section-iv33 kv pole top bracket gi 100x50mm 33 kv pin insulator (porcelain) 33 kv g.i. pin 90 kn...

Tech. Specification NIT No. NESCO Utility/ 33KV Line / 29/ 07.02.19

SECTION-IV

TECHNICAL SPECIFICATION OF MATERIALS

FOR CONSTRUCTION OF NEW 33KV LINE FROM BARUAN PSS TO

BRAHMABARADA PSS.

TENDER N O T I C E NO:- NESCO Utility / 33KV Line / 29 /18-19/ 3315 Dtd.07.02.19


TECHNICAL SPECIFICATION FOR CONSTRUCTION OF 33KV LINE

1.0 NATURE OF WORK

The work covered by this Specification for construction of new 33KV line tapping from Baruan PSS to Brahmabarada new 33/11 KV Sub-station , Electrical Inspection , testing ,commissioning and handing over. To heightening & maintain specific line clearance from the highest water level in the river crossing at one location , the 4 pole structure with 15 mtr. joist at either side of the river will be constructed under this scope.

1.1 SCOPE OF WORK

1) 3Ph3W 33KV line with 100mm2 AAAC with 13mtr Rs joist =13 Km. (Average span length 70 mtr.)

2) 4-Pole Structure with 13mtr Joist =9 nos. (only River crossing with 15mtr Joist)

3) 4-Pole Structure with 15mtr Joist =2 nos. (only River crossing )

4) DP Structure with 13mtr RS Joist= 15 nos.

5) Guarding for road crossing at one locations = 60mtr

6) 33KV Line 630A Isolator with earth switch = 1set

7) 33KV Line 400A AB switch (Horizontal) = 1set

1.4 Item Description : The electrical installation work to be carried 33KV line on “turnkey‟ basis with supply of materials . Details item description in which the following materials shall be included .

Sl no. Item Particulars Include the supply materials


1 Construction of 33KV Line with supply & erection of all materials.

(Using 13mtr long 150x150 mm RS joist pole with all accessories having average span length 70 mtr.)

13 mtr long, 150x150 mm RS Joist – 185 nos. 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

33 KV Pin Insulator (Porcelain)

33 KV G.I. Pin 90 KN B&S Disc Insulator (Porcelain) 33KV B&S hard ware fittings 20 mm GI stay sets -56 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 6/8 SWG GI wire Danger Board Anti climbing device made of Barbed wire with clamping arrangement (2Kg per support). Guarding with 6/8 SWG GI wire 16 mm GI Nuts & Bolts with washer Coil Earthing Padding & Mass concreting of line poles & stay set

Red oxide primer , Aluminium paint & Black paint

2 Construction of DP structure with supply & erection of all materials .

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

13 mtr. long 150x150 mm RS joist 20mm GI stay sets- 60 Sets ( with stay clamp, 7/8SWG stay wire, stay insulator)

100x50x6 mm MS Chanel

75x40x5 mm MS chanel

50x50x6 MS angle GI Flat 50x6 mm & 25x3 mm 40mm dia 3mtr. long GI earthing device & earthing materials Danger Board Anti climbing device made of Barbed wire with clamping arrangement (2Kg per support). 16 mm GI Nuts & Bolts with washer , PG Clamp Coil Earthing Padding& Mass concreting of line poles & stay set Red oxide primer , Aluminium paint & Black paint Sundries


2 Construction of 4- pole structure with AB switch with supply & erection of all materials .

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

13 mtr. long 150x150 mm RS joist -36 nos. 13 mtr. long 150x150 mm RS joist- 8 nos. 400 Amp 3Pole AB Switch (Horizontal) 630 Amp 3Pole Isolator with Earth switch 20mm GI stay sets- 44 sets ( with stay clamp, 7/8SWG stay wire, stay insulator)

100x50x6 mm MS Chanel

75x40x5 mm MS chanel

33KV Lightning Arrestor(30KV,10KA)- 12 nos.

50x50x6 MS angle GI Flat 50x6 mm & 25x3 mm 40mm dia 3mtr. long GI earthing device & earthing materials Danger Board Anti climbing device made of Barbed wire with clamping arrangement (2Kg per support). 16 mm GI Nuts & Bolts with washer , PG clamp Coil Earthing Padding & Mass concreting of line poles & stay set Red oxide primer , Aluminium paint & Black paint Sundries

N.B : 1. Any other materials required to complete the work which cover in the contract to be provided by the

executing agency. 2. All MS materials such as V cross ms, Clamps , Pole top bracket,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.

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

Stay wire , GI Pin , Isolator, AB Switch 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 any 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.

2.0 Methodology:- The complete procedures for the execution of the project are explained herewith should be carried out by the executing agency; i. Detailed survey of Lines ,substation followed by single line diagrams of different location enclosed and any

modification or alternation required to complete the work , if require then the agency should prepare diagram with BOQ and get it approved from NESCO Utility before execution within the estimated cost .

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 . v. Packing and transportation of materials from the manufacturer’s works 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. Construction of HT line with crossing over river Brahmani.

xi. RS Joist poles are to be used for construction of new HT lines .

xii. Concreting of all poles & stays.

xiii. Testing, Commissioning of lines / installations. xiv. Getting the lines inspected by Electrical Inspector after completion of work including deposit of required

inspection fees without claim to NESCO Utility. xv. All expenditure towards inspection of materials at manufacturers site and inspection of work after completion

shall be borne by the executive agency. xvi. Dismantling of existing electrical network i f any and return of these dismantled items at the NESCO

Utility’s stores including transportation cost. 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) Construction of 33KV Line : 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.

2.0.6 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 In case of 33 KV R S Jo is t a re to 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 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.

6.0 RS Joist (150x150 mm 15 Mtr. & 13 Mtr.)

TECHNICAL SPECIFICATION OF R.S Joist Pole

6.1 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 & 15mtr. 34.6kg/mtr MT

6.2 Standards:

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

specified otherwise.

6.3 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

6.4 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;


6.5 Dimensions and Properties

RSJ DESIGNATION 150 x 150 mm ISHB

Length of Joist in Mtr with +100mm/-

0% Tolerance

15 Mtr,13mtr

Weight kg/m with±2.5% Tolerance 34.6

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

6.6 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

6.7 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 -

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

in the IS shall prevail.

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

6.10.150x150mm 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.

6.11. 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.

6.12. 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) Dimensions and Properties :

PARTICULARS Specification Specification By the

Bidder

Length of Joist in Mtr with +100mm/-0% Tolerance 13mtr & 15mtr Weight kg/m with±2.5% Tolerance 34.6 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

460.00

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


“V” CROSS ARM, BACK CLAMP FOR “V”CROSS ARM & POLE TOP BRACKET (F CLAMP)

TECHNICAL SPECIFICATIONS

The prospective bidder may source the above items from manufacturers /suppliers full filling the technical specification. a) 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. b)The Pole Top Bracket (F Clamp) shall be made out of 100x50x5 mm MS Channel for 33 KV 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. 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 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.)



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


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

Sl. No.

Description Unit Unit Bidder‟s offer

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


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 .

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. 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.


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 OF 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.

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


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. B & S Hardware Fittings (A) Ball & Socket type Hardware fittings(Conversional/ Performed )90 KN for B & S type Strain Insulators The hardware fittings 4 -b o l ted (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. 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 33 KV H/W FITTINGS ( B&S )

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 4500 Kg (min.)

4. Dimensions in accordance with

IS: 2486(Part-II)

5 Material used and reference to Standard:

i) Cross arm Strap(35x6 mm) 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 (4-bolted) U bolt with with double nut M12 – 4 pairs

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.

Bidder’s Signature with Seal

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

Bidder’s Signature with Seal


GUARANTEED TECHNICAL PARTICULARS FOR 33 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

14 Conforming standard As per IS

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



GURANTEED TECHNICAL PARTICULARS OF 33 KV HT 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 bidder

1 Anchor Plate

8 mm thick +2.5%-5%

300x300mm+1% GS Plate 8 mm thick

2 Anchor Rod

20 mm dia +5%- 3%

Length 1800mm + 0.5%

GS Round 18mm dia

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

GS Round 18mm dia

3. Turn Buckle Bow

20 mm dia +5%-3%

995mm+1% GS Round 18mm dia.

Length200mm +1%

GS Channel 100x50x4.7mm

4. Eye Bolt Rod

20 mm dia +5%-3%

Length 450mm + 1%

GS Round 18 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.

Name & Signature of Agency with seal


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



TECHNICAL SPECIFICATION OF 33 KV 3 POLE, 400 AMP , HORIZONTAL TYPE AB SWITCH

1.0 SCOPE:- This specification covers manufacturing testing and supply of 3 Pole, 400 AMP, 50 Hz, Single break, 33 KV class Air Break switches for outdoor installations to be used at 33/11 KV Sub-stations and for incoming & outgoing Lines suitable for operation under off load conditions.

1.1 DESCRIPTION OF THE MATERIALS:-The A.B. Switch sets shall confirm to the following

parameters:-

Sl. No.

Description Parameters of AB Switch

Parameters of AB 33 KV

i) No. of poles 3

ii) Number of Post insulator per pole 4 nos. 22/24 KV class

iii) Nominal system voltage (KV) 33 iv) Highest System Voltage (KV) 36

v) Rated frequency 50HZ

vI) System earthing Effectively earthed.

vII) Rated nominal current Amp.

viii) Altitude of installation Not exceeding 1000 M

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

Sl.

No.

Description

Parameters P.I. of AB Switches for

33 KV

i) Power frequency withstand voltage

95

ii) Power frequency withstand voltage (wet) KV (RMS)

75

iii)

iii

Impulse withstand voltage (dry) KV

170 KV (peak)

170 iv) Power frequency puncture

1.3 times the actual dry flashover voltage of the unit

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

i) IS-9920 (Part-I to V.)


ii) IS-2544/1973 ( for porcelain post insulators

iii) IS-2633 (for galvanization of ferrous parts.) or its latest amendments if any.

1.3 INSULATORS:-

22 KV / 24 KV class Post Insulators complete with pedestal 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.

The bidder shall mention make, type of insulation materials, metal fittings, Creep age distance, protected Creep age distance, tensile strength, compression strength, torsion strength and cantilever strength.

1.4 CLIMATIC CONDITIONS:-

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

1.

Conditions

Maximum ambient air temperature.

45 0 C

2. Maximum daily average air temperature 35 0 C 3. Maximum yearly average ambient air temperature 30 0 C 4. Maximum temperature attainable by a body exposed to the

sun. 50 0 C

5. Minimum ambient air temperature

0 0 C

6. Maximum relative humidity. 100%

7. Minimum number of rainy days per annum 70

8. Average number of rainy days per annum 120

9. Average annual rain fall. 150 cm.

10. Number of months of tropical monsoon conditions 4

11. Maximum wind pressure. 260 Kg./ mm2

12. Degree of exposure to atmospheric pollution. Normally polluted atmosphere.

1.5 TECHNICAL DETAILS:-

1.5.1 The 33 KV A.B. Switch Set shall be gang operated (with double tandem pipe) single air break outdoor

type horizontal mounting having 4 nos. 22/24 KV post insulator 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 straining that might adversely affect any of its


parts. The required base M.S. Channel, phase coupling rod, operating rod with intermediate guide

braided with flexible electrolytic copper, tail piece of required current carrying capacity and

operating mechanism with ‗ON‘ & ‗OFF‘ positions shall be provided. The operating rod shall be

medium gauge of 32mm diameter nominal bore G.I. pipe single piece 6 meters. The phase coupling

rod for gang operation shall medium gauge 25mm dia nominal bore G.I. Pipe. Rotating post insulators

shall be provided with suitable bearing mounted on a base channel with 6 mm thick 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

through stainless steel bolts with double nuts. The post insulators should be fixed with the base

channel using Galvanized Nuts and Bolts.

All the bearings shall be provided with grease nipple. All ferrous parts shall be galvanized and polished. The pipes shall be galvanized in accordance with IS-4736/1968.

1.5.2 Mounting: - The A.B. Switches shall be suitable for horizontal mounting in all type of sub-station

structures.

1.5.3 Switching Blades: - It shall be made out of electrolytic copper with silver plated. The approximate

size shall be 250mm x 50 x 8mm. 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.

1.5.4 Fixed Contacts:- The fixed jaw type female contracts (50x8x95 )mm shall be made of electrolytic

copper ( minimum 95 % copper composition) duly electroplated controlled by Phosphor 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 moving contract blade without the same being transmitted to the post insulator. The

arrangement made in this regard shall be specifically shown in the drawing.

1.5.5 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 10 mm dia G.I. Rod with spring assisted operation.

1.5.6 Terminal Connectors:- Terminal connectors shall be robust in design. The size of fixed connector

shall be ( 80 x 50 x8 mm) and size of movable connector shall be of ( 80 x50) x ( 80 x 50) x 8 mm

of copper casting with uniform machine finishing duly silver plated made out of minimum 95 %

copper composition with 2 nos. 12 mm dia holes provided with suitable brass bolts and double nuts,

flat washers & 2 nos. bimetallic solderless sockets suitable up to ACSR Panther or AAAC 232 mm2

conductor.


1.5.7 Spacing:- The minimum clearance between phase to the switch shall be 1200 mm. The operating

down rod shall be at a transverse distance of 300 mm from the outer limb of the switch. The centre

spacing between two post insulators of the same phase shall be 560 mm. In the open position of the

A.B. Switches the moving blade shall rotate through anangle of 90 0 . This shall be exhibited in the

drawing.

1.5.8 Drawing & Literatures:- Drawings of 33 KV 400 amp, 3 Pole, single break A.B. Switch shall be

furnished along with the tender.

The details of construction and materials of different parts of the A.B. Switches shall clearly be

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

the tender.

1.6 TESTS & TEST CERTIFICATE

1.6.1 Type Test:- Certificates for the following type tests conducted within five years proceeding to

the date of opening of tender on prototype set of A.B Switch in a Govt. Approved Testing

Laboratory preferably at CPRI, Bhopal/ Bangalore shall have to be submitted for reference and

scrutiny.

i. Impulse voltage dry test

ii. Power frequency voltage dry test

iii. Power frequency voltage wet test

iv. Temperature of resistance.

v. Measurement of resistance.

vi. Test to prove the capability of carrying the rated peak short circuit current and the rated short time current.

vii. Mainly active load breaking capacity test. viii. Transformer off-load breaking test.

ix. Line charging breaking capacity test.

x. Operation tests.

xi. Mechanical endurance test.

xii. Mechanical strength test for the post insulator as per IS-2544/1973.

xiii. Test for galvanization of metal (ferrous) parts as perm IS-2633/1973.

Besides, mechanical endurance test will have to be conduct on one set in the presence of our authorized person who shall be deputed to carryout acceptance tests before delivery of the materials.

1.6.2 Routine Tests: - The following routine tests shall have to be conducted on each sets and results are to be furnished for consideration of deputing inspecting officer for inspection and conducting testing of the


materials.

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.

1.7 GUARANTEED TECHNICAL PARTICULARS:-

The Bidder shall furnish the guaranteed technical particulars duly filled in the format at

Appendix-I along with the tender.

1.8 COMPLETENESS OF EQUIPMENT:-

Any fittings, accessories for apparatus which may not have been specifically mentioned in this

specification but which are usual or necessary in equipment of similar plant 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.

1.9 INSPECTION:-Routine and acceptance tests shall be conducted at the place of manufacturer. The bidder

are requested to furnish details of equipment which will be used for testing along with tender. The bidder of

those 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 guaranteed certificate for

approval prior to offer of materials for inspection for each consignment of offer.


GUARANTEED TECHNICAL PARTICULARS FOR 33KV, 400A, 50 HZ, 3 POLE, SINGLE BREAK TYPE AB SWITCH

Sl. No

Particulars

Desired values Bidder‘s

offer

1 2 3 4

1. Maker‘s name and country

of origin

To be specified by the tenderer

2. Type of Switch Rotating type only

3. Suitable for mounting Horizontal only

4. Number of supporting post insulators per phase

4 nos.22 KV / 24 KV Post Insulators per phase as per ISS-2544/1973.

5. No. of Breakers per phase Single Break

6. Post Insulator. a) Maker‘s name and country

of origin

Techno Ceramics / Allied Ceramic/JSI/Equivalent type test certificate to be provided along with bid.

b) Type of cementing To be quoted for original cemented only & as per IS-2544-1973 & relevant IEC.

c) One minute power frequency withstand voltage Dry

95 KV RMS.

d) One minute power frequency withstand voltage Wet

75 KV RMS.

e) Visible discharge voltage 27 KV RMS.

f) Dry Flashover Voltage To be specified by the tenderer

g) Power frequency puncture with stand voltage

1.3 times of actual dry flash over voltage

h) Impulse withstand voltage

(switch in position)

170 KV (peak)

i) Creepage distance (mm) 450 mm minimum. (actual creepage distance for which type test have been conducted is to be specified by the tenderer

7.

Impulse withstand voltage for positive and negative polarity 1.2 / 50 mircro- second wave.

a) Across the isolating distance 195 KV (peak)


b) To earth & between poles 170 KV (peak)

8. One minute power frequency withstand voltage.

a) Across the isolating distance 80 KV (RMS)

b) To earth & between poles 70 KV (RMS)

9.a) Rated normal current and rated frequency

400 amps. 50 Hz

b) Rated short time current. 16 KA ( RMS )

10. Rated short circuit making capacity

25 KA (RMS)

11. Rated peak withstand current 40 KA ( Peak )

12. Rated cable charging breaking capacity

40 KA ( RMS )

13. Rated Transformer off load breaking capacity

16 Amp (RMS)

14. Rated line charging breaking capacity

5.3 Amps ( RMS)

15. Minimum clearance between adjacent phases

a) Switch Closed ( centre to centre) 1200 mm

b) Switch Opened ( centre to edge of blade)

640 mm

16. Temperature rise

Temperature rise shall not exceed the maximum limit as specified below at an ambient temperature not exceeding in 40 0 C

b) Copper contacts in air 65 0 C

c)

Terminal of switch intended to be connected to external conductor by bolts

50 0 C

17. Vertical Clearance from top of insulator cap to mounting channel

508 mm (minimum)


18.

Type of Contact: -

a) Self aligned, high pressure jaw type fixed contacts of electrolytic copper of size 50 mm x 8 mmx95 mm duly silver plated. Each contact should be revetted with three nos. Copper rivets with a bunch (minimum 3 mm thick) consisting of copper foils, each may vary from 0.15 mm to 0.25 mm. These total thickness of copper foils per jaw should be 6 mm. Jaw assemblies are to be bolted through stainless steel bolts and nuts with stainless steel flat and spring washer.

b) Solid rectangular blade type moving contact of electrolytic copper size 250 mm x

50 mm x 8 mm duly silver plated ensuring a minimum deposit of 10 micron of silver on copper contacts or as may be prescribed under relevant ISS / IEC.

c) Pressure spring to be used in jaw contacts shall be Stainless Steel having 8 nos of turn x 28 mm height x 14.4 mm diameter with 14 SWG wire (minimum six nos springs shall be used)

19.

Connectors:-

Terminal connectors for both movable and fixed should be of copper flats of same size similar to that of moving contact blades (minimum 95% copper composition). The fixed connector shall of size 80 mm x 50 x 8 mm and the size of movable connector shall be size 80 x 50 x 8 mm with machine finishing duly silver plated with 2 nos. of 3/8‖ stainless steel bolts, nuts, plain washers & spring washers should be provided along with 2 nos solder less bimetallic sockets for each connector suitable sockets for each connector suitable up to 232 mm² AAA conductor.

20.

Moving Contacts supports:-

Movable contact is to be supported by galvanized angle of 50 x 50 x 5 mm in each phase and the moving contact are to be bolted through 2 no stainless steel bolts and nuts with suitable stainless steel flat and spring washers.


21. Galvanization a) Iron parts shall be dip galvanized as per

IS-2633/1972.

b) b) The pipe shall be galvanized as per IS-

4736/1968.

22.

Details of Phase

a)

Coupling Rod 25 mm nominal bore G.I. pipe medium gauge.

b)

Operating Rod

32 mm nominal bore G.I. pipe medium gauge single length 6 mtrs. The detailed dimension of the G. I. pipe as per IS-1239 (Pt. I) as mentioned below :-

Nominal base (mm)

Outside

diameter

Diameter thickness (mm)

Max Min

25 34.2 33.3 3.25

32 42.9 42 3.25

c) Arcing Horns 10 mm dia G.I. rod with spring assisted operation.

d) Force of Fixed contact spring To be specified by the tenderer.

e)

Copper braided flexible tapes:-

450 mm long 2 nos. of flexible electrolytic copper tape or braided chord (with tin coated) having minimum weight 450 gms per meter and both ends shall be crimped with copper sockets through brass bolts and nuts with brass flat washers. Two nos of suitable copper sockets shall be used at both ends. The minimum no. of flexible wires should be 1536 of 36 SWG for each flexible chord.

f) Quick break device Lever mechanism.

g)

Bearings

4 nos. self lubricated bearing to be provided with grease nipple including 4th bearing being a thrust bearing.

h) Locking arrangement Pad Lock & Key arrangement at both ‗ON‘

& ‗OFF‘ position.

i) Earth Terminal: To be provided at base channels.


23. Supporting Channels 100 x 50x5 mm M.S. Channel hot dip galvanized.

24. Weight of each pole complete

To be specified by the tender

25. Detailed drawing To be submitted by the bidder

NB- Every AB Switch should bear the marking of manufacturer’s name ,Purchaser’s name , P.O. No., Sl. No. etc.



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)

Particulars

Bidder’s Offer 1. Location of Factory or Place of Manufacture

2. Maker’s Name, Address & Country

3. Size of

a Pipe (40 mm N.B. ISI marked)

b Earthing Strips (50x6 mm)

4. Length (3 Mtr. Long)

5. Thickness of Pipe (3.2 mm , Medium Gauge)

6. Galvanization Process ( Hot dip )

7. Galvanization thickness

a For Earthing device( 610 gm/mm²)

b For Connecting Flat( 610 gm/mm²)

8. Galavanization tests to be conducted as per ISS : 2633/72 &2629/85

9. Any other Particulars ( like details of Clamp/ G.I. Bolts M12 with spring washer)

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.


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.

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 of completed Barbed wire

3.7 KN

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



TECHNICAL SPECIFICATION OF 33 KV AIR BREAK ISOLATOR 1.0 SCOPE 1.01 This specification covers design, manufacture, testing and supply of. Manually operated outdoor type 33

KV, 3-phase,630 Amp, triple pole, double break, gang operated, centre rotating type Isolator with gang operated Earth switches, including Insulators and complete in all respects with arcing horns , bimetallic connectors, operating mechanism, indicating devices, fixing details etc. Upright mounting type Isolators.

1.02 The isolator shall be of the manual operated type with earthing switches and shall complete with all

parts and accessories including insulator operating rods, mounting attachments, necessary for their efficient operation.

1.03 It is not intent to specify completely herein, all details of the design and construction of equipments, however the equipment shall confirm in all respect to high standards of

engineering mentioned in clause No. 4.0 design and workmanship and shall capable of performing in continuous commercial operation up to the suppliers guarantee in a manner acceptable to the purchaser, who will interpret the meanings of drawing and specification and shall have the powers to reject any work or material which, in his judgment, is not in accordance therewith. The equipment offered shall be complete with all components necessary for its effective and trouble free operation along with associated equipments, interlock, protection schemes, etc. Such components shall be deemed to be within the scope of bidder's supply irrespective of whether those are specifically brought out in this specification or not. All similar parts particularly removable ones shall be interchangeable.

2.00 LOCATION: The isolators are required to be installed at proposed 5 nos. locations of 33/11 KV Sub-stations for

construction of 33KV Bay . 3.00 SERVICE CONDITIONS: 3.01 The 33 kV triple pole air break isolators are intended to be used to isola t e the 33 KV Line ins ide

p rima ry S tructure . 3.02 ATMOSPHERIC CONDITIONS: Please refer to meteorological data furnished elsewhere in this document. 4.00 GOVERNING SPECIFICATION: 4.01 The isolator shall unless otherwise specified, generally conform the IS : 9921 (Part I to IV) - 1985, which shall be applied in the manner altered, amended or supplemented by this specification, the

latest Indian Electricity Rules wherever applicable. 4.02 Any deviation from this specification offered to improvement performance, utility and efficiency of equipment proposed by the bidder will be given due consideration, provided full particular with

justification thereof are furnished. 4.03 In the preparation of this specification, details have been taken from IEC 600 - 129

"alternating current disconnects (Isolators) and earthing switches", and IS 9921 (Part-I to IV) "Specification for alternating current disconnects (isolators) and earthing switches for voltages above 1000V ”.

4.04 Equipment meeting with the stipulations of equivalent IEC, ANSI, CSA, DIN standards which ensure equal or better quality than the standards listed in Clause No. 4.05, shall also be acceptable. In


such case the bidder should submit along with this offer, two copies of such In case of dispute, the stipulations in English translation, submitted by the bidder shall prevail. Further, in

the event of conflict between the stipulations of the standard adopted be the bidder, corresponding Indian Standard specification shall prevail.

4.05 In this specification reference has been made to the following Indian standard and other specification:

Standards

Sl. Standards Particulars

1 IS : 9921-85 Part-I, II, III & IV)

Specification for alternating current Disconnects (isolators) and earthing switches for voltages above 1000V

2 IS: 2544-1973 & IS : 5250-1970

Porcelain post insulators for systems with nominal voltage greater than 1000V

3 IS : 7608 Phosphor bronze wires (for general engineering purposes)

4 IS : 2108-1977 Black hard malleable iron castings 5 IS : 1570 Part - IQ- 1979 Carbon steel (unalloyed steels) 6 IS : 2071 (Part-I & ll)-

1974

General definitions, test requirements & test proedures

7 IEC: 600129

Alternating current disconnects (isolators) and earthing switch

8 IS : 7906 (Part-Ill)-1975 Helical compression springs 9 IS: 5561 – 1970 Electric power connectors 10 IS: 5358-1969 Galvanizing of ferrous parts 11 IS : 2633

Method of testing conformity of coating of zinc

coated article 5.00 RATING AND OTHER PARTICULARS 5.01 The isolators shall be designed for the following rating and other particulars:

Ratings & Other particulars

Sl. Particulars

33KV

1 Type

Manually operated Double break, upright mounting with the movement of the blade

in a horizontal plane suitable for outdoor installation.


2 No. of poles (Phases) Three

3 Rated Voltage 36 KV

4 Rated normal current 630A

5 Rated frequency 50Hz

6 System neutral earthing Effectively earthed

7 Rated short time withstand current of main switch

25KA rms for 3 sec.

8 Rated peak withstand current 2.5 times the rated short time withstand current

9 Rated 1.2/50 micro second impulse withstand voltage (peak)

a) to earth 170 KV

b) across isolating distance 195 KV

10 Temperature rise Max. Temp deg.C

a) Copper contacts in air

i Silver faced Copper 105

ii Bare copper 75

b) Terminal of isolator to be connected to external conductors by bolts

i Silver faced copper 105

ii Bare copper 90

c) Metal parts acting as springs

The temperature shall not exceed a value, where the elasticity of the materials is impaired. For

pure copper the temp. limit is 75deg. C

11 Safe duration of over load

a) 150 % of rated current 5 minutes

b) 120% of rated current 30 minutes

12 Minimum creep age distance

840


(mm)

13 Rated mechanical terminal load

a) Straight load (Kgf) 35

b) Across load (Kgf) 13.26

14 Phase to Phase spacing for installation(mm)

1500

15 Height of center line of terminal pad above ground level (mm)

4000

5.02 : The isolator are required to be closed or interrupt the 33 kV line / UG cable line charging current. Hence isolators should be capable of closing or interrupting a current of magnitude indicated in 5.01

(iv) above. 5.03 : CLEARANCE: . 5.03.1 The clearance between live parts and ground structure shall not be less than those specified in the IS – 10118, part – III, 1982. The length of break in full open position should be such that there

is absolutely, no possibility of arc over from the live parts to the de-energized parts on which any maintenance work have to be done. The speed of opening or closing the switch shall be designed to ensure that the arcing during the operation is reduced to the minimum.

6.00 GENERAL TECHNICAL REQUIREMENTS

6.01 TYPE OF ISOLATORS :

The ISOLATORS shall be of three phase gang operated horizontal, double break type with turn and twist type moving blades. 6.02 CURRENT DENSITY:

Current density, to be adopted, for all parts of isolator and terminal connector & shall not exceed the following limits. a) Hollow tube sections – Copper- 2.0 A / Sq. mm - Aluminium -1.25 A/Sq. mm b) Other sections and terminal connectors - Copper - 1. 6 A/Sq. mm - Aluminium- 1.0 A/Sq. mm

6.03 Designs & Drawings:

The full particulars of design, manufacture, template and quality control devices developed for manufacture of the equipments - offered in respect of the following items shall be furnished with drawings and

descriptions.


Sl. No. Particulars

1 Contacts , Material etc.

2 Design of contact pressure

3 Contacts support and fixing arrangement on insulators

4 Turn and twist mechanism, clamps, locks, etc.

5 Bearings, housing of bearing, bushes, etc.

6 Balancing of heights.

7 Coupling pipes, joints, connection adjustments.

8 Base plates.

9 Down pipe, guides joints.

10 Brass bushes and bearings at various joints

11 Operating mechanism, type of gear, size and thickness of box, degree of protection.

Gland Plate , gland ,etc.

12 Nuts, bolts and fasteners

6.04 TYPE AND CONSTRUCTION: The design of the isolators shall be such that the switch can be changed to right or left hand control without

excessive labour and with a minimum change of parts. The live parts shall be of non-rusting, non-corroding metal. Current carrying parts shall be nonferrous. Bolts, screws and pins shall be provided with lock washers, keys or other equipment locking facilities. Current carrying parts shall be made of copper alloy or equivalent material. The switch shall not require lubrication of any part, at frequent intervals.

The isolator shall be suitable for mounting in upright position (with the blades moving in horizontal plane) on steel / fabricated steel structures. The heights at which the isolators will be dimensions, will be intimated to successful bidder. Necessary lengths of operating rod as required shall be supplied..

6.05: OPERATING MECHANISM FOR MANUALLY OPERATED ISOLATOR: a) Manual operating mechanism, gang operated through crank & reduction gear shall be provided for main switch. b) The design of the operating mechanism shall be Such that minimum energy is required for


operation and one person shall be able to operate the switch without undue effort. The blades shall be in positive continuous control throughout tile entire cycle of operation. Suitable reduction gear to achieve above aspects may be provided, for main switch and shall close or open with about 20 revolutions of the crank.

c) The operating pipes and rods shall be sufficiently rigid to maintain positive control without tension or compression & there shall also be capable of withstanding all torsional and bending stresses

due to operation of the disconnecting switch. It shall not be possible, after final adjustment has been made for any part of the mechanism to be displaced at any point in the travel sufficiently to allow improper functioning of the switch, when the switch is opened or closed at any speed. All holes, ill crank, linkages, etc., having moving pins, shall be drilled to accurate fit, so as to maintain the minimum amount of slack and lost motion. The operating mechanism and its controls shall be so designed that under no circumstances the switch blades travel is interrupted before it reaches the fully close or open position. The operating mechanism shall be suitable to hold the main switch or earth switch in closed or opened position to prevent operation by gravity, wind, short circuit, seismic acceleration, vibration, shock, accidental touching etc.

6.06. CONTROL CABINET: The operating mechanism mid all accessories shall be enclosed in a weather, dust and vermin proof

cabinet. The control cabinet of each operating mechanism shall be made out of 12 SWG (2.64 mm thick) steel sheet. or 10mm thick aluminum in the form plate or casting. Control cabinet shall be provided with hinged doors along with padlocking arrangement. Sloping rain hood shall be provided to cover all sides. 15 mm thick neoprene or better type gasket shall be provided to ensure degree of protection atleast IP 55 as per S : 2147.

The motor operating mechanism / manually operating mechanism shall be mounted on the base supporting structures or on a separate Support- structure at a height of 300 mm from the ground level. Operating or lever for manual operation shall be at a convenient height of 1000 mm above ground level for easy operation. The unsupported length of the operating rod shall not. exceed 3 meters. Guide bearings shall be provided at suitable intervals. All brackets angles or other members mid accessories necessary for fixing the operating mechanism to switch supporting structure. and the bearing for operating rods shall be supplied. Rust proof pins and bearings of the bronze bushing, ball or roller type shall be provided. All ball and roller bearings shall be protected from weather by means of covers and grease retainers. Bearing pressures shall be kept low to ensure long life.

6.06 GEAR: The disconnect may be required to operate occasionally with considerably long idle intervals. Special care shall be taken for selection of material for gear and lubrication of gears to meet lubricated for

life with graphite or better quality non-draining or non-hardening grease. complete details of components, materials, self-lubricating arrangement, grade of lubricant, details of jigs, fixtures and devices used for quality check shall be furnished in the bid.

CONSTRUCTIONAL FEATURES: 6.07.01FIXED AND MOVING CONTACTS: a) The isolator shall have heavy-duty self-aligning high pressure - contacts of modem design. The contact shall be made of high grade, high conductivity, and heat resisting material. The main contacts shall

be made of hard drawn electrolytic copper and the surface shall be silver plated. Arcing contacts


wherever provided shall close first and open last. b) The isolators blades / arms shall be made preferably from tubular section of hard drawn electrolytic copper having suitable diameter and shell thickness, and the contact surface shall be heavily

silver plated. c) The surface of the contacts shall be liberally designed to withstand safely the-highest short circuit current of the system as specified in the clause 05.01 (vii) - (viii) of part - I. d) The male and female contact assembly and blades shall ensure i. Electro dynamic withstand ability during short circuit without any risk of repulsion of contacts. ii. Thermal with stand ability during short circuits. iii. Constant contact pressure even when the live parts of the insulators stacks are subjected to tensile stresses

the insulators stacks are subjected to tensile stresses due to linear expansion of connected bus - bars, flexible conductors either because of temperature variation or strong winds.

iv. Self - wiping action during closing and opening (preferably twisting type contacts). The surface shall be

wiped during closing and opening operation to remove any film, oxide coating, etc. wiping action shall not cause scouring or abrasion of surfaces.

v. Self - wiping ensuring smooth closing of the switch. The temperature rise of the contacts and other current

carrying parts shall not be more than 45 °C over an ambient air temperature of 45°C, while carrying the rated current continuously. The temperature rise due to passage of rated short-circuit current for a period of 3 seconds shall not cause an), annealing or welding of contacts.

e) Fixed guides shall be provided so that proper seating of contacts will be obtained by closing even when a

blade is out of alignment by 2.5 min or less. f) All movable pars which may be in the current path shall be shunted by flexible copper conductors to prevent

breaking due to repeated bending. g) Fabrication shall be made with suitable jig to avoid deviation during production. Details of size and shape

of contact, springs, back plate, fixing arrangements, design of contact pressure, life of contacts, limit of temperature rise etc., shall be furnished along with the tender.

6.08.MOUNTING OF CONTACTS: Fixed contacts shall be mounted on a block or channel welded to 10 mm thick M.S. plate with holes for fixing on insulators. Slots shall be provided for marginal adjustment of height of contacts. The

contacts shall rest on a brass block and with initial tension. Suitable device shall be provided to prevent dashing. Fabrication, welding etc. shall be done in suitable jig to avoid deviation during production.

6.09.TURN AND TWIST MECHANISM: Turn and twist mechanism shall be provided with adequate locking to avoid opening or loosening by wind, short circuit force etc., on moving blade. The springs shall be made out of stainless steel or

phosphor bronze or any other better material to have adequate strength and resilience and shall be encased with grease to avoid exposure to rain. The clamps and plates be made out of at least 10 mm thick M.S. plate or flat. Fasteners with unlock nuts shall be used wherever necessary. Vulnerable parts shall be fabricated by tubular gas cutting and milling. The entire- mechanism shall be fabricated in suitable jig and template to avoid deviations during production.


6.10.All lives parts shall be designed to have smooth surfaces without any sharp points, edges and other corona producing surfaces so as to eliminate corona at specified extinction voltage or at 1.1 x rated voltage, if extinction voltage is not specified. 6.11.FASTNERS: Nuts, bolts and washers of M -16 and higher size shall be hot-dip galvanized. The bolts used on tapped holes of insulators cap shall be galvanized by centrifuge process to avoid excess deposition of

zinc on threads. Nuts, bolts and washers of less than M -16 size shall be of stainless steel when used on live parts and nickel plated brass in other parts.

6.12. BEARINGS a) The design and construction of the various bearings should embody all the features required to withstand

the climatic conditions specified to ensure dependable and effective operation, even after long period of in action. All bearings in the current path except those specially designed as high pressure contact should be shunted by flexible copper housing having adequate cross section.

b) Rotating insulator shall be mounted on a housing with bearings. The housing shall be made of gravity

die cast metal with smooth surfaces and suitably machined for seating the bearings. Two nos. of bearings with adequate shaft diameter and distance between the bearings shall be provided to avoid wobbling during operations. The bearings shall be of at least 75 mm internal diameter. The bearings shall be of reputed make and lubricated for life. All other friction locations shall be provided with suitable bearings or stainless or brass bushes. The bearings, bushes, joints, springs, etc., shall be so designed that no lubrication shall be required during the service. Complete details of bearings, bushes housing greasing, etc., shall be furnished with tender.

6.13. TANDEM AND DOWN PIPE: a) The operating down pipe mid tandem pipe shall be of heavy duty GI pipe of the following sixes (Bore

dia) for different KV class. i) Bore dia of tandem pipe ------- 32 mm. ii) Bore dia of down operating pipe – 50 mm b) The outside diameter and thickness of pipe shall be as follows as per table - 3 of IS : 1239 (Part - 1) 1990.

Mild steel tubes. –

Sl. No.

Nominal Bore in mm

Outer Dia. Maximum (mm)

Outer Dia. Minimum (mm)

Minimum Thickness (mm)

1 32 42.9 42 4

2 40 48.8 47.9 4

3 50 60.8 59.7 4.5


a) Two Nos. of tandem pipe shall be used for phase coupling of double break isolator. Base plate of insulators for connection of tandem pipe shall be made out of one piece of at least 10 mm. thick MS plate. Bolt and shackle device shall be used to connect tandem pipe to the base plate. Wherever unavoidable, sliding clamps may be used. These clamps shall be made out of at least 10 mm thick MS plate with four(4) nos. of nuts and bolts. A grub screw shall be provided for securing connection of tandem pipes.

b) The pipe shall be terminated into a suitable swivel or universal type joint between the insulator bottom bearing of the operating mechanism to take cares of marginal angular misalignment at site. All

brackets, guides, etc., shall be mounted on the base of the isolator. Arrangement of mounting any guide, bracket, mechanism and the base shall not be accepted, for upright mounting type isolator.

6.14. BASE : Each pole of the isolator shall be provided with hot dip galvanized rolled steel base provided with holes for

mounting bolts and designed for mounting on a steel structure. The bases shall be rigid and self supporting and shall require the guying or cross bracing between phases other than the supporting structure. The composite frame of the base shall be made of single channel of 150 x 75 x 6 / 8 mm.

6.15 INSULATORS: 6.15.1.The isolator shall be provided with solid core insulators. a) These shall be of stacking type to be used. The dimensions and other parameters unless otherwise specified shall generally conform to IS - 5350-Part-11 & IEC 273. b) The cylindrical type post insulators shall be of solid core type. Insulators of similar type shall be interchangeable. The mechanical strength class for outdoor cylindrical post insulators shall be

of strength class 6, corresponding mechanical strength in tension, compression and torsional shall be as per IS : 53550 Part - II. When operated at maximum system voltage, there shall be no electrical discharge. Shielding rings, if necessary shall be provided.

c) The parameters of the insulators required shall conform to IS : 0350 - Part - II - 1973 or IEC 273. d) The cylindrical post insulators shall consist of single unit only. e) The insulator shall be provided with a completely galvanized steel base designed for mounting on the

support. The base and mounting arrangement shall be such that the insulator shall be rigid and self supporting and no guying or cross bracing between phase shall be necessary.

6.15.2. Porcelain of the insulator: a) The porcelain used for the manufacture of the insulators shall be homogenous, free from laminations and other flaws or imperfections that might effect the mechanical or dielectric. quality

and shall be thorough vitrified, tough and impervious to moisture. The glazing of the porcelain shall be uniform brown colour, with a smooth surface arranged to shade away rain water and free from blisters, burns and other similar defects. Insulators shall be inter-changeable.

b) The porcelain and metal parts shall be assembled in such a manner and with such materials that any differential thermal expansion between the metal and porcelain parts throughout the operating

temperature range will not loosen the parts or electrical strength or rigidity. The assembly shall not have excessive concentration of electrical stress in any section or across leakage surfaces. The cement used shall not give rise to chemical reaction. with metal fittings. The insulator shall be suitable for water washing by rains or artificial means in service conditions. Further the insulators to be supplied shall be of high- quality and should not result in mismatch and misalignment of stacks during erection


and operation. c) Each cap shall be of a high grade cast iron or malleable steel casting or steel forging. Cap and base insulators shall be interchangeable with each other. The insulator shall conform to the

requirement of the latest edition of IS : 2544,or any other equivalent standard. The bidder should furnish the characteristics of insulators.

6.15.3 All the ferrous metal part shall be hot dip galvanized smoothly as per IS : 3638 (as amended up to date), IS : 2623 or any other equivalent authoritative standard. The material shall be galvanized only

after shop operations upon it have been completed. The metal parts for galvanization should be thoroughly cleaned of any paint, grease, rust, scales or alkalies or any foreign deposit which are likely to come in the way of galvanization process. The metal parts coating shall withstand minimum four one minute dips in copper sulphate solution as per IEC - 168.

The insulator unit shall be assembled in a suitable jig to ensure correct positioning of the top and bottom metal fittings relative to one another. The phases of the metal fitting shall be parallel and at right angle to the axis of the insulator and corresponding holes in the top and bottom metal fittings shall be in a vertical plane containing the axis of the insulator.

It shall be sole responsibility of the supplier to carry out thorough inspection and quality, checks on the

insulators at the insulator supplier works before offering the insulators for purchaser's inspection. 6.16 PADLOCKING DEVICE: The isolator shall be provided with padlocking device to permit locking of the isolator in both fully open

and fully closed positions. 6.17 EARTHING: The frame of each disconnect shall be provided with two reliable earthing terminals for connection to the earthing conductor / flat so also clamping screw suitable for carrying specified

short time current. The diameter of clamping screw shall be at least 12 mm. The connecting point shall be marked with earth symbol.

6.18 TERMINAL CONNECTORS a) The disconnecting switches shall be provided with high conductivity bimetallic terminal connectors and suitable for Aluminium pipes (BS 1600 schedule 40) and 232 mm AAA conductors size

of which will be indicated. to successful bidder. The connector shall be rigid in respect of AAA conductors & flexible for UG Cable connections. The terminal connectors shall be expansion type in respect of Aluminium pipes. The terminal connector shall conform to IS : 5561 1970.

b) Further the terminal connectors shall be suitable for both horizontal or vertical take off. c) For bimetallic type of connectors, necessary steps shall be taken by the manufacturers to ensure that there is no adverse effect on the connector and the connected equipment due to bimetallic action. 6.19. SUPPORTING STRUCTURE:


These galvanized support structures shall be fabricated as per the requirement. 6.20. ASSEMBLY The disconnect shall be fully assembled at the works of the bidder. Typical operation shall be carried out on each type of fully assembled disconnect to ascertain that all parts fit correctly and function

satisfactorily. 6.21. PAINTING, GALVANIZING AND CLIMATE PROOFING: a) All interiors and exteriors of enclosures, cabinets mid other metal parts shall be thoroughly cleaned to remove all rust scales, corrosions, grease and other adhering foreign matter and surfaces treated

by recognized phosphating (Eg. Seven tank phosphating sequence), After such preparation of surfaces tow coats of zinc oxide primer shall be given by suitable stoving and air-drying, etc., before final paint.

b)Colour of the final paint shall be of shade No. 631 of IS-5, i.e., epoxy light grey. The final painted cubicle shall. present aesthetically pleasing appearance free from any dent of uneven surface Paint inside the metallic housing shall be of anti - condensation type and the paint on outside surfaces shall be suitable for outdoor installation.

c) All ferrous parts not suitable for painting such as structural steel, pipes, rods, levers, linkages, nuts and bolts used in other than current path etc., and also supporting structures shall be hot dip galvanized.

Galvanization shall be done after completion of fabrication which shall be capable to prevent corrosion in view of the severe climatic conditions.

d) Thickness of zinc coating shall not be less than 610 gm of zinc per sq. meter of surface. Zinc coating shall be smooth clean and of uniform thickness and free from defect. Preparation of galvanizing

and the galvanizing itself shall not adversely effect the mechanical properties of the coated material, The quality shall be established by tests per IS : 2633. Galvanizing of nuts and bolts shall be carried out by centrifugal or suitable process so that the bolts will easily fit into the tapped holes / nuts.

e) All components shall be given adequate treatment of climate proofing as per IS : 3202 so as to withstand corrosion and severe conditions.

7.00 TESTS : 7.01Type tests : a) The equipment offered, shall be fully type tested. The type test reports shall not be older than 5 years on the day of bid opening. The type tests are to conducted again if the reports are older than 5 years

on the day of bid opening at no extra cost to owner. b) During the type test the disconnect shall be mounted on its own support structure or equivalent

support structure and installed with its own operating mechanism to make the type test representative. Drawing of equivalent support structure if any and mounting arrangement made for type tests shall be furnished for purchaser's approval before conducting the type tests.

c) The type tests shall be conducted on the disconnect along with approved insulators and terminal connectors.

d) Mechanical endurance test shall be conducted on the main switch. e) LIST OF TYPE TESTS: List of type tests to be carried out as per IS : 9921 Part - VI 1985, are as given below.


i) Visual examination of components, ii) Dimensional verification of parts. iii) Assembly, interchangeability and verification of critical dimensions. iv) Measurement of resist-circuit of main circuit and earth circuit (before and after mechanical

endurance test) v) Temperature rise test (before and after mechanical endurance test) vi) Mechanical endurance test. vii) Short time withstand current and peak withstand current tests. viii) One minute power frequency voltage wet withstand tests across the isolating distances and to earth. ix) Standard lightning impulse voltage withstand tests on auxilia~3, and control circuits and auxiliary

switches. x) One minute power frequency, withstand voltage test on auxiliary and control circuits and auxiliary

switch. xi) Verification of operation during application of rated mechanical terminal loads. xii) Galvanization tests. xiii) Chemical composition of contact material, springs and fasteners and bushes. xiv) Physical tests on springs and fasteners and copper strip / tubes. 7.02 ACCEPTANCE AND ROUTING TESTS: a) All acceptance and routine tests as stipulated in the relevant standards shall be carried out by the supplier in presence of purchaser's representative. b) Mechanical operation tests (routine test) shall. be conducted on the complete disconnect (man switch

and earth switch) at supplier's works and a certified test report be furnished to the purchaser. Alternatively the bidder may offer to conduct this test at purchaser's sub- station in which case the purchaser shall make necessary arrangement to erect the disconnect at his sub-station site under supervision of bidders representatives for supervision shall not be borne

by the purchaser. c) The test report of power frequency voltage withstand test conducted on the insulator shall be furnished

for purchaser's acceptance in lieu of conducting the power frequency (dry) test on main circuit (routine test).

d) LIST OF ROUTING TESTS: List. of routine test to be carried out as per IS : 9921, Part - IV - 1985 are as given below: i) Visual examination of components. ii) Assembly, interchangeability and verification of critical dimensions. iii) One minute power frequency voltage dry withstand tests across the isolating distance and to earth. iv) Measurement of resistance of isolator contacts and between terminals of the main circuits. v) Power frequency voltage withstand tests on auxiliary and control circuits and auxiliary switches at 2

KV (rms) for one minute. vi) Mechanical operation tests. Special tests listed below shall be carried out in presence of purchaser's representative. a) Test on insulators – Conforming to IS - 2544 b) Test on insulators – Conforming to IEC - 168 c) Test on terminal connecters – IS : 5561


d) Operation tests on operating mechanism - IS : 2623. e) Test certificates and documents of the following items shall be furnished at the time of routine

tests. • Chemical analysis of copper. • Bearings • Fasteners • Universal/ swivel joint coupling. • Insulators. • Gears 8.00 INSPECTION 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. Inspection and acceptance of any equipment under this specification by the purchaser, shall not relieve the supplier of his obligation of furnishing equipment in accordance with the specification and shall not prevent subsequent rejection if the equipment is found to be defective. The supplier shall keep the purchaser informed in advance, about the manufacturing programme so that arrangement can be made for inspection. The purchaser reserves the light to insist for witnessing the acceptance / routine testing of the bought out items.

9.0. DOCUMENTATION: All drawings shall conform to International Standard Organization (ISO) ' A ' series of drawing sheet / Indian standards specification IS : 656. All drawings shall be in ink and suitable for micro filming. All

dimensions and data shall be in system international units. 10.0 LIST OF DRAWINGS AND DOCUMENTS: a) The bidder shall furnish the following drawings along with his offer: General outline and assembly drawings of the disconnect, operating mechanism, structure, insulator and terminal connector. b) Sectional views and descriptive details of items such as moving blades, contacts arms, contact springs, contact support, turn and twist mechanism, bearing, housing of bearing, bushes, balancing of heights,

phase coupling pipes, base plate, operating shaft, guides, swivel -joint operating mechanism and its components, etc.

i) Loading diagram. ii) Drawings with structure for the purpose of type test iii) Name plate iv) Schematic drawing v) Type test reports in case the equipment has already been type tested vi) Test reports, literature, pamphlets of the bought out items and raw material. 11.0 INSTRUCTION MANUALS: The two copies of the erection, operation and maintenance manuals in English shall be supplied one month prior to dispatch of the equipment. The manual shall be bound volume and shall contain all

drawings and information required for erection, Operation and maintenance of the disconnect including


but not limited to the following particulars. a) Marked erection prints identify the component parts of the disconnect as shipped with - assembly drawings. b) Detailed dimensions and description of all auxiliaries. c) Detailed views of the insulator stacks, metallics, operating mechanism, structure etc.

GUARANTEED TECHNICAL PARTICULARS FOR 33KV, 630A, 50 HZ,3 POLE, DOUBLE BREAK TYPE ISOLATOR

Sl. No

Particulars Requirement Bidder’s Offer

1 2 3 4 1. Type/ Installation Double Break outdoor,

Banging Horizontal

2. Maker‘s name and country of origin

To be specified by the Bidder

3. Standards according to which the isolatorare manufactured.

IS:9921 & IEC-129

4. Suitable for mounting Horizontal only

5. Maximum Operate voltage 36 KV

6. Rated voltage & frequency 33 KV , 50 Hz

7. Maximum current for safely interrupted Inductive(A&%PF) Capacitive(A&%PF)

0.7 Amp. at 0.15PF 0.7Amp at 0.15 PF

8. Continuous current rating 630 Amp.

9. Rated short time current

25 KA (rms) for 1 sec. 62.5 KA (peak )

10 a)

Dry Flashover Voltage To be specified by the tenderer

b)

Power frequency puncture with stand voltage

1.3 times of actual dry flash over voltage

c)

Impulse withstand voltage (switch in position)

170 KV (peak)

d)

Creepage distance (mm) 25 mm/KV

840 mm minimum. (actual creepage distance for which type test have been conducted is to be

11.

Impulse withstand voltage for positive and negative polarity 1.2 / 50 mircro- second wave


a) Across the isolating distance 195 KV (peak)

b) To earth & between poles 170 KV (peak)

12. One minute power frequency withstand voltage

a) Across the isolating distance 80 KV (RMS)

b) To earth & between poles 70 KV (RMS)

13.a)

Rated normal current and rated frequency

630 amps. 50 Hz

b) Rated short time current for 3 sec. 25 KA ( RMS )

14 Operating mechanism

Isolator Manual

b)Earth switch Manual

15 Insulator Data a) Bending Strength (kgf) 600

b) Height (mm) 508

c) Bottom PCD (mm) 76

d) No. of holes & hole dia 4xM12

e) Top PCD 76

16 Bus Bar height from Plinth level (mm) 3700

17 Phase Spacing (mm) 1500

18 Minimum clearances (mm)

a) Phase to Phase 320

b) Phase to earth 320

c) Sectional clearance 3000

19 Tandem & Down Pipe

Bore dia of tandem pipe 32 mm

ii)Bore dia of down operating pipe 50 mm

20 Mounting arrangement To be specified by the bidder

21 Drawing To be enclosed by the bidder

Bidders Signature with Seal


TECHNICAL SPECIFICATION OF 33KV METAL OXIDE (GAPLESS) LIGHTENING ARRESTERS

The specification covers the design, manufacture, shop & laboratory testing before despatch, supply delivery of 33 KV, Station class heavy duty, gapless metal oxide Surge Arrestors, insulating base, clamps, complete fittings & accessories suitable for 33 KV transformers/feeders including arrester's electrode earthing. 1.0 STANDARDS: The design, manufacture and performance of Surge Arrestors shall comply with IS: 3070 Part-3 and other specific requirement stipulated in the specification Unless otherwise, specified, the equipment, material and processes shall confirm to the latest application Indian/International Standards.

2.0 GENERAL REQUIREMENT:

The Metal Oxide gap less Surge Arrestor without any series or shunt gap shall be suitable for protection of 33 KV power transformers, associated equipment and 33 KV lines from voltage surges resulting from natural disturbance like lightening as well as system disturbances. 3.0 ARRESTOR HOUSING 3.1 The arrestor housing shall be made up of porcelain/silicon polymeric housing and shall be homogenous, free from laminations, cavities and other flaws of imperfections that might affect the mechanical and dielectric quality. The housing shall be uniform brown colour, free from blisters, burrs and other similar defects. Arrestors shall be complete with insulating cases, fasteners for stacking units together and terminal connectors. 3.2 The housing shall be so coordinated that external flashover shall not occur due to application of any impulse or switching surge voltage upto the maximum design value for arrestor. The arrestors shall not fail due to contamination. The 33 KV arrestors housing shall be designed for pressure relief class as given in Technical Parameters of the specification. 3.3 Sealed housing shall exhibit no measurable leakage. 4.0 TESTS : 4.1 Test on surge Arrestor:

The Surge Arrestors offered shall be type tested not earlier than 5 years before the date of opening of this tender. The surge arrestors shall be subjected to routine and acceptance tests in accordance with IS: 3070(Part3)-1993. In addition, the suitability of the Surge Arrestors shall also be established for the following:

Residual voltage test Reference voltage test Leakage current at M.C.O.V. P.D. Test Sealing test Thermal stability test Aging and Energy capability test Watt loss test

Each metal oxide block shall be tested for guaranteed specific energy capability in addition to routine/acceptance test as per IEC/IS

TECHNICAL REQUIREMENTS FOR 30 KV METAL OXIDE (GAPLESS)


SURGE ARRESTERS The Surge Arrester under this Specification shall conform to the parameters given below :- Sl. No.

Particulars. Technical Parameters

Bidder,s Offer

1 Nominal system voltage (phase to phase) (KV rms).

33

2 Highest system voltage (phase to phase) (KV rms).

36

3 System Frequency (HZ). 50 ±5% 4 System Neutral earthing. Effectively earthed

5 Installation. Outdoor 6 Class. Station class, 10 KA, heavy duty

type.

7 Type of construction for 10 KA rated arrester.

Single column, single phase

8 No. of phases. Three 9 Maximum duration of earth

fault (Sec.) 3

10 Maximum prospective symmetricalfault current at arrester location (KA rms.)

40

11 Rated arrester voltage (KV rms) 30

12 Nominal discharge current (KAP) Disscharge current at which insulation co ordination will be done

10 KA of 8/20 micro- Second Wave.

13 Minimum energy discharge capability (KJ/KV)

As per relevant ISS/IEC

Maximum continuous operating voltage at 50ºC C (KV rms)

25

15 Maximum switching surge residual voltage (KVP)

72 at 500A

16 Maximum residual voltage at 8/20 micro second(KVP)

(i) 5 KA. 85 (ii) 10 KA Nominal

discharge current. 90

(iii) 20 KA. 100 17 Long duration discharge

class 2

18 High current short duration test value (KAP)(4/10 Micro-second wave).

100

19 Current for pressure relief test (KA-rms)

40

20 Minimum total creepage distance (mm).

900


21 One minute dry and wet power frequency withstand voltage of Arrester housing (KV-rms).

70

22 (a)

(b)

Impulse withstand voltage of arrester housing with 1.2/50 micro-second wave (KVP). Switching Impulse Voltage (Wet) (KVP)

+170

-

23 Pressure relief class. A 24 Corona extinction voltage

(KV-rms). -

25 RIV at 92 KV rms. Less than 500 micro volts

26 Partial discharge at 1.05 times continuous over- voltage.

Nor more than 50 PC

27 Seismic acceleration. 0.3g horizontal 0.15g vertical

28 Reference ambient temperature.

50 C

29 (a) IR at MCOV. Less than 400 micro amperes

(b) IC at MCOV. Less than1200 micro amperes

30 a) Reference Current (mA) 1 to 5 mA

b) Reference voltage at reference current.

Greater than rated voltage.

31 Maximum steep current Impulse RDV (KVP). at10 KAP

100

32 Maximum cantilever strength of the arresters (KGM).

325

33 TOV(KVP). (i) 0.1 sec. 53 (ii) 1.0 sec. 51 (iii) 10.0 sec. 49 (iv) 100.0 sec. 47 34 Drawing To be submitted by the bidder

Signature of the Bidder with Seal


TECHNICAL SPECIFICATION OF 100MM²

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 3 232 19/3.94 19.70 636.67 0.1471 68.05

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.

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.

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.


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


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 100 MM² 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 : 4.30

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 : 100

6.

Minimum breaking load in KN


ii) Standard Conductor (U.T.S) : 29.344

7.

Approximate mass in Kg. Per KM of Aluminium Alloy conductor


ii) Standard Conductor : 272.86

8. Calculated maximum DC resistance at 200C in Ohm/Km


ii) Standard Conductor : 0.339

13. Modulus of Elasticity of Aluminium Alloy conductor Kg/Sq.mm :

16.

Co-efficient of linear expansion per degree centigrade for

a) Individual /0C

b) Standard conductor/0C

:

:

23X106


17. Standard length (Mtr.)

: 2000 +5%

18. Lay ratio for 7 wire conductor : Min Max


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

Bidders Signature with Seal

section-iv33 kv pole top bracket gi 100x50mm 33 kv pin insulator (porcelain) 33 kv g.i. pin 90 kn...

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