = Actual diameter of the conductor (mm)


15.7 Rejection and Retests

Should any one of the test pieces first selected fail to pass the tests, two further samples from the

same batch shall be selected for testing, one of which shall be from the length from which the

original test sample was taken unless the length has been withdrawn by the supplier.

Should the test pieces from both of these additional samples satisfy the requirements of the tests,

the batch represented by these samples shall be deemed to comply with the standard. Should the

test pieces from either of the two additional samples fail, the batch represented shall be deemed

to have failed. 16.0 COMPLIANCE WITH SPECIFICATION:

The Aerial Bunched Cable shall comply in all respects with the requirements of this

specification. However, any minor departure from the provisions of the specification shall be

disclosed at the time of bidding in the Non-compliance Schedule of this document. 17.0 COMPLIANCE WITH REGULATIONS:

All the cables shall comply in all respects with the Indian Regulations and Acts in force. The

cables and connections shall be designed and arranged to minimize the risk of fire and any

damage, which might be caused in the event of fire. 18.0 NON-CONFORMING PRODUCT:

The Purchaser reserves the right for decisions regarding acceptance, modification or rejection of

non-conforming items.

19.0 INSPECTION AND TESTING:

The NESCO Utility authorized representative has free entry at all times, while work on the

contract is being performed, to all parts of the manufacturer’s works which concerns the

processing of the cables ordered. The manufacturer shall afford the purchaser or his

authorized representatives without charge, all reasonable facilities to ensure that the cable being

furnished is in accordance with these specifications.

The cables shall successfully pass all the routine tests & acceptance Tests referred to in the

section on tests and those listed in the most recent edition of the standards given in the

specification.


The Purchaser reserves the right to reject any of the cables if the test results do not comply with the

values specified or with the date given in the Technical data schedule.

Type Test Certificates for the tests conducted earlier shall be submitted with the bid for

evaluation. The requirements of additional type tests will be at the discretion of the Purchaser

The Purchaser shall witness routine tests .In order to facilitate this, the contractor shall give the

purchaser of 15days notice that the material is ready for inspection & testing. The supplier shall

extend all assistance to the representative of the Purchaser during his inspection & testing of samples

at his works. The materials shall be dispatched only after approval of such Test Reports and issue of

Dispatch clearance by the Purchaser. However the Purchaser reserves the right to retest the materials

after delivery at any NABL Accredited Testing Laboratory in case of any disputes regarding size

& quality of supplied materials at a later date during guarantee period. The cost of such retesting

shall be borne by the supplier.

All costs in connection with the testing, including any necessary retesting shall be borne by the

Contractor, who shall provide the Purchaser with all the test shall have the right to select the samples

for test and shall also have the right to ensure that the testing apparatus is correct. Measuring

apparatus for routine tests shall be calibrated at the expense of the contractor at an approved

laboratory and shall be approved by the purchaser before testing.

The Contractor shall be responsible for the proper testing of the materials supplied by sub-

Contractor to the same extent as if the materials were completed or supplied by the contractor.

Any cost incurred by the Purchaser in connection with inspection or retesting as a result of failure

of the equipment under test or damaged during transport or off loading shall be to the account of the

Contractor.

The Contractor shall submit to the Purchaser three signed copies of the test Certificates, giving

the results of the tests as required. No materials shall be dispatched until the Purchaser has

received the test certificate and the contractor has been informed that they are acceptable.

The test certificate must show the actual values obtained from the tests, in the units used in this

specification, and most merely confirm that the requirements have been met.

In the case of components for which specific type tests or routine tests are not given in this


specification, the Contractor shall include a list of the tests normally required for these

components. All materials used in the Contract shall withstand and shall be certified to have

satisfactorily passed such tests.

No inspection or lack of inspection or passing by the Purchaser’s representative of equipment or

materials whether supplied by the Contractor or sub- Contractor, shall relieve the contractor from

his liability to complete the contract works in accordance with contract or exonerate him from

any of his guarantees. 20.0 GUARANTEE:

The contractor shall guarantee the following:

Quality and strength of materials used.

Satisfactory operation during the guarantee period of 24 months from the date of commissioning

or 30 months from the date of receipt of the cables at site whichever is earlier.

Performance figures as supplied by the bidder in the technical data sheet. 21.0 PACKING AND SHIPPING:

The cable shall be wound on strong drums or reels capable of withstanding all normal

transportation and handing.

Each length of cable shall be durably sealed before shipment to prevent ingress of moisture. The

drums reels or coils shall be lagged or covered with suitable material to provide physical

protection for the cable during transit or during storage and handling operations.

In the case of steel drums adequate precautions shall be taken to prevent damage being caused by

direct contact between the cable sheath and the steel. These precautions hall be subject to the

approval of the Purchaser


If wooden drums are used then the wood shall be treated to prevent deterioration from attack by

termites and fungi. Each drum or reel shall carry or be marked with following information:

Individual serial number

Standard ISI Mark, 14255-95, Manufacturer‟s B.I.S License No.

Name of the Purchaser : ……………….

Destination

Purchase Order No. & Date

Manufacturer’s name Year

of manufacture

Cable size and type

Length of conductor (meters)

Net and Gross mass of conductor (Kg)

All necessary slinging and stacking instructions

Destination

Country of origin The direction of rolling as indicated by an arrow shall be marked on a flange. 22.0 STORAGE:

The site selected for the storage of cable drums shall be well drained and preferably have a

concrete/ firm surface which will prevent the drums sinking into the ground or being subjected to

excess water thus causing flange rot. All drums shall stand on battens, in the upright position and in such a manner to allow sufficient space

between them for adequate air circulation. During storage the drums shall be rotated 900 every three

months. In no instances shall be the drums be stored “flat” on their flanges or one on top of each other.

23.0 SHIPPING:

The Contractor shall be responsible for the shipping of all cables, drums and reels supplied from

abroad to the ports of entry and for the transport of all goods to various specified destinations

including customs clearance, off loading, warehousing and insurance. The Contractor shall inform himself fully as to all relevant transport facilities and requirements and

loading gauges and ensure that the equipment as packed for transport shall conform to these


limitations. The contractor shall also be responsible for verifying the access facilities specified. The contractor shall be responsible for transportation of all the loads associated with the contract and

shall take all reasonable steps to prevent damage of any highway or bridges by his vehicles by

selecting routes, choosing proper vehicles for use and restricting and distributing loads to avoid the

risk of damage. The Contractor shall immediately report to the Purchaser any claims made against

the contractor arising out of alleged damage to a highway or bridge. All items of equipments shall be securely clamped against movement to ensure safe transit from

the manufacturer’s facilities to the specified destinations. 24.0 HAZARDOUS SUBSTANCES:

The Contractor shall submit safety data sheets for all hazardous substance used with the

equipment. The contractor shall give an assurance that there are no other substances classified as

hazardous in the equipment supplied. He shall also take responsibility for the disposal of such

hazardous substances that may be found for any injuries resulting from those substances. 25.0 SUBMITTALS:

The following shall be required in duplicate along with the bid:

Completed technical data sheets;

Descriptive literature giving full technical details of equipment offered.

Outline dimension drawing for each type of conductor, for each bundle showing the conductor

strand, composition and the bundle twist;

Type test certificates, where available, and sample routine test reports;

Detailed reference list of customers already using equipment offered during the last five years

with particular emphasis on units of similar design and rating;

Performance reports from the customers for the supplied LT XLPE AB Cables.

Details of manufacturer’s quality assurance standards and programme and ISO 9000

series or equivalent national certificates;

Deviations from this specification to be submitted as per Non-Compliance.Only deviations

approved in writing before award of contract shall be accepted;

List of recommended spare parts for five years of operation with prices and spare parts

catalogue with price list for future requirements.

Any other documents to establish qualifying & credibility requirements as specified in


this Tender Document. 26.0 PERMANENT EMBOSSING:

All materials supplied under this tender shall bear distinct mark of “NESCO Utility”, and Purchase

Order No. & Date, length marking in meter “by way of embossing /enamel painting etc. including

other information mentioned in GTP. This should be clearly visible to naked eye.

GUARANTEED TECHNICAL PARTICULARS FOR 3X50+1X35 +1X16 MM² LT XLPE AB CABLE.

Sl No

Description Specified Bidder’s Offer

1 Ref. ISS / IEC followed IS 14255/95, IS 398 Part IV

2

Phase Conductor material / Insulation type H2 / H4 E.C grade aluminium as per IS 8130/84 / XLPE insulation ( IS 14255/95)

3 Material of Neutral Catenary Aluminum alloy as per IS 398 Pt -IV

4 Voltage Class 0.65/1.1 KV No. of Strands of Phase Conductor 7

5 No. of strands/ Average /Minimum Strand Dia. In mm. (Finished Phase conductor.)

7/3.05

6 Approximate Overall Dia. Of compacted phase conductor after removal of insulation.(in mm.)

9.15

7 No. of Strands / Average Strand Dia. In mm. ( Neutral Catenary.)

7/2.54

8 Minimum Overall Dia. Of compacted Bare

Neutral Caternary .(in mm.)

7.62

9

No. of Strands / Average strand dia. / Nomunal cross sectional area of conducting part In No / mm2. ( St. Light Conductor)

7/1.75/16mm²

10 Minimum average thickness of insulation of phase Cond. (mm)

1.5

11 Minimum thickness of insulation of Phase Cond. At any point (mm )

1.25

12 Minimum thickness of insulation at any point in street light conductor (mm)

0.98

13 Maximum DC resistance of Phase conductor at

20 o C ohmn/ KM

0.64

14 Maximum DC resistance of street light conductor Ω / Km

1.91

15 Maximum DC resistance of neutral cond. Ω / Km 0.986 16 Ultimate tensile strength of neutral conductor

(KN) 14

17 Maximum temperature (Continuous) 90°C for phase and 75 °C forneutral


18

Embossing on insulation at each one meter interval

Distinct Non-erasable ISI Mark, IS 14255-95, Manufacturer‟s B.I.S License No., Name of the Purchaser, Name of the manufacturer, Size of cable, voltage Grade along with sequential marking of length..

19 Cable drum length 500 / 1000m 20 Volume Resistivity of insulation at 27°C 1X1013Ώ - cm min.

21 Volume Resistivity of insulation at 70°C 1X1011Ώ - cm min.


GUARANTEED TECHNICAL PARTICULARS FOR 3X95+1X70 +1X16 MM² LT XLPE AB CABLE.

Sl No

Description Specified Bidder’s Offer

1 Ref. ISS / IEC followed IS 14255/95, IS 398 Part IV

2

Phase Conductor material / Insulation type H2 / H4 E.C grade aluminium as per IS 8130/84 / XLPE insulation ( IS 14255/95)

3 Material of Neutral Catenary Aluminum alloy as per IS 398 Pt - IV

4 Voltage Class 0.65/1.1 KV No. of Strands of Phase Conductor 19

5 No. of strands/ Average /Minimum Strand Dia. In mm. (Finished Phase conductor.)

19/2.54

6 Approximate Overall Dia. Of compacted phase conductor after removal of insulation.(in mm.)

12.7

7 No. of Strands / Average Strand Dia. In mm. ( Neutral Catenary.)

7/3.6

8 Minimum Overall Dia. Of compacted Bare

Neutral Caternary .(in mm.)

10.8

8i) Mass of Bare neutral (messanger) Kg/Km (Approx.)

191.8

9

No. of Strands / Average strand dia. / Nomunal cross sectional area of conducting part In No / mm2. ( St. Light Conductor)

7/1.75/16mm²

10 Minimum average thickness of insulation of phase Cond. (mm)

1.5

11 Minimum thickness of insulation of Phase Cond. At any point (mm )

1.25

12 Minimum thickness of insulation at any point in street light conductor (mm)

0.98

13 Maximum DC resistance of Phase conductor at

20 o C ohmn/ KM

As per ISS

14 Maximum DC resistance of street light conductor Ω / Km

As per ISS


15 Maximum DC resistance of neutral cond. Ω / Km As per ISS 16 Ultimate tensile strength of neutral conductor

(KN) 14

17 Maximum temperature (Continuous) 90°C for phase and 75 °C forneutral

18

Embossing on insulation at each one meter interval

Distinct Non-erasable ISI Mark, IS 14255-95, Manufacturer‟s B.I.S License No., Name of the Purchaser, Name of the manufacturer, Size ofcable, voltage Grade along with sequential marking of length..

19 Cable drum length 500 / 1000m 20 Volume Resistivity of insulation at 27°C 1X1013Ώ - cm min.

21 Volume Resistivity of insulation at 70°C 1X1011Ώ - cm min.


Suspension Clamp Dead End Clamp Pole Clamp with Eye Hook

1.0 Scope

This specification covers the design, manufacture, assembly, testing and supply of Suspension Clamp, Dead end Clamp & Eye hook for making connections to Aerial Bunched Cables rated 1100 volts and insulated with cross-linked polyethylene.

2.0 Standard

The design, performance and test requirements shall confirm to this specification and the following

standards. However in case of any conflict, the requirements of this specification shall prevail.

1) REC Specification 32/1984

2) REC Specification 84/2010 (dead end & Suspension clamp) The devices shall also be compatible with the cables of sizes & dimensions as defined in the cable Specifications for the cables with which they are intended to be used.

3.0 Type Test For all accessories, the Type Test Report should be submitted from an Independent NABL Accredited Laboratory like CPRI The Test report shall include the Model Number, Applicable size Range, and GA Drawing showing the principal parts and dimensions of the connector.

4.0 Acceptance Test


The Acceptance Tests & sampling plan to be conducted as per REC Spec. 83/ 2010 and as per relevant IS Specifications.

4.4 Drawings & Samples:

GA drawing and other particulars along with samples are to be submitted along with offer.

ANCHOR (DEAD END) & SUSPENSION CLAMPS 5.0 Scope

This specification covers the design, manufacture, assembly, testing and supply of Accessories for

anchoring & suspending Aerial Bunched Cables rated 1100 volts and insulated with cross-linked

polyethylene and aluminum alloy bare messenger.

Description Application

a)

Dead end Clamp ( as per REC Construction standard E-35)

For fitting onto a pole for anchoring the end of a length of ABC, or for a major change in direction.

b)

Suspension Clamp (Bolted Type as per REC Construction standard E-34)

For supporting a length of ABC at an intermediate pole in a length, with small angle of deviation.

5.1 Cable Data

The standard sizes and characteristics of the phase and street lighting conductors, messenger wires shall

be as specified in REC specification 32/1984 or IS: 14255-1995.

The strength of the messenger shall be not less than the Value shown in Table 1.

Table-1

Conductor Size (mm2.)

Messenger Rating (as per IS 14255)

35 9.8 KN

70 17.5 KN 5.2. Marking / Embossing

Anchoring Clamp, Suspension clamp should bear

- Manufacturers trade mark and logo

- Name of Purchaser, P.O. No. & Date. - Product Code or Reference

- Traceability Code/Batch Number


5.3. Type Test For Dead End & Suspension clamps, the Type Test Report s should be submitted from an Independent NABL Accredited Laboratory / CPRI as per REC Spec-84/2010.


The Acceptance Tests & sampling plan to be conducted as per REC Spec. 84/ 2010. & as per relevant

IS Specifications.. 5.5 Drawings & Samples:


6.0 EYE HOOKS

a) Eye hooks shall be as per REC construction standard E-35 (Type – A) b) It should be made of forged hot dip galvanized steel as per IS-1570 c) The clamp corrosion resistance should conform to standards IS 2629 & IS 2633. d) Minimum breaking Load should be 20 KN.

6.1 Type Test For Eye hooks, the Type Test Report s should be submitted from an Independent NABL Accredited Laboratory / CPRI as REC Spec-32/1984 & 84/2010 and as per relevant IS Specifications.


The Acceptance Tests & sampling plan to be conducted as per REC Spec. 32/ 1984. & 84/2010 and as

per relevant IS Specifications. 6.2 Drawings & Samples:


GUARANTEED TECHNICAL PARTICULARS FOR SUSPENSION CLAMP FOR BARE MESSENGER WIRE

Sl. No.

Description

Guaranteed particulars to be submitted by

the Vendors along with offer

1

Name and address of the manufacturer

2

Applicable standard

3

Type of clamp

4

Type of design

5

Voltage Grade(kV)


6

Loop anchor attachment(open/close)

7

Installation (with/without dis-assembly)

8 Type & grade (metallic/non-metallic material)

9 Type of hot dip galvanizing & thickness of Zinc coating

10

Marking

11

Colour of non-metallic parts

12

Dimensions

13

Approximate weight

14

Minimum Breaking Load (KN)

15

Maximum allowable load(KN)

16 Max. angle of deviation of conductor (degrees)

17

18

Method of casting

Are GA drawing & samples enclosed


GUARANTEED TECHNICAL PARTICULARS FOR DEAD END CLAMP FOR BARE MESSENGER WIRE (To be submitted along with offer)

Sl..

Description

Guaranteed particulars to be submitted by the Vendors

1

Name and address of the manufacturer

2

Applicable standard

3

Type of clamp

4

Type of design

5

Voltage Grade(kV)

6

Loop anchor attachment(open/close)

7

Installation (with/without dis-assembly)

8 Type & grade (metallic/non-metallic material)

9 Type of hot dip galvanizing & thickness of Zinc coating

10

Marking

11

Colour of non-metallic parts


12

Dimensions

13

Approximate weight

14

Ultimate tensile strength(KN)

15

Maximum allowable load(KN)

16

Slip Strength (KN)

17

18

Method of casting Operating temperature (deg.cent) a) Continuous Operation b) Short circuit condition

Are GA drawing & samples enclosed


Guaranteed Technical Particulars of Eye Hook

Sl. No.

Description

Guaranteed Technical Particulars submitted by

Vendors

1

Name and Address of the Manufacturer

2 Type of Hooks

3 Maximum weight span for 4x95's Maximum weight span for 4x50's

4 Horizontal pull out load

5 Types of Facades for which it is suitable

6 Stand off from Facade

7 Method of fixing to Façade

8 Installation(with/without disassembly)

9 Type and grade of Metallic Material

10 Type of Hot Dip Galvanizing Thickness of Zinc Coating

11 Markings:- As specified in IEC - 947

12 Dimensions

13 Net Weight 14 Ultimate tensile strength


15 Acceptance tests


Barbed Wire TECHNICAL SPECIFICATION FOR G.I. BARBED WIRE STANDARDS: Unless otherwise specified elsewhere in this specification, the rating as well as performance and testing of the G.I.Barbed wire shall conform to the latest revisions available at the time of placement of order of all the relevant standards but not limited to as listed below. IS:280:1978 Mild steel wire for general engineering purposes (third revision) IS:1340:1977 Code of practice for chromate conversion coating of zinc and cadmium coated articles and zinc base alloys (first revision) IS:1521:1972 Method for tensile testing of steel wire (first revision) IS:1755:1983 Method for wrapping test for metallic wire (first revision) IS:2633:1986 Method for testing uniformity of coating of zinc coated articles(second revision) IS:4826:1979 Hot dipped galvanized coating on round steel wires (first revision) IS:12753:1989 Electro galvanized coatings on round steel wire – Specification 3. GENERAL TECHNICAL REQUIREMENTS: GI Barbed wire shall be 2 PLY with a 2.5mm diameter. The barbs shall have a 2mm diameter and be 12.5mm in length. The barbs shall have four points and shall be formed by twisting two point wires, each two turns, tightly around both line wires making altogether four complete turns. G.I. Barbed wire shall be of type IOWA with size and dimensions as under:- Line wire - 2.5 mm Point wire - 2.0 mm Distance between two bars shall be 75 mm ( + 12 mm ). SPECIFIC TECHNICAL PARTICULARS FOR 2.5 MM X 2.0 MM G.I.BARBED WIRE

Sl.No. Particulars Particulars Specified Bidders Offer 1 Size of wire- mm Line wire- 2.5 mm + 0.08 mm

Point wire- 2.0 mm + 0.08 mm

2 Type of Barbed Wire Iowa Type 3 Tensile strength of line

wire 390 to 590 N/mm²

4 Minimum breaking load 3.7 KN


of completed Barbed wire 5 Mass of complete

Barbed wire (minimum) 115 gms / Mtr.

6 Distance between two Barbs

(75 + 12 ) mm

7 No. of lays between the Barbs ( minimum )

4

8 Method of Galvanising Hot dipped according to IS:4826 /1979 with medium coating.

9 Mass of coating (minimum) Line wire- 110 gms/Mtr² Point wire- 105 gms/Mtr² ( testing after barbing )

10 No. of dips the wire is able to withstand without copper coating

( testing after barbing )

A) For Line Wire 2 dip in Min B) For Point Wire 2 dip in Min


SUB-STATION FENCING WITH BARBED WIRE: For Sub-Station fencing with Barbed wire refer attached Drawing MATERIALS HANDLING AND INSURANCE The contractor shall deliver all equipment/materials against this contract to his site stores under cover of Transit Insurance to be taken in his name. Cost of such insurance is to be borne by the contractor. Cost of transportation of all materials from contractor‟s store to the site of work as well as department supply items like Conductors, AB cables, Power cables, etc shall be borne by the contractor irrespective of mode of transportation and site condition.The contractor has to bear the cost of premiums on insurance for all materials, tower accessories and total erection cost of the line including cement, rods for foundation. It will be the responsibility of the contractor to report to the concerned Police Station about all incidents of thefts and lodge, pursue and settle all claims with Insurance Company in case of damage/loss due to theft, pilferage, flood and fire etc. and the employer of the work shall be kept informed promptly in writing about all such incidents. The loss, if any, on this account shall be recoverable from the contractor if the claims are not lodged and properly pursued in time or if the claims are not settled by the insurance company due to lapses on the part of the contractor. The contractor shall have to replenish promptly damaged, stolen tower members and accessories conductors, earth wire, hardware‟s etc. and repair/re-erect the damaged lines, free of cost to the employer so as to maintain the programme of work. The employer will not be responsible in any way for such loss of materials.


TECHNICAL SPECIFICATION ALL ALUMINIUM ALLOY CONDUCTOR (AAAC)

1. SCOPE

This specification covers design, Engineering, Manufacture, Testing, Inspection before dispatch, forwarding, packing, transportation to sites, Insurance (both during transit & storage ), storage, erection, supervision testing & commissioning of all sizes of All Aluminum Alloy Conductors of the aluminum – magnesium- silicon type for use in the distribution overhead power lines of NESCO of Odisha.

The equipment offered shall have been successfully type testes and the design shall have been satisfactory operation for a period not less than two years on the date of bid opening. Compliance shall be demonstrated by submitting with the bid, (i) authenticated copies of the type test reports and (ii) performance certificates from the users.

The scope of supply includes the provision of type test, Rates of type tests shall be given in the appropriate price schedule of the bidding document and will be considered for evaluation. The Purchaser reserves the right to waive type tests as indicated in the section on Quality Assurance, Inspection and Testing in the specification. The Aluminum Alloy Conductor shall conform in all respects to highest standards of engineering, design, workmanship, this specification and the latest revisions of relevant standards at the time of offer and the Purchaser shall have the power to reject any work or materials, which, in his judgment, is not in full accordance therewith. STANDARDS Except where modified by the specification, the Aluminum Alloy Conductor shall be designed, manufactured and tested in accordance with latest editions of the following standards.

IEC/ISO/ Other International

Standard

IS Subject

IEC :1089 Round wire concentric lay overhead electrical standard conductors

IS 398

Aluminum Alloy Stranded Conductors

IS 9997 Aluminum Alloy redraw rods for electrical purposes

IEC 502 : 1994 Extruded solid dielectric insulated power cables for rated voltages 1.0 KV up to 30 KV

IEC 104 Aluminum Magnesium Silicon alloy wire for overhead

IS 1778

line conductors Reels and drums of bare conductor.

BS : 6485-1971

PVC covered conductors for overhead power lines.


This list is not to be considered exhaustive and reference to a particular standard or recommendation in this specification does not relieve the contractor of the necessity of providing the goods complying with other relevant standards or recommendations.

3. GENERAL

The wires shall be of heat treated aluminum, magnesium silicon alloy containing approximately silcon-0.5 to 0.9 %. magnesium-0.6 % to 0.9%,Fe-0.5% (maximum) , Copper- 0.1% (max ), mn- 0.03% , Cr-0.03%, Zn-0.1%, B-0.06%, and having the mechanical and electrical properties specified in the table and be smooth and free from all imperfections, such as, spills, splits and scratches.

Neutral grease shall be applied between the layers of wires. The drop point temperature of the grease shall not be less than 1200 C.

3.1 Mechanical and Electrical Characteristics of Aluminium Alloy Wires used in the

Construction of Stranded Aluminium Alloy Conductors

Nominal Diameter

Minimum Diameter

Max. Diameter

Cross

Sectional Area

Mass

Minimum Breaking Load

Maximum Resistance at

200C Before stranding

After stranding

1 2 3 4 5 6 7 8 mm mm mm mm2 Kg/km KN KN ohms/ km

3.15 3.12 3.18 7.793 21.04 2.37 2.29 4.290 3.81 3.77 3.85 11.40 30.78 3.52 3.34 2.938 4.26 4.22 4.30 14.25 38.48 4.40 4.18 2.345

Maximum resistance values given in column 8 have been calculated from the maximum values of the resistively as specified and the cross sectional area based on the minimum diameter. The minimum breaking load is calculated on nominal diameter at ultimate tensile strength of 0.309 KN / mm2 for wire before stranding and 95% of the ultimate tensile strength after stranding. 4. PHYSICAL CONSTANTS FOR ALUMINIUM ALLOY WIRES

4.1 Resistively:

For the purpose of this specification, the standard value of resistively of aluminum alloy wire which shall be used for calculation is to be taken as 0.0325 ohm mm2 /m at 200 C. the maximum value of resistively of any single wire shall not , however, exceed 0.0328 ohm. mm2/m at 200 C.


4.2 Density : At a temperature of 200 C, the density of aluminum alloy wire is to be taken as 2700 kg/m3. 4.3 Temperature Coefficient of Linear Expansion : The temperature coefficient of linear expansion of aluminium alloy wire is to be taken as 23 x 10 –6

0 C 4.4 Constant – Mass Temperature Coefficient At a Temperature of 200 C, the constant – mass temperature coefficient of resistance of aluminum alloy wires, measured between two potential points rigidly fixed to the wire, is taken as 0.00360/0 C

5. STANDARD SIZES

5.1 Nominal Sizes of Wires

The aluminum alloy wires for standard constructions covered by this specification shall have the diameters as specified in the table and a tolerance of ±1% shall be permitted on the nominal diameter.

5.2 Standard Conductors

The sizes, resistance and masses (excluding the mass of grease ) of stranded aluminum alloy conductors shall be as given in table.

5.3 Mechanical and Electrical Characteristics of Aluminum Alloy Stranded

Conductors

Sl. No.

Actual Area

Stranding and Wire

Dia

Approx. Overall Dia

Approx. Mass

Calculated Maximum Resistance at 200 C

Approx Calculated Breaking

Load 1 2 3 4 5 6 7

mm2 mm mm kg/km ohms/km KN 1 55 7/3.15 9.45 149.20 0.621 16.044 2 100 7/4.26 12.78 272.86 0.339 29.344

5.3.1 Increase in Length due to Stranding

When straightened out, each wire in any particular layer of a stranded conductor, except the central wire, is longer than the stranded conductor by an amount depending on the lay ratio of that layer.


5.3.2 Resistance and Mass of Conductor

The resistance of any length of stranded conductor is the resistance of the same length of any one wire multiplied by a constant as set out in the table below.

The mass of each wire in any particular layer of the stranded conductor, except the central wire, will be greater than that of an equal length of straight wire by an amount depending on the lay ratio of that layer. The total mass of any length of an aluminum stranded conductor is, therefore, obtained by multiplying the mass of an equal length of straight wire by an appropriate constant as mentioned below. In calculating the stranding constants as mentioned in the table below, the mean lay ratio, that is the arithmetic mean of the relevant minimum and maximum values in table for lay ratio has been assumed for each layer.

5.3.3 Calculated Breaking Load of Conductor

For a conductor containing not more than 37 wires, 95% of the sum of strength of the

individual wires calculated from the values of the minimum breaking load given in this specification.

For a conductor containing more than 37 wires, 90% of the sum of the strengths of

the individual wire calculated from the values of the minimum breaking load given in this specification.

5.3.4 Calculated Area and Maximum Resistance of Conductor

The actual area of a stranded conductor has been taken as the sum of the cross- sectional areas of the individual wires of nominal diameter. Maximum resistance values of stranded conductor have been calculated on the basis of maximum resistivity and the cross-sectional area based on the minimum diameter of wires.

5.3.5 Stranding Constants

Number of Wires in Conductor

Stranding Constants

Mass Electrical Resistance (1) (2) (3) 7 7.091 0.1447 19 19.34 0.05357

6. JOINTS IN WIRES

6.1 Conductor containing seven wires

There shall be no joint in any wire of a stranded conductor containing seven wires, except those made in the base rod or wire before final drawing.


In stranded conductors containing more than seven wires, joints in individual wires are permitted in any layer except the outermost layer ( in addit ion to those made in the base rod or wire before final drawing ) but no two such joints shall be less than 15 m apart in the complete stranded conductor. Such joints shall be made by cold pressure butt welding. They are not required to fulfill the mechanical requirements for unjointed wires.

6.2 Conductors containing more than seven wires

In stranded conductors containing more than seven wires, joints in individual wires are permitted in any layer except the outermost layer ( in addit ion to those made in the base rod or wire before final drawing ) but no two such joints shall be less than 15 m apart in the complete stranded conductor. Such joints shall be made by cold pressure butt welding. They are not required to fulfill the mechanical requirements for unjointed wires.

7. STRANDING The wire used in the construction of a stranded conductor shall, before and after stranding, satisfy all the relevant requirements of this standard.

The lay ratio of the different layers shall be within the limits given in the table for lay ratio. In all constructions, the successive layers shall have opposite directions of lay, the outermost layer being righ-handed. The wires in each layer shall be evenly and closely stranded.


8. LENGTHS AND VARIATIONS IN LENGTHS :

Unless otherwise agreed between the Employer and the Contractor, stranded aluminum alloy conductors shall be supplied in the manufacturer’s usual production lengths to be indicated in the bid Schedule. The Employer reserves the right to specify particular lengths of conductor such that certain drum lengths will be shorter than others. There will in both cases be a permitted variation of –0 + 5% in the length of any one conductor length.

9. TESTS

9.1 Type Tests

The following tests shall be carried out as per relevant ISS once on samples of completed line conductor during each production run of up to 500 kms of the conductor from each manufacturing facility.

9.1.1 Ultimate Tensile Strength Test

This test is intended to confirm not only the breaking strength of the finished conductor but also that the conductor has been uniformly stranded.

A conductor sample of minimum 5 m length fitted with compression dead end clamps at either end shall be mounted in a suitable tensile test machine. Circles perpendicular to the axis of the conductor shall be marked at two places on its surface. Tension on the conductor sample shall be increased at a steady rate upto 50% of the minimum UTS specified and held for one minute. The circles drawn shall not be distorted due to relative movement of the individual strands. Thereafter the load shall be increased at a steady rate to the specified minimum UTS and held at that load for one minute. The conductor sample shall not fail during this period. The applied load shall then be increased until the failing load is reached and the value recorded.

9.1.2 D.C Resistance Test

On a conductor sample of minimum 5 m length two contact clamps shall be fitted with a pre-determined bolt torque. The resistance between the clamps shall be measured using a Kelvin double bridge by initially placing the clamps at zero separation and subsequently one meter apart. The test shall be repeated at least five times and the average value recorded. The value obtained shall be corrected to the value at 200 C, which shall conform to the requirements of this specification.

9.2 Routine Tests

Measurement of Physical Dimensions: The samples should meet the desired dimensional requirements before conducting following Routine Tests as per relevant ISS.

9.2.1 Selection of Test Samples

Samples for the tests specified in this specification shall be taken by the manufacturer before stranding, from not less than 10% of the individual lengths of aluminium alloy wire included in any one final heat-treatment batch and which


Alternatively, if desired by NESCO at the time of placing an order, that the tests be made in the presence of his representative, samples of wire shall be taken from length of stranded conductor.

Samples shall then be obtained by cutting 1.2 meters from the outer end of t he finished conductor from not more than 10% of the finished reels or drums.

Tests for electrical and mechanical properties of aluminum alloy wire shall ordinarily be made before stranding since wires unlaid from conductors may have different physical properties from those of the wire prior to stranding because of the deformation brought about by stranding and by straightening for test.

Spools offered for inspection shall be divided into equal lots, the number of lots being equal to the number of samples to be selected, a fraction of a lot being counted as s complete lot. One sample spool shall be selected at random from each lot.

The following test shall be carried out once on samples of completed line conductor during each production run of up to 500 kms of the conductor from each manufacturing facility.

9.2.2 Breaking Load Test

The breaking load of one specimen, cut from each of the samples taken shall be determined by means of a suitable tensile testing machine. The load shall be applied gradually and the rate of separation of the jaws of the testing machine shall be not less than 25 mm / min and not greater than 100mm /min.

9.2.3 Elongation Test

The elongation of one specimen cut from each of the samples taken shall be determined as follows:

The specimen shall be straightened by hand and an original gauge length of 200 mm shall be marked on the wire. A tensile load shall be applied as described above and the elongation shall be measured after the fractured ends have been fitted together. If the fracture occurs outside the gauge marks, or within 25 mm of either mark, and the required elongation is not obtained, the test shall be disregarded and another test should be made.

When tested before and after stranding, the elongation shall not be less than 4% on a gauge length of 200 mm.


9.2.4 D.C Resistance Test

The electrical resistance test of one specimen cut from each of the samples taken shall be measured at ambient temperature. The measured resistance shall be corrected to the value at 200 C by means of the formula :

1

R20 = RT --------------------------- 1 + (T-20)

where ,

R20 = resistance corrected at 200 C RT = resistance measured T0C

= constant – mass temperature coefficient of resistance, 0.0036, and T = ambient temperature during measurement.

The resistance corrected at 200 C shall not be more than the maximum values specified.

9.2.5 Chemical Analysis of Aluminum Alloy

Samples taken from the alloy coils / strands shall be chemically / spectrographically analyzed. The results shall conform to the requirements stated in this specification. The contractor shall make available material analyses, control documents and certificates from each batch as and when required by the Purchaser.

Test should be conducted at the independent test house by the purchaser in the case of absence Of facility at manufacturer. However the cost of such testing shall be borne by the manufacturer.


9.2.6 Dimensional and Lay Length Check

The individual strands of the conductors shall be dimensionally checked and the lay lengths checked to ensure that they conform to the requirements of this specification.

Ten percent drums from each lot shall be rewound in the presence of the Purchaser or his representative to allow visual checking of the conductor for joints, scratches or other surface imperfections and to ensure that the conductor generally conforms to the requirements this specification. The length of conductor wound on the drum shall be re-measured by means of an approved counter / meter during the rewinding process.

9.2.7 Visual and dimensional Checks on the Conductor Drums.

The drums shall be visually and dimensionally checked to ensure that they conform to the requirements of this specification and of IS 1778: Specification for reels and drums of bare conductors. For wooden drums, a suitable barrel batten strength test procedure is required. The Bidder shall state in his bid the tests to be carried out on the drums and shall include those tests in the Quality Assurance Programme.

9.2.8 Acceptance Tests :

All tests required to confirm enclosed Guaranteed Technical Particulars (GTP) requirements of this specification needs to be conducted as Acceptance Tests.

9 . 3 Test Reports.

a) Copies of type test reports shall be furnished in at least six copies along with one original. One copy will be returned duly certified by the Owner only after which the commercial production of the material shall start.

b) Record of routine test reports shall be maintained by the Supplier at his works for periodic

inspection by the Owner’s representative.

c) Test certificate of tests during manufacture shall be maintained by the Contractor. These shall be produced for verification as and when desired by the Owner.

10. Packing.

a) The conductor shall be supplied in returnable, strong, wooden drums provided with lagging of adequate strength, constructed to protect the conductor against any damage and displacement during transit, storage and subsequent handling and stringing operations in the


field. The Contractor shall be responsible for any loss or damage during transportation handling and storage due to improper packing. The drums shall generally conform to IS: 1778-1980, except as otherwise specified hereinafter.

b) The drums shall be suitable for wheel mounting and for letting off the conductor under a minimum controlled tension of the order of 5 KN.

c) The Contractor should submit their proposed drum drawings along with the bid. d) The Contractor may offer more than one length of the conductor in a single drum. e) All wooden components shall be manufactured out of seasoned soft wood free from defects that

may materially weaken the component parts of the drums. Preservative treatment shall be applied to the entire drum with preservatives of a quality, which is not harmful to the conductor.

f) The flanges shall be of two ply construction with a total thickness of 64 mm with each ply at right angles to the adjacent ply and nailed together. The nails shall be driven from the inside face flange, punched and then clenched on the outer face. Flange boards shall not be less than the nominal thickness by more than 2mm. There shall not be less than 2 nails per board in each circle. Where a slot is cut in the flange to receive the inner end of the conductor the entrance shall be in line with the periphery of the barrel.

g) The wooden battens used for making the barrel of the conductor shall be of segmental type. These shall be nailed to the barrel supports with at least two nails. The batten shall be closely butted and shall provide a round barrel with smooth external surface. The edges of the battens shall be rounded or chamfered to avoid damage to the conductor.

h) Barrel studs shall be used for the construction of drums. The flanges shall be holed and the barrel supports slotted to receive them. The barrel studs shall be treaded over a length on either end, sufficient to accommodate washers, spindle plates and nuts for fixing flanges at the required spacing.

i) Normally, the nuts on the studs shall stand protruded of the flanges. All the nails used on the inner surface of the flanges and the drum barrel shall be counter sunk. The ends of barrel shall generally be flushed with the top of the nuts.

j) The inner cheek of the flanges and drum barrel surface shall be painted with bitumen based paint.

k) Before reeling, card board or double corrugated or thick bituminous water proof bamboo paper shall be secured to the drum barrel and inside of flanges of the drum by means of a suitable commercial adhesive material. The paper should be dried before use. After reeling the conductor, the exposed surface of the outer layer of conductor shall be wrapped with water proof thick bituminous bamboo paper to preserve the conductor from dirt, grit and damage during transport and handling.

l) A minimum space of 75 mm for conductor shall be provided between the inner surface of the external protective lagging and outer layer of the conductor. Outside the protective lagging, there shall be minimum of two binders consisting of hoop iron/galvanized steel wire. Each protective lagging shall have tow recesses to accommodate the binders.

m) Each batten shall be securely nailed across grains as far as possible to the flange, edges with at least 2 nails per end. The length of the nails shall not be less than twice the thickness of the battens. The nails shall not protrude above the general surface and shall not have exposes sharp, edges or allow the battens to be released due to corrosion.

n) The nuts on the barrel studs shall be tack welded on the one side in order to fully secure them. On the second end, a spring washer shall be used.

o) A steel collar shall be sued to secure all barrel studs. This collar shall be located between the washers and the steal drum and secured to the central steel plate by welding.

p) Outside the protective lagging, there shall be minimum of two binders consisting of hoop iron/ galvanized steel wire. Each protective lagging shall have two recesses to accommodate the binders.

q) The conductor ends shall be property sealed and secured with the help of U-nail on the side of one of the flanges to avoid loosening of the conductor layers during transit and handling.

r) As an alternative to wooden drum Contractor may also supply the conductors in non- returnable


painted steel drums. After preparation of steel surface according to IS: 9954, synthetic enamel paint shall be applied after application of one coat of primer. Wooden/Steel drum will be treated at par for evaluation purpose and accordingly the Contractor should quote in the package.

11.0 Marking.

Each drum shall have the following information stenciled on it in indelible ink along with other essential data:

(a) Contract/Award letter number

(b) Name and address of consignee.

(c) Manufacture’s name and address.

(d) Drum and lot number

(e) Size and type of conductor

(f) Length of conductor in meters

(g) Arrow marking for unwinding

(h) Position of the conductor ends

(i) Number of turns in the outer most layer.

(j) Gross weight of the drum after putting lagging.

(k) Average weight of the drum without lagging.

(l) Net weight of the conductor in the drum

(m) Month and year of manufacture of conductor

The above should be indicated in the packing list also.

12.0 Verification Conductor Length The Owner reserves the right to verify the length of conductor after unreeling at least five (5) percent of the drums in a lot offered for inspection. For the balance drums, length verification shall be done by the owner based on report/certification from Manufacturer/ Contractor.

13. REJECTION AND RETESTS

13.1 Type Tests

Should the conductor fail any of the type tests specified above, the Purchaser will not accept any conductor manufactured from the material, nor conductor made by the manufacturing methods used for the conductor which failed the test.


The manufacturer shall propose suitable modifications to his materials and techniques in order that he can produce conductor which will satisfactorily pass the type test requirements.

13.2 Routine Tests

Should any one of the test pieces first selected fail the requirements of the tests, two further samples from the same batch shall be selected for testings, one of which shall be from the length from which the original test sample was taken unless that length has been withdrawn by the manufacturer.

Should the test pieces from both these additional samples satisfy the requirements of the tests, the batch represented by these samples shall be deemed to comply with the standard. Should the test pieces from either of the two additional samples fail, the batch represented shall be deemed not to comply with the standard.

If checks on individual strand diameters, conductor lay lengths and conductor surface condition indicate non-compliance with the requirements of the specification, the particular drum will be rejected. Inspection will then be carried out on two further drums within the same batch. If the conductor on either of the drums is non-complaint, the complete batch will be rejected.


GURANTEED TECHNICAL PARTICULARS

FOR ALL ALUMINIUM ALLOY CONDUCTOR

Sl.

No. Particulars Specified Requirement Details furnished by the

bidder

1. Nominal Aluminium Alloy area of conductor in Sq.mm : 100

2. No. of stands : 7

3.

Wire dia. in mm

a) Nominal : 4.26

b) Minimum : 4.22

c) Maximum : 4.3

4. Approximate Over all diameter of conductor in mm : 12.78

5.

Cross sectional area in Sq.mm

i) Individual wire : 14.25

ii) Standard Conductor : 99.81

6.

Minimum breaking load in KN


ii) Standard Conductor (U.T.S) : 29.26

7.

Approximate mass in Kg. Per KM of Aluminium Alloy conductor



8. Calculated maximum DC resistance at 200C in Ohm/Km



13. Modulus of Elasticity of Aluminium Alloy conductor Kg/Sq.mm :

16.

Co-efficient of linear expansion per degree centigrade for

a) Individual /0C

:

:

23X106


b) Standard conductor/0C

17. Standard length (Mtr.)

: 2000 +5%

18. Lay ratio for 7 wire conductor : Min Max

10 14

19. Direction of Lay : Right hand

20. Standard according to which the conductor will be manufactured and tested

: IS : 398 (Part-4) – 1994

21. Size of the drum in mm (as per IS-1778/80 with Amendment I /1989 : To be offered by the

Bidder

22. Length of conductor in each drum in Km : To be offered by the

Bidder


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