KARNATAKA POWER TRANSMISSION CORPORATION LIMITED

BID ENQUIRY NO.

KPTCL/CEE/T&P/66KV/HTLS/Package-158 /TTK/ TL-522

BIDDING DOCUMENTS

FOR
Combined package of following Replacement of existing ACSR conductors by HTLS conductor including
Supply of all Materials/Equipments and Erection (Including Civil Works) of all Materials/Equipments, Testing
and Commissioning and buy back of released materials on Total Turnkey basis.
A: Replacing the existing 66kV DC Coyote ACSR conductor by High Temperature
Low Sag conductor (HTLS) between 220/66/11kV Hebbal station and 66/11kV
ITI sub station for a distance of 14.334kms. in Bangalore East Taluk,
Bangalore Urban District on Total Turnkey Basis.
B: Replacement of the existing Lynx conductor by High Temperature Low Sag
(HTLS) conductor suitable for Coyote in the existing 66kV Peenya-
Brindavan SC line for a distance of 3.0kms. in Bangalore North Taluk,
Bangalore Urban District on Total Turnkey Basis.

DOCUMENTS CONSIST OF THE FOLLOWING VOLUMES

VOLUME- I COMMERCIAL REQUIREMENTS

1. Section – I Invitation For Bids - IFB

2. Section – II Instruction to Bidders - ITB
3. Section – III General Terms and Conditions
of the Contract - GCC
4. Section – IV Erection Conditions of Contract - ECC
5. Section – V Special Conditions of Contract - SCC
6. Section – VI ANNEXURE - ANNEX

VOLUME-II TECHNICAL REQUIREMENTS

VOLUME- III BID PROPOSAL SHEETS

1. Section – I TECHNO COMMERCIAL SHEETS

2. Section – II PRICE SHEETS

537456407.doc Page 1
 THIS CONTAINS THE FOLLOWING VOLUMES

VOLUME – II: TECHNICAL SPECIFICATIONS FOR LINES - TSL

OTHER VOLUMES CONTAIN THE FOLLOWING:

VOLUME- I COMMERCIAL REQUIREMENTS

1. Section – I Invitation For Bids - IFB

2. Section – II Instruction to Bidders - ITB
3. Section – III General Terms and Conditions
of the Contract - GCC
4. Section – IV Erection Conditions of Contract - ECC
5. Section – V Special Conditions of Contract - SCC
6. Section – VI ANNEXURE - ANNEX

VOLUME- III BID PROPOSAL SHEETS

1. Section – I TECHNO COMMERCIAL SHEETS

2. Section – II PRICE SHEETS

537456407.doc Page 2
 Karnataka Power Transmission Corporation Limited

BID ENQUIRY NO.

KPTCL/CEE/T&P/66KV/HTLS/Package-158 /TTK/ TL-522

BIDDING DOCUMENTS

FOR
Combined package of following Replacement of existing ACSR conductors by HTLS conductor including
Supply of all Materials/Equipments and Erection (Including Civil Works) of all Materials/Equipments, Testing
and Commissioning and buy back of released materials on Total Turnkey basis.
A: Replacing the existing 66kV DC Coyote ACSR conductor by High Temperature Low
Sag conductor (HTLS) between 220/66/11kV Hebbal station and 66/11kV ITI sub
station for a distance of 14.334kms. in Bangalore East Taluk, Bangalore Urban
District on Total Turnkey Basis.
B: Replacement of the existing Lynx conductor by High Temperature Low Sag (HTLS)
conductor suitable for Coyote in the existing 66kV Peenya-Brindavan SC line for
a distance of 3.0kms. in Bangalore North Taluk, Bangalore Urban District on
Total Turnkey Basis.

VOLUME- II

TECHNICAL SPECIFICATIONS

---------------------------------------------------------------------------------------------------
ISSUED BY:
The Chief Engineer, Electricity, Tel: 080-2274744, 2120905
Tendering & Procurement, Fax: 0091-080-2212456
Kaveri Bhavan
Bangalore:560 009

537456407.doc Page 3
 SECTION – I
(VOLUME – II)

GENERAL TECHNICAL CONDITIONS

(GTC)

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 VOLUME-II
SECTION-I

GENERAL TECHNICAL CONDITIONS

1.0 GENERAL

2.0 SCOPE

3.0 APPLICABLE STANDARDS

4.0 SERVICE CONDITIONS

5.0 DRAWING

6.0 BASIC TECHNICAL PARAMETERS OF THE LINES

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 VOLUME – II

SECTION–I

GENERAL TECHNICAL CONDITIONS

1.00 GENERAL:

This part covers technical conditions pursuant to the contract and

will form an integral part of the contract. The following provisions
shall supplement all the detailed technical specifications and
requirements brought out in accompanying Technical Specifications.
The Contractor’s proposal shall be based upon the use of equipment
and materials complying fully with the requirements specified herein.
It is recognized that the contractor may have standardized on the
use of certain components, materials, processes or procedures
different than those specified herein. Proposals offering similar
equipment based on the manufacturer’s standard practice will be
considered provided such equipments meet other authoritative
standards and will be of an equal or higher quality than the
standard specified. Such equipment will also to meet the
performance requirements specified and be acceptable to the Owner.
1.1 Limit Of Contract:
Equipment Furnished shall be complete in every respect with all
mountings, fittings, fixtures and standard accessories normally
provided with such equipment and/or needed for erection,
completion and safe operation of the equipment as required by
applicable codes, even though they may not have been specifically
detailed in the technical specifications, unless included in the list of
exclusions. All similar standard components/parts of similar

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 standard equipments provided, shall be inter-changeable with one
another.
Similarly, all services as may be necessary for the execution of the
Contract though they may not have been specifically detailed in the
Technical Specifications, unless specifically excluded, shall be
furnished by the Contractor.
1.2 Equipment Performance Guarantee:
The performance guarantee of the equipment under the scope of the
contract has been detailed in the Technical Specifications. These
guarantees shall supplement the general performance guarantee
provisions covered under General Conditions of Contract.
Liquidated damages for not meeting performance guarantees during
the performance and guarantee tests shall be assessed and
recovered from the Contractor as detailed in Special conditions of
Contract. Such liquidated damages shall be in addition to damages,
if any, payable under any other clause of Conditions of Contract,
Special Conditions of Contract.
1.3 Engineering Data:
The furnishing of engineering data by the Contractor shall be in
accordance with the schedule for each set of equipment and
materials as specified in the Technical Specifications. The review of
the data by the Engineer will cover only general conformance of the
data to the specifications and documents, interfaces with the
equipment and materials provided under the Specifications, external
connections and of the dimensions which might affect plant layout.
This review by the Engineer may not indicate a thorough review of all
dimensions, quantities and details of the equipment and materials,
any device or item indicated or the accuracy of the information

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 submitted. This review and/or approval by the Engineer shall not be
considered, by the Contractor, as limiting any of its responsibilities
and liabilities for mistakes and deviations from the requirements,
specified under these Specifications and Documents.
All engineering data submitted by the Contractor after final process
including review and approval by the Engineer shall form part of the
Contract Documents and all the works performed shall be in strict
conformity with these specifications unless otherwise expressed in
writing by the Engineer.
1.4 Drawings:
All drawings submitted by the Contractor including those submitted
at the time of Bid shall be in sufficient detail to indicate the type,
size, arrangement, material description, Bill of Materials, weight of
each component, break down for packing and shipment, the external
connections, fixing arrangements required, the dimensions required
for installation and inter-connections with other equipment and
materials, clearances and spaces required for installation and inter-
connections between various portions of equipment and any other
information specifically requested in the Specifications.
Each drawing submitted by the Contractor shall be clearly marked
with the name of the Owner, the unit/scheme designation, the
specifications title, the specification number and the name of the
project/scheme. If standard catalogue pages are submitted, the
applicable items shall be indicated therein. All titles, noting,
markings and writings on the drawing shall be in English. All the
dimensions shall be in metric units.
The drawings submitted by the Contractor shall be reviewed by the
Engineer within four (4) weeks and shall be modified by the

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 Contractor if any modifications and/or corrections are required by
the Engineer. The Contractor shall incorporate such modifications
and/or corrections and submit the final drawings for approval. Any
delay arising out of failure by the Contractor to rectify the drawings
in time shall not alter the contract schedule.
The drawings sent for approval to the Engineer shall be in
quadruplicate. One print of such drawings will be returned to the
Contractor, by the Engineer marked ‘Approved/ Approved with
corrections’ or resubmit with corrections as noted. The Contractor
shall thereupon furnish to the Owner such number of prints of
approved drawings as may be mutually agreed upon between the
Owner and the Contractor and one reproducible original of the drawings,
after incorporating all corrections. The Contractor shall supply soft copy of
all such drawings in 3½” Floppy diskettes / CD for easy reproduction
later.
1.5 Inspection, Testing And Inspection Certificate:
The Engineer, his duly authorized representative and/or an outside
inspection agency acting on behalf of the Owner shall have, at all
reasonable times, access to the Contractor’s or its Sub-vendor’s/Sub-
Contractors’ premises or works and shall have the power, at all reasonable
times to inspect and examine the equipment materials and workmanship
of the works during its manufacture or prior to despatch and if part of
equipment and materials is being manufactured or assembled at other
premises or works, the Contractor shall obtain for the Engineer and for his
duly authorised representative, permission to inspect as if the equipment
and materials were being manufactured or assembled on the Contractor’s
own premises or works.
1.6 Packaging And Transportation:

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 All the equipment and materials shall be suitably protected coated,
covered or boxed and crated to prevent damage or deterioration during
transit, handling and storage at Sites till the time of erection, the
contractor shall be responsible for any loss or damage during
transportation, handling and storage due to improper packing.
While packing all the equipment and materials, the limitations from the
point of view of availability of Railway wagon sizes in India should be taken
account of.
The Contractor shall also give due consideration to the
encumbrances, infringements etc., likely to be encountered during
the transportation of the equipment to the site and shall, at his own
cost, make all arrangements as may be necessary to ensure smooth
and safe movement of the goods to the site.
The Contractor shall at its own cost carry out investigation to select
the route and the mode to be adopted for transportation of the
goods.
1.7 Protection:
All coated surfaces shall be protected against corrosion, erosion,
abrasion, impact, discolouration and any other damage. All exposed
threaded portions shall be suitably protected with either a metallic or
a non-metallic protecting device. The parts that are likely to suffer
damage by elements of nature especially those transshipped across
the seas, shall also be properly treated and protected in a suitable
manner.
2.00 SCOPE:
2.1 The general scope of the work involved is the total / partial turnkey
construction of 220kV, 110kV and 66kV lines which includes supply
of tower parts and other materials, erection, testing and satisfactory
commissioning of the lines as per Technical Specifications.

537456407.doc Page 10
2.2 The details of the lines with point of connection and termination, the
approximate length of the lines, the voltage class of the lines is
indicated in the Technical Specifications.

2.3 The detailed scope of the work involved is as follows:

2.3.1 Survey:

Preliminary and detailed survey, which includes route profiles, tower

spotting and tower schedules have been got conduct by KPTCL. The
contractor is required to conduct only a check survey for which
KPTCL will provide the contractor with the necessary data such as
topo sheet extracts, route profiles, tower schedules etc. However, in
case the contractor finds upon site verification that the alignment of
the line as per the survey conducted by KPTCL is not feasible for
execution then the contractor will again conducted detailed surveys
as per the technical specifications Section–II, Vol-II titled “Detailed
Technical Specifications for conducting surveys, tower spotting etc”
attached here to.
2.03.02 Towers:

The contractor shall supply the towers and extension pieces as per
Detailed Technical Specifications for transmission line tower –
Section-III (Volume-II).
2.3.3 Overhead Line Power Conductors:

The power conductors shall be got manufactured tested and supplied

as per the detailed technical specifications Section-IV (Volume-II)
titled “Detailed Technical Specifications for manufacture, testing and
supply of ACSR power conductors” attached here to.
2.3.4 Ground Wires:

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 The static ground wire or earth wire conductor shall be got
manufactured and supplied as per the detailed technical
specification Section–V (Volume-II) titled “Detailed Technical
Specification for Ground wires” attached here to.
2.3.5 Power Line Conductor Insulators:

The insulators shall be got manufactured and supplied as per the

detailed technical specification Section–VI (Volume-II) titled “Detailed
Technical specifications for insulators” attached here to.
2.3.6 Power Line Conductor Accessories:

The power conductor accessories shall be got manufactured and

supplied as per the detailed technical specifications Section-VII
(Volume-II) titled “Detailed technical specification for Power line
conductor accessories” attached here to.
2.3.7 Ground Wire Accessories:

The ground wire accessories shall be got manufactured and supplied

as per the detailed technical specification Section–VIII (Volume-II)
titled “Detailed Technical Specification for ground wire accessories”
attached here to.
2.3.8 Insulator Hardware:

The power line conductor insulator hardware shall be got

manufactured and supplied as per the detailed technical
specification Section–IX (Volume-II) titled “Detailed Technical
Specification for insulator hardware” attached here to.
2.3.9 Line erection, insulation, testing and commissioning:

The line erection which includes soil investigation, soil testing for
tower foundations, stub assembly, stub setting, concreting of
foundations, back filling and curing, assembly of tower
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 superstructure, pave out of conductors, hoisting of insulators,
stringing and tensioning of power and ground wire conductors, fixing
of conductor accessories, fixing of tower accessories etc testing and
commissioning of the lines and handing over of lines shall be as per
the detailed technical specification Section-X(A) titled “Stub setting
and casting of foundations” and Section–X(B) titled “Erection,
installation, testing and commissioning of lines” attached here to.
3.00 APPLICABLE STANDARDS:

The applicable standards are specified in each of the detailed

technical specifications Section-I to X attached here to.
4.00 SERVICE CONDITIONS:

The lines covered under this contract are to run in plains /

undulating hilly terrain (Western Ghats)/coastal areas of Karnataka
and shall be suitable for the hot and humid tropical climatic
conditions prevailing in the State. These are furnished here below:
a) Peak ambient day temperature in still air – 500C.

b) Minimum night temperature – 100C.

c) Average maximum ambient day temperatures.

i. June to January – 350C.
ii. February to May – 450C.

d) Relative humidity maximum – 90 % in coastal area; minimum –

10 % in the Western Ghats and plains.

e) Maximum rainfall – 200 mm in the plains/6000 mm in the

coastal areas and the Western Ghats.

f) Average number of rainy days:- 120 between April and

November.

g) Average number of thunderstorm days – 50 between April and

November.
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 h) Altitude.

i. Varying from 0 to 250 m in the coastal areas.

ii. Varying from 250 to 1000 m in the plains.
iii. 500 m in the Western Ghats.

i) Maximum wind speed.

i. 39 m/sec in the coastal areas, the Western Ghats and the

plains of northeastern Karnataka.

ii. 33 m/sec in the plains of northwestern and southern

Karnataka.

5.00 VOID

6.00 BASIC TECHNICAL PARAMETERS OF THE LINES:

A) Electrical System Data:

a) System Voltage (kV rms) 220 110 66
b) Maximum Voltage (kV rms) 245 123 72.5
c) Lightning impulse withstand voltage
1050 550 325
(dry & wet) (kVp)
d) Power frequency withstand voltage
460 230 140
(wet) (kVp)
e) Power frequency withstand voltage
510 265 165
(dry) (kVp)
f) Short circuit level (KA)/duration 40/1 Sec 31.5/1 Sec 31.5/1 Sec
B) Line Data:
i) Conductor: ACSR ACSR ACSR
a) Name DRAKE LYNX COYOTE
b) Strands and wire diameter of
i. Aluminium 26/4.442 30/2.79 26/2.55
ii. Steel 7/3.45 7/2.79 7/1.90
c) Overall diameter (mm) 28.13 19.53 15.86
d) Weight (kg/km) 1623.5 844 521
e) Conductor per phase Single Single Single
f) Spacing between the conductors of
4900 3100 2100
same phase (Vertical) mm

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 g) Configuration
i. Single Circuit Delta Right Right
angled angled
Triangle triangle

ii. Double Circuit Vertical Vertical Vertical

h) Minimum ultimate tensile strength
14175 7950 4625
(kg)
i) Conductor tension at 320C without
external load
i. Initial unloaded tension 35% 35% 35%
ii. Final unloaded tension 25% 25% 25%
C) Galvanized Steel Earthwire (Ground
Wire):
a) Size (strands and wire diameter) (mm) 7/3.15 7/3.15 7/3.15
b) Overall diameter (mm) 9.45 9.45 9.45
c) Standard weight (Kg/km) 432 432 432
d) Location of earth wire One continuous earth wire to run
horizontally on the top of the towers
and conductors
e) System of Grounding Solidly Solidly Solidly
earthed earthed earthed
f) Progressive shielding angle 300 300 300
g) Isokeraunic level 50 50 50
h) Tensile load in each earth wire
i. At minimum temperature of 1219 1303 1286
0
10 C and in still air (kgs)
ii. At everyday temperature of 320C 1090 1161 1129
and still air (kgs)
iii. At 100C and 2/3rd full wind (kgs) 1323 1404 1371
D) Towers:
a) Span length in metres: 320 320 275
b) Wind span in meters 352 352 302
c) Wind Load (Kg/sq.m) 130 130 130
E) Insulators:
a) Type of Insulators PORCELAIN DISC / LONG ROD

Arcing horns both on the conductor

b) Lightning protection to insulator
side and cross arm side

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 The Weight spans for 220 kV/110kV/66kV DC towers considered in
the design which is being supplied to the successful contractor is as
follows:

220KV & 110KV TOWERS 66KV TOWERS

Tower Type Normal Cond BWC Normal Cond BWC

Max Min Max Min Max Min Max Min

‘DA’ 480 160 288 80 412 138 247 70

‘DB’, ’DC’, 480 -480 288 -288 412 -412 247 -247
‘DD’

.These values shall be used for tower spotting during survey.

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 SECTION – II
(VOLUME – II)

TECHNICAL SPECIFICATIONS
FOR

SURVEYS AND TOWER SPOTTING

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 VOLUME-II

SECTION-II

DETAILED TECHNICAL SPECIFICATIONS FOR CONDUCTING SURVEYS

AND TOWER SPOTTING

1.0 GENERAL

2.0 APPLICABLE STANDARDS

3.0 ROUTING

4.0 SURVEYS

5.0 PROFILE

6.0 TOWER SPOTTING

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 VOLUME – II

SECTION – II

DETAILED TECHNICAL SPECIFICATION FOR CONDUCTING

SURVEYS AND TOWER SPOTTING

1.00 General:

The survey shall be executed very carefully and accurately. Hence

sufficient care shall be taken to avoid both field and office errors by
adopting sufficient checks and cross checks. This is very necessary
since it may involve unnecessary heavy expenditure by way of
realignment with additional towers, increase in length of conductor etc.
2.00 Applicable Standards:

IS 5613: Code of practice for design, installation and

Part – II maintenance of overhead power lines.
Section – II

3.00 Routing:

KPTCL has got done the detailed surveys of the lines. The tower profiles
and tower spotting data will be furnished to the successful bidder along
with the topo extract of the area through which the lines have to pass
through. This is to enable the contractor to carryout a walk over
survey / route inspection / check survey of the detailed surveys got
done by KPTCL. In case the contractor finds upon verification that the
detailed surveys got done by KPTCL is not feasible for execution, then
the contractor shall conduct detailed survey afresh for the stretches
where the alignment is not feasible and the size shall be approved by the
Engineer. The detailed surveys to be so got done by the contractor shall

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 follow the guidelines as enumerated here below in the succeeding
paragraphs.
The scope of check survey also includes preparation of route alignment
map as per check survey, tower profiles and tower schedules and
obtaining approval of the concerned engineer.
The route shall be aligned preferably close to an all weather road. This
is to ensure accessibility to the line both during construction and later
during line patrolling and maintenance. The routing shall also confirm
to the following clauses from 3.1 to 3.11.
3.1 Railway Crossings:

The latest regulations governing crossings of overhead lines above

railway tracks shall be strictly followed in so far as maintaining the
vertical clearance above the tracks and in the location of the towers
adjacent to the railway tracks and railway station limits. Wherever
railway crossings are involved a detailed plan and profile showing all
details of railway tracks shall be prepared and submitted to KPTCL
along with questionnaire of railway authorities duly filled in. The towers
on either side of the railway track shall be anchor towers with double
tension insulator strings.

3.2 River and Nallah Crossings:

River crossing towers shall be located in the straight reaches of the river,
since the flow in these reaches is uniform without much stress on the
flood banks. The clearances as stipulated in the latest I.E. Rules for
both navigable and non-navigable rivers shall be strictly followed. The
same is also indicated in transmission manual, Chapter-4 of CBIP.

3.3 Telecommunications:
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 Parallelism:

The transmission lines shall be routed to be as far as possible away

from existing P & T and other Telecommunication lines such that a safe
distance of at least 3 (three) KMs is maintained in the run of parallelism
between power and telecom lines. KPTCL will obtain necessary
statutory clearances from PTCC authorities.
Crossings:

The angle of crossing above the telecom lines shall as far as possible be
900 and in no case less than 600. No guarding is required to be
interposed between power and telecom lines.
A minimum vertical clearance of 3.05mt shall be maintained between
the lowest power conductor and the telecommunication circuit in
respect of 220 kV, respectively (as per CBIP, Chapter-4).

3.4 Plantations:

It is necessary to avoid coconut, areca nut, rubber and other cash crop
plantations. If it is not possible to avoid such plantations, then the line
shall cut across the corner or the thinnest belt of such plantations.
3.5 Marshes and Back Waters:

Marshes and backwaters shall under all circumstances be avoided.

3.6 Wet Land:

It is desirable to avoid long stretches of wetlands but where such

crossings are inevitable, then the towers shall be located in dry land.

3.7 Road Crossing:

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 It is desirable to cross National and State Highways at 90 0 and in any
case not less than 600. Towers to be located at the crossing span should
be located such that one tower is close to the Road nearer by about
30 M to 40 M. Besides the crossing span shall be reduced to 80% of the
ruling span.
The vertical clearance shall be as stipulated in I.E. Rules but further
enhanced by another 0.3 M so as to ensure better safety and clearances
between tractors, trailers, trucks and lorries loaded with huge packages.
Thus a clearance of 7.8 M shall be maintained between the lowest
conductor and the top surface of the Road. The towers on either side of
National and State Highways shall be with double suspension / tension
strings and shall be tension type towers. The maximum span shall be
250 m.
3.8 Aerodromes:

3.8.1 Civil Installations:

The regulations of the civil aviation authorities shall be strictly followed

while routing the lines. Accordingly the line shall be routed to be about
12.8 KM away from the final approaches of the runways or 8 KM from
the perimeter of the aerodrome. KPTCL will under no circumstances
approach the civil aviation authorities for waival of these clearances if
there is any infringement of these stipulated clearances.

3.8.2 Defense (I.A.F. Installations):

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 The routing of the line in the vicinity of defence (I.A.F. installations) shall
follow the following stipulations.
1. Within 805 M of Radar and
No structure of any height
Wireless Receiving Stations.
2. Between 805 M and 3200 M Structure of not more than
24.4 M height
3. Between 1375 metres and An angle of less than 10 9
3200 mtrs from the perimeter min from Aerodrome outer
of the air field perimeter to the top of the
structure.
4. Within flying funnel area of an - Do -
air field up to 1373 M from the
nearest end of the runway.

3.9 Power Line Crossings:

A minimum clearance as per table below shall be maintained between

the lowest power conductor and the top most conductor of the other
power line.
Minimum clearances between lines when
Crossing
220 33 110 220
each other 66 kV 132 kV
kV kV kV kV
(Meters)
250 V 2.44 2.44 2.44 2.75 3.05 4.58
650 V 2.44 2.44 2.44 2.75 3.05 4.58
11 kV 2.44 2.44 2.44 2.75 3.05 4.58
22 kV 2.44 2.44 2.44 2.75 3.05 4.58
33 kV 2.44 2.44 2.44 2.75 3.05 4.58
66 kV 2.44 2.44 2.44 2.75 3.05 4.58
110 kV 2.75 2.75 2.75 2.75 3.05 4.58
132 kV 3.05 3.05 3.05 3.05 3.05 4.58
220 kV 4.58 4.58 4.58 4.58 4.58 4.58

3.10 Clearance from Buildings:

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 The line shall preferably be routed away from buildings, huts by at least
15 M. But where this is inevitable the following vertical and horizontal
clearances shall be maintained.
220 kV 110 kV 66 kV
1 Vertical 5.49 M 4.58 M 3.97 M
2 Horizontal 3.66 M 2.75 M 2.14 M

3.11 Miscellaneous:

The line shall be routed so as to be sufficiently away by at least 15 M,

from temples, churches, mosques, other religious institutions, burial
and cremation grounds, cemeteries, archaeological monuments and
other historical landmarks.
4.0 Surveys:

4.1 Reconnaissance:

The route should be reconnoitered by duly taking into consideration

various local factors such as physical features, roads, rivers, etc., and to
provisionally fix a feasible route on the map.
4.2 Preliminary Survey:

The function of the preliminary survey is to ensure that the

reconnoitered route is feasible for execution on the ground. It is
preferable that the preliminary survey be completed using a theodolite.
4.3 Detailed Survey:

The detailed survey involves final theodolite alignment along with chain
survey and levelling.
The final alignment shall be fixed very precisely from angle point to
angle point. Pegs or concrete blocks/pillars shall be driven in to the
ground with only 5 cm projecting at each and every angle point. They

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 may be painted yellow with identification nos. if necessary, for easy
location. These pegs/blocks shall be prevented from damage or
disturbance by stone Cairns. If the stretch between two angle points is
very long then intermediate pegs at an interval of say 1 KM or 0.5 KM
shall be driven into the ground.
The chain survey and levelling shall be conducted either simultaneous
with final theodolite alignment or after completion of final theodolite
alignment. In either case the chain survey and levelling shall follow the
final theodolite alignment. The following details shall be incorporated in
the chain survey and levelling field book.
1) Centre line of the proposed line.

2) LT lines, 11 kV lines, 33 kV lines and EHV lines 66 kV, 110 kV,

220 kV & 400 kV.
3) Telephone and Telegraph lines.

4) Roads.

5) Watercourses, rivers, drainage’s, and channels.

6) Buildings, Huts, etc.

7) Temples, Churches, Mosques, etc.

8) Burial grounds, Cemetery, etc.

9) Swamps, outcrop of rocks.

10) Cross slopes in hilly areas, terrace, etc.

11) Cultivation, wet, dry land etc.

12) Plantation – Rubber, Tea, Cardmum, Coconut, Areca nut,

etc.
13) Type of soil, normal, soft rocky, hard rock, etc.

537456407.doc Page 25
 14) Railway track.

The level shall be taken at frequent intervals, to show the actual contour
of the centerline. Every terrain and change in levels must be shown. If
the ground is fairly level then levels must be taken at 30-M intervals.
Wherever there are slopes cross sectional levels must be taken at right
angles at suitable intervals of 5.0 M and 10.0 M to ensure adequate
clearance of the conductor on the higher slope side.
In hilly regions with peaks and valleys, survey shall be adopted by using
theodolite and levelling staff whereby both the distances and levels at
various points are measured.

5.0 Profile:

After completion of detailed survey namely final theodolite alignment,

chain survey levelling along the alignment and tachometric survey in hill
ranges, the results shall be plotted in continuous centimeter graph
sheet rolls. These rolls shall preferably be 10 M in length and 60 cm in
width. The profile shall be plotted to a scale of 1 cm: 2 m vertical and 1
cm : 20 m horizontal.
The bottom 10 cm shall be utilized for plan and balance for longitudinal
section.
The following details shall be incorporated in the profile.

5.1 L.T. Line and 11 kV Line and Other EHT Lines :

Voltage, number of phases, number of circuits, type of construction,

vertical, triangular or flat, distance of adjoining poles, angle of crossing,
numbers of poles, if any. Height to top most wires from the ground have
to be shown in the levelling sheets to check adequacy of clearance.
5.2 Telephone Lines:

537456407.doc Page 26
 Number of wires whether service, phone, carrier, distance of adjoining
pole and angle – numbers on pole if any. The angle of crossing should
not be less than 600 otherwise the telephone line has to be deviated.
Height of top most wires from the ground has to be shown in the
levelling sheets to check adequacy of clearance.

5.3 Telegraph Lines:

Number of wires whether service, phone, carrier, distance of adjoining

pole and angle – numbers on pole if any. The angle of crossing should
not be less than 600 otherwise the telephone line has to be deviated.
Height of top most wires from the ground has to be shown in the
levelling sheets to check adequacy of clearance.
5.4 Roads:

Whether national highways, state highways, inter district road, minor

metalled road, graveled road, cart track, etc. Type of surface road width,
road limit, LT and telephone lines on road margin.
5.5 Rivers, Water Courses:

M.F.L. – Flood banks – navigable or not – if navigable height of topmost

mast – condition of flood bank – liable to scour or not, protective work, if

any – bridges nearby.

5.6 Irrigation Channels, Drains:

MWL position of bank and height. The bottom of the foundation of the
tower has to be above hydraulic gradient.

537456407.doc Page 27
5.7 Buildings, Huts, Etc.

Accurately up to 15 Mtrs and approximately beyond 15 mtrs up to 30

mtrs – the type and height of roofing. It is desirable to avoid taking the
EHT lines over the buildings. But if it is inevitable the following
minimum clearances have to be obtained over buildings vertical and
horizontal.

Vertical in mtrs. Horizontal in mtrs

66 kV 3.97 2.14
110 kV 4.58 2.75
220 kV 5.5 3.66

5.8 Temples, Churches, Mosques and other religious institution to be

avoided within 15 Mtrs.
5.9 Burial and cremation grounds to be avoided within 15 Mtrs.
5.10 Swamps, outcrop of rocks – precipices – these are to be shown to
avoid location of tower.
5.11 Vertical drops and tenaces – to assess clearances and location of
tower.
5.12 Cross slops – at suitable intervals for assessing clearance of
location of tower to be taken 15 mtrs on either side of the
longitudinal section to be plotted at a separation distance of 5
mtrs above and below for 66 kV and 110 kV lines and 8 mtrs
above and below for 220 kV lines for assessing clearance.
5.13 Type of cultivation – Wet, Dry, etc.

5.14 Type of plantation – Rubber, Tea, Coffee, Cardmum, Coconut,

Arecanut etc.
5.15 Railway Track:

a) Angle of crossing must be at least 600.

537456407.doc Page 28
 b) Between railway station with their names.

c) Whether inside or outside station limits.

d) Whether track has to be electrified/electrified or not.

e) Gauge – Broad Gauge, Narrow Gauge, Meter Gauge.

f) Number of tracks – single, double, etc.

g) Level of top of rail.

h) Clearances expected for the line over the tracks for the line.
6.0 Tower Spotting:

6.1 Sag Template:

KPTCL will furnish the necessary sag – template and tower spotting
charts to the successful bidder on a blue print. The Contractor shall
prepare the same on an acrylic/plastic sheet and submit one copy to the
Engineer for verification of profiles.

6.2 Tower Location:

The tower location shall be marked on the profile using the owner
supplied sag – template and tower spotting chart. The following points
shall be taken into consideration while spotting the tower locations.

6.3 Span:

The number of consecutive spans between the section points shall not
exceed 15 spans or 5 KM in plain country and 10 spans or 3 KM in hilly
terrain Section-A point shall be taken to comprise of a tension point
with ‘B’ type or ‘C’ type tower.

537456407.doc Page 29
6.4 Extensions:

An individual span shall be as near to the normal design span as

possible. In case an individual span becomes too short with normal
supports on account of undulations in ground profile, one or both the
supports of the span may be extended by inserting standard
superstructure extensions (3 M or 6 M extensions) designed for the said
purposes, so that the span is nearer the normal span and within the
designed wind/weight span as per the decision of the owners
representative.
6.5 There shall not be any upward force on suspension towers under
normal working conditions and the suspension towers shall support at
least the minimum weight span as provided in the designs. In case
uplift is unavoidable, it shall be examined if the same can be overcome
by adding standard superstructure extensions to the towers failing
which tension towers shall be employed at such positions.
6.6 Tower Schedule:

The profile sheets duly spotted, along with tower schedules indicating
type of towers, type of foundations, wind span, angle of deviation, river
or road crossing and incorporating other details as in Clause 5.0 shall
be got approved from the owner before execution.

6.7 Check Survey Of Tower Location:

A check survey shall be conducted to make a check on detailed survey

and to relocate, if found necessary, the tower positions on ground
conforming to the approved profile and tower schedule. In the process,

537456407.doc Page 30
 it is necessary to have the pit centres peg marked. The contractor shall
prepare the route alignment maps, tower schedules and tower profiles
and submit the same to the owner for approval.

*****

537456407.doc Page 31
 SECTION – IIIA
(VOLUME – II)

TECHNICAL SPECIFICATIONS
FOR

TRANSMISSION LINE TOWERS

537456407.doc Page 32
 VOLUME-II

SECTION-IIIA

DETAILED TECHNICAL SPECIFICATIONS FOR

TRANSMISSION LINE TOWERS

1.0 SCOPE
2.0 STANDARDS
3.0 STATUTORY REQUIREMENTS
4.0 MATERIALS
5.0 TOWER DESIGNS
6.0 TOWER TYPES AND FABRICATION / ERECTION MARK
7.0 FABRICATION
8.0 DRILLING AND PUNCHING
9.0 GALVANIZING
10.0 FASTERNERS: BOLTS, NUTS AND WASHERS
11.0 TOWER ACCESSORIES
12.0 PACKING
13.0 TOWER FOUNDATIONS

537456407.doc Page 33
 VOLUME – II

SECTION–IIIA

DETAILED TECHNICAL SPECIFICATIONS FOR

TRANSMISSION LINE TOWERS

1.00 SCOPE:

This specification covers the preparation of fabrication/shop drawings,

fabrication, galvanizing, Supply and delivery to site of power
transmission line supporting structures (towers) including the supply of
galvanised bolts and nuts, washers and tower accessories.
It is proposed for Construction of Combined package of
following Replacement of existing ACSR conductors by HTLS conductor
including Supply of all Materials/Equipments and Erection (Including Civil
Works) of all Materials/Equipments, Testing and Commissioning and buy back of
released materials on Total Turnkey basis
A: Replacing the existing 66kV DC Coyote ACSR
conductor by High Temperature Low Sag conductor
(HTLS) between 220/66/11kV Hebbal station and
66/11kV ITI sub station for a distance of
14.334kms. in Bangalore East Taluk, Bangalore
Urban District on Total Turnkey Basis.
B: Replacement of the existing Lynx conductor by High
Temperature Low Sag (HTLS) conductor suitable for
Coyote in the existing 66kV Peenya-Brindavan SC
line for a distance of 3.0kms. in Bangalore North
Taluk, Bangalore Urban District on Total Turnkey
Basis

2.00 STANDARDS:
Notwithstanding anything contained in the succeeding clauses the
fabrication, galvanising and supply of towers and tower accessories shall

537456407.doc Page 34
 conform to the following Bureau of Indian Standard Specifications (BIS
or IS) with their latest amendments thereof:
IS 209
Code of practice for use of structural steel in
IS 800
Building construction
Use of structural steel in overhead transmission line
IS 802 (Part-1/Sec-1) – 1995
towers
IS 802 (Part-2) – 1977 Fabrication, Galvanising, Inspection and Testing
Dimensions for rolled steels, beams, columns,
IS 808 – 1989
channel and angle sections
IS 1239 – 1968–Part-I Mild Steel Tubes
Hexagonal head bolts, screws and nuts of product
IS 1363 (Part – 3) – 1992
grade C.
Mechanical properties and test methods for nuts
IS 1367 (Part – 6) – 1980
with specified loads
IS 1367 (Part – 13) – 1985 Hot dip galvanised coatings on threaded fasteners
IS 1573 – 1986 Electroplated coatings of Zinc on iron and steel
IS 1730 – 1989 Dimensions for steel plates, sheets strips and flats
IS 2062 – 1992 Steel for general structural purposes
IS 2551 – 1982 Danger Notice Plates
Methods of testing of uniformity of Zinc coating on
IS 2633 – 1972
Zinc coated articles
Single coil rectangular section spring washers for
IS 3063 – 1972
bolts, nuts and screws
IS 3757 – 1985 High strength structural bolts
Code of practice for high strength bolts in steel
IS 4000 – 1992
structures
Hot dip zinc coatings on structural steel and other
IS 4759 – 1984
allied products
Code of practice for design installation and
IS 5613 (Part-2/Sec-I)–1985 maintenance of overhead lines (Part-2 – Lines above
11 kV and up to and including 220 kV)
IS 5624 – 1970 Foundation bolts
IS 6610 – 1972 Heavy washers for steel structures
IS 6623 – 1985 High strength structural nuts (first revision)
IS 6639 – 1972 Hexagonal bolts for steel structures
Hardened and tempered washers for high strength
IS 6649 – 1983
structural bolts and nuts (first revision)
Structural steel – Micro-alloyed (Medium and high
IS 8500 – 1992
strength qualities) (First revision)
IS 10238 – 1982 Step bolts for steel structures
IS 12427 – 1988 Transmission line tower bolts

537456407.doc Page 35
3.0 STATUTORY REQUIREMENTS:

In accordance with clauses 3.1 & 3.2 of IS 802(Part-1/Sec-1).

4.0 MATERIALS:

4.1 Structural Steel:

The structural steel to be used shall be in accordance with clauses 5.1

and 5.1.1 of IS 802 (Part-1/Sec-1), that is steel conforming to IS 2062,
Grade-A designated Fe 410WA.
4.2 Bolts:

In accordance with sub-clauses 5.2.1 to 5.2.4 of IS 802 (Part-1/Sec-1),

only 16 mm and 12 mm etc dia bolts shall be used for the entire tower
assembly as per Bill of Materials.
4.3 Nuts:

In accordance with sub-clauses 5.3.1 to 5.3.2 of IS 802 (Part-1/Sec-1).

4.4 Washers:

In accordance with sub-clauses 5.4.1 to 5.4.2 of IS 802 (Part-1/Sec-1).

4.5 Galvanisation:

In accordance with sub-clauses 5.5.1 to 5.5.3 of IS 802 (Part-1/Sec-1).

4.6 Other Materials:

The other materials to be used in the construction and erection of the

tower are the tower accessories such as number plates, circuit plates,
phase plates, danger boards, earthing materials, anti-climbing devices.
These are detailed separately under supply of tower accessories.

5.00 TOWER DESIGNS:

537456407.doc Page 36
 Design of Normal Towers and +3M & +6M Body extensions along with
FOUNDATIONS are not in the scope of this specification. However,
KPTCL has standardized 220kvD/C, 110KvD/C and 66Kv D/C towers
of M/s. Kalpataru make for all the ongoing works of EHV transmission
lines in the state. The Structural drawings along with the BOM and also
the foundation drawings of the towers will be furnished to the successful
bidder and he shall make the proto type assembly of each type tower
and offer the same for proto inspection by the purchaser. The mass
fabrication shall be taken only after the approval of proto assembly.
However, in case, other types of towers or extension pieces (+9M or
+12M or +15M Etc.,) other than the ones furnished , the successful
bidders shall prepare such design/drawings as per IS 802-1977 and
submit the same for approval. The loading trees of the normal tower, if
required, will be furnished to the bidder for the above purpose.

I WEIGHT OF 220 kV DC TOWERS & BODY EXTENSIONS IN KG

220 kV DC 220kV DC 220 kV DC 220 kV DC

Sl. ‘DA’ ‘DB’ ‘DC’ ‘DD’
No Super Bolt & Super Bolt & Super Bolt & Super Bolt &
. Structure Nuts Structur Nuts Structur Nuts Structur Nuts
.
1 Normal
3281.00 115.00 5083.00 187.00 5759.00 215..00 7156.00 268.00
Tower
2 +3M
463.00 15.00 925.00 28.00 1167.00 33.00 1435.00 39.00
Extn.
3 +6M
861.00 23.00 1478.00 35.00 2073.00 47.00 2579.00 68.00
Extn
4 Stub 142.00 3.00 244.00 3.00 301.00 3.00 443.00 7.00

537456407.doc Page 37
 130x130x10
110x110x10
110x110x10
100x100x7 110x100x8
100x100x7
100x100x6 75x75x5 150x150x12
110x110x8
90x90x6 70x70x5 130x130x10
100x100x10
80x80x6 80x80x6 110x110x8
Sizes of 70x70x5
65x65x5 100x100x6 90x90x8
90x90x6
Steel 70x70x5 65x65x5 90x90x6
80x80x6
5 Section 50x50x4 65x65x4 75x75x5
75x75x5
used in 55x55x5 60x60x4 70x70x5
65x65x5
mm 55x55x4 75x75x6 65x65x5
60x60x4
45x45x4 55x55x4 55x55x4
55x55x4
45x30x4 90x90x6 50x50x4
45x45x4
60x60x4 50x50x4 45x45x4
50x50x4
65x65x4 75x75x6
45x30x4
45x45x4
45x30x4

537456407.doc Page 38
II A : WEIGHT OF 110 kV DC TOWERS & BODY EXTENSIONS IN KG

110 kV DC 110 kV DC 110 kV DC 110 kV DC

‘DA’ ‘DB’ ‘DC’ ‘DD’
Sl
Super Bolt & Super Bolt & Super Bolt & Super Bolt &
N
Structure Nuts Structur Nuts Structure Nuts Structure Nuts
. . .
1 Normal
1860.00 70.00 3060.00 85.00 3060.00 85.00 4246.00 18000
Tower
2 +3M
327.00 8.00 724.00 10.00 724.00 10.00 1050.00 28.00
Extn.
3 +6M
698.00 18.00 1178.00 22.00 1178.00 22.00 1517.00 36.00
Extn
4 Stub 114.00 1.00 256.00 1.00 256.00 1.00 364 .00 2.00
110x110x10
100x100x8 130x130x12
100x100x8
110x110x10 80x80x6
110x110x10
100x100x10 75x75x5
100x100x10
90x90x6 70x70x5 70x70x5
70x70x5
70x70x5 65x65x4 65x65x5
65x65x4
55x55x5 60x60x4 45x45x4
60x60x4
50x50x5 40x40x4 60x60x4
Sizes of 40x40x4
50x50x4 45x30x4 45x45x4
45x30x4
Steel 45x45x4 50x50x4 60x60x4
50x50x4
5 Section 45x30x4 110x110x8 100x100x8
110x110x8
used in 40x40x4 65x65x5 100x100x6
65x65x5
mm 80x80x6 100x100x7 110x110x8
100x100x7
60x60x5 45x45x4 60x60x4
45x45x4
65x65x5 60x60x5 55x55x4
60x60x5
60x60x4 90x90x6 45x30x4
90x90x6
55x55x4 55x55x5 50x50x4
55x55x5
75x75x5 130x130x10
75x75x5
55x55x4 75x75x6
55x55x4
60x60x5 90x90x6
60x60x4
75x75x5

537456407.doc Page 39
II B : WEIGHT OF 110 kV MC TOWERS & BODY EXTENSIONS IN KG

110 kV MC 110 kV MC
110 kV MC ‘MA’
Sl ‘MC’ ‘MD’
N Super Bolt & Super Bolt & Super Bolt &
Structure Nuts Structure Nuts Structure Nuts
1 Normal
6900.81 312.186 12402.32 422.259 17279.96 511.553
Tower
2 +3M
863.56 32.509 1543.28 44.990 2012.79 49.100
Extn.
3 +6M
1737.28 67.698 2900.80 96.064 3749.51 105.390
Extn
4 +9M
1761.04 66.648 3008.24 96.106 3888.25 105.256
Extn
5 Stub 362.12 4.768 817.44 7.536 1039.36 10.560
45x45x4
45x45x4
45x45x5
45x45x5
50x50x4
50x50x4
50x50x5
50x50x5
55x55x4
45x45x4 55x55x5
55x55x5
45x45x5 60x60x5
60x60x5
50x50x5 65x65x5
65x65x5
50x50x4 65x65x6
65x65x6
55x55x5 70x70x5
75x75x6
Sizes of 60x60x5 75x75x5
80x80x6
65x65x6 75x75x6
Steel 90x90x6
75x75x6 80x80x6
5 Section 90x90x7
80x80x6 90x90x6
used in 90x90x8
90x90x8 90x90x7
mm 100x100x7
100x100x7 90x90x8
110x110x10
110x110x8 100x100x7
130x130x8
110x110x10 110x110x10
130x130x10
130x130x10 130x130x10
130x130x12
130x130x12 130x130x12
150x150x12
150x150x12
150x150x16
150x150x16
150x150x18
200x200x16
200x200x16
200x200x20

537456407.doc Page 40
 III A WEIGHT OF 66 kV DC TOWERS & BODY EXTENSIONS

66 kV DC 66 kV DC 66 kV DC 66 kV DC
‘DA’ ‘DB’ ‘DC’ ‘DD’
Sl.Sl. No. Super Bolt & Super Bolt & Super Bolt & Super Bolt &
Structure Nuts Structure Nut Structur Nuts Structur Nuts
e.
Normal
1 1225.00 55.00 1540.00 52.00 1757.00 62.00 2288.00 82.00
Tower
+3M
2 285.00 10.00
9 384.00 10.00 394.00 11.00 543.00 15.00
Extn.
+6M
3 604.00 15.00 77100 16.00 852.00 18.00 1212.00 33.00
Extn
S4 Stub 67.00 1.00 105.00 1.00 105.00 1.00 153.00 1.00
110x110x8
100x100x6
80x80x6
90x90x6
90x90x6
75x75x5
80x80x6
60x60x4
75x75x5 75x75x6 100x100x7
65x65x5
70x70x5 65x65x4 60x60x4
S Sizes of 40x40x4
55x55x5 65x65x5 90x90x6
50x50x5
Steel 50x50x5 60x60x4 55x55x4
45x45x5
5 Section 50x50x4 55x55x5 50x50x4
100x100x8
used in 55x55x4 55x55x4 75x75x5
100x100x6
mm 40x40x4 50x50x5 60x60x5
110x60x4
45x45x4 45x45x4 45x45x4
55x55x4
45x30x4 45x30x4 45x30x4
45x30x4
40x40x4
50x50x4
50x50x4
130x130x10
75x75x6
90x90x6
75x75x5

537456407.doc Page 41
III B : WEIGHT OF 66 kV MC TOWERS & BODY EXTENSIONS IN KG

66 kV MC ‘MA’ 66 kV MC ‘MC’ 66 kV MC ‘MD’

Sl
N Super Bolt & Super Bolt & Super Bolt &
Structure Nuts Structure Nuts Structure Nuts
1 Normal
4177.65 256.053 6794.38 250.492 8687.51 346.015
Tower
2 +3M
556.56 28.586 1053.84 30.73 1317.20 38.858
Extn.
3 +6M
1200.96 56.620 2222.52 68.023 2664.36 90.880
Extn
4 +9M
1295.04 57.063 2300.88 68.023 2779.56 95.272
Extn
5 Stub 297.36 2.384 549.44 7.152 711.72 10.048
40x40x6
45x45x4
45x45x4
45x45x5
45x45x5
50x50x4
45x45x4 50x50x4
50x50x5
45x45x5 50x50x5
60x60x5
50x50x5 60x60x5
65x65x6
Sizes of 60x60x5 65x65x6
75x75x6
65x65x6 75x75x5
Steel 80x80x6
75x75x6 75x75x6
5 Section 90x90x8
90x90x6 80x80x6
used in 110x110x8
90x90x7 90x90x6
mm 110x110x10
100x100x8 110x110x10
130x130x10
110x110x10 130x130x12
130x130x12
110x110x12 150x150x12
150x150x12
150x150x16
150x150x16
150x150x18
150x150x20

537456407.doc Page 42
IV FOUNDATION VOLUMES FOR 66KV D/C TOWERS
(Common for Normal, +3M, & +6M Body Extension Towers)
Type of Soil/ Tower Concrete Mix. Earth Exvn. Steel Re inf
Foundation Type in CMT/Twr in CMT/Twr in Kg/Twr.
1:2:4 1:3:6
Normal DA 1.54 - 14.2 -
DRY DB 2.08 - 20.6 -
DC 2.64 - 27.65 -
DD 4.03 - 41.07 -
Normal DA 3.5 - 23 -
DB 4.72 0.59 38.79 133
WET
DC 5.82 0.72 52.27 166
DD 8.27 1.11 84.27 219
Partially DA 4.51 0.62 36.99 118
DB 6.48 0.93 57.62 175
Sub-Merged
DC 7.83 1.11 75.84 215
DD 10.46 1.51 111.63 274
Fully DA 6.05 O.8 50.69 154
DB 8.37 1.28 76.89 222
Sub-Merged
DC 9.73 1.46 97.2 240
DD 13.04 1.99 142.83 351
Wet DA 8.84 1.36 74 206
DB 11.94 1.91 110 291
Black Cotton
DC 14.03 2.25 144 382
DD 18.9 3.04 212 593
Dry DA 1.9 - 4.99 41
DB 2.5 - 6.2 44
Fissured Rock
DC 2.6 - 7.91 51
DD 4.03 - 17.97 56
Submerged DA 5.91 - 18.98 44
DB 8.95 - 29.23 50
Fissured Rock
DC 10.87 - 42.45 56
DD 16.5 - 67.79 60

537456407.doc Page 43
V - A : FOUNDATION VOLUMES FOR 110KV D/C TOWERS
(Common for Normal, +3M, & +6M Body Extension Towers)
Type of Soil/ Tower Concrete Mix. Earth Exvn. Steel Re inf
Foundation Type in CMT/Twr in CMT/Twr in Kg/Twr.
1:2:4 1:3:6
Normal DA 2.35 - 23.06 -
DB 3.34 - 35.82 -
DRY
DC 4.42 - 43.77 -
DD 7.70 - 66.27 -
Normal DA 5.08 - 41.53 -
DB 8.54 - 66.64 -
WET
DC 9.41 1.22 92.06 260
DD 12.88 1.56 134.87 427
Partially DA 6.69 1.0 61.94 179
DB 8.38 1.2 90.75 248
Sub-Merged
DC 14.62 2.18 155.52 459
DD 15.97 2.42 171.4 615
Fully DA 8.78 1.39 82.98 241
DB 10.55 1.6 117.5 319
Sub-Merged
DC 14.62 2.18 155.5 450
DD 19.42 3.04 211.6 835
Wet DA 12.34 2.04 117.6 359
DB 15.6 2.52 177.8 558
Black Cotton
DC 20.31 3.2 221.86 738
DD 26.43 4.29 291.0 1276
Dry DA 2.01 - 7.59 46
DB 3.41 - 11.62 56
Fissured Rock
DC 4.5 - 20.08 57
DD 7.74 - 34.0 59
Submerged DA 9.96 - 34.9 51
DB 12.56 - 62.06 61
Fissured Rock
DC 17.95 - 72.21 61
DD 14.56 2.18 102.39 509

V-B: FOUNDATION VOLUMES FOR 110KV M/C TOWERS

(Common for Normal, +3M, & +6M Body Extension Towers)
Type of Soil/ Tower Concrete Mix. Earth Exvn. Steel Re inf
Foundation Type in CMT/Twr in CMT/Twr in Kg/Twr.
1:2:4 1:3:6
Normal MA 12.00 1.30 95.00 836
MC 32.8 3.2 225.00 2856
DRY
MD 43.00 4.00 270.00 4148
Normal MA 24.6 2.5 175 1300

537456407.doc Page 44
WET MC 58.9 6.00 390 5100
MD 84.6 7.7 510 8384
Partially MA 28.4 2.9 205 1388
MC 66.7 6.8 450 5832
Sub-Merged
MD 86.0 8.7 575 8676
Fully MA 33.2 3.6 245 1544
MC 75.0 7.7 510 6224
Sub-Merged
MD 105 10 640 9080
Wet MA 33.8 3.6 245 1604
MC 76.0 7.7 510 6468
Black Cotton
MD 96.5 10.0 640 9788
Dry MA 24.2 2.5 130 1252
MC 58.0 6.0 320 4872
Fissured Rock
MD 76.0 7.7 425 8032
Submerged MA 33.8 3.6 185 1608
MC 76.0 7.7 425 6192
Fissured Rock
MD 96.5 10.0 545 9972
Hard Rock MA 13 0 13 396
MC 13.0 0 13 512
MD 14.0 0 14 774

537456407.doc Page 45
 VI FOUNDATION VOLUMES FOR 220KV D/C TOWERS
(Common for Normal, +3M, & +6M Body Extension Towers)
Type of Soil/ Tower Concrete Mix. Earth Exvn. Steel Re inf
Foundation Type in CMT/Twr in CMT/Twr in Kg/Twr.
1:2:4 1:3:6
Normal DA 3.54 - 32.15 -
DRY DB 5.33 - 47.8 -
DC 6.82 - 56.66 -
DD 9.37 1.48 109.44 492
Normal DA 6.14 0.76 50.63 167
DB 10.73 1.27 95.43 294
WET
DC 11.0 1.51 111.63 301
DD 17.34 2.66 187.13 806
Partially DA 9.11 1.12 71.29 226
DB 13.6 1.8 130.68 350
Sub-Merged
DC 13.79 2.02 145.32 431
DD 21.07 3.43 236.5 1270
Fully DA 11.88 1.53 94.25 297
DB 16.8 2.38 168.7 498
Sub-Merged
DC 16.86 2.58 181.59 602
DD 26.67 4.25 289.3 1409
Wet DA 14.14 2.24 133.23 461
DB 22.45 3.39 234.4 704
Black Cotton
DC 23.22 3.72 255 985
DD 34.13 5.64 377.6 2134
Dry DA 6.26 - 24.98 47
DB 11.26 - 47.04 59
Fissured Rock
DC 14.19 - 56.84 60
DD 25.83 - 98.36 62
Submerged DA 11.16 1.8 68.92 310
DB 16.92 2.61 125.26 523
Fissured Rock
DC 18.59 2.96 144.56 734
DD 29.69 4.71 249.8 1706

6.00 TOWER TYPES AND FABRICATION/ERECTION MARK:

i) Single circuit – A, B, C & D.

ii) Double circuit – DA, DB, DC, DD.
iii) Tower types/deviation limit/typical use.

Type of Deviat Typical use

537456407.doc Page 46
 ion
Tower
Limit
A & DA 00 to 20 To be used as tangent tower
a) Angle tower with tension insulator string.
b) Tension tower for uplift forces resulting from
a uplift span up to 200 metres.
c) Power line crossing with a suitable body
B and 0 to
0
extension.
DB 150 d) To be used where unbalanced tension
results due to unequal ruling span of 200
metres and 400 metres on each side of
tower.
e) To be used as section tower.
a) Angle tower with tension insulator.
b) To be used where unbalanced tension
results due to unequal ruling span of 200
C and 150 to
metres and 400 metres on each side of the
DC 300
tower.
c) Tension tower for uplift forces due to uplift
span.
a) Complete dead end.
b) To be used for river crossing with longer
D and 300 to wind span.
DD 600 c) Angle tower with tension insulator.
d) Dead-end with 00 to 150 deviations both on
line and substation side (slack span).

NOTE: The above towers may also be used for longer span with smaller
angle of deviations.
iv) Erection Mark – These shall be done on each member with marking
dies of 16 mm size before galvanizing and shall be legible after
galvanizing. The notation shall be as follows:

A – BB – CC – DDD
A – Owner’s Code – Alphabet – K
BB– Contractor’s Mark – Number
CC – Tower Type Alphabet
DDD – Mark number – Numerical

537456407.doc Page 47
 (v) The three phase conductors of the double circuit tower shall be
in vertical formation (I, I, I)

7.00 FABRICATION:

7.1 The details of fabrication of towers shall be in conformity with IS:802

(Part – II) : 1978 except to the extent modified herein.
7.2 Butt splices shall be used and the inside angle and outside plate shall
be so as to transmit the load and the inside cleat angle shall not be less
than half the thickness of heavier member connected plus 2 mm. Lap
splice may be used for connecting members of unequal size. The inside
angle of lap splice shall be rounded at the heel to fit the fillet of the
outside angle. All splices shall develop full stress in the members
connected through bolts. But as well as lap splice shall be made as
close to the main panel point as possible.
7.3 Joints shall be so arranged as to avoid eccentricity as far as possible.
The use of gusset plates for joining tower members shall be avoided as
far as possible. However, where the connections are such that the
elimination of the gusset plates would result in eccentric joints or where
more than three members are joining at a particular point, gusset plates
and spacer plates may be used in conformity with modern practices.
The thickness of the gusset plates, required to transmit stress, shall not
be less than that of members connected.
7.4 The use of filler in connection shall be avoided as far as possible. The
diagonal web members in tension may be connected entirely to the
gusset plate where necessary to avoid the use of filler and it shall be
connected at the point of inter-section by one or more bolts.
7.5 The tower structures shall be accurately fabricated to bolt together
easily at site without any undue strain on the bolts.

537456407.doc Page 48
 7.6 No angle member shall have the two leg flanges brought together by
closing the angle.
7.7 The structure shall be such that all parts shall be accessible for
inspection and cleaning. Drain holes shall be provided at all points
where pockets of depressions are likely to hold water.
7.8 All similar parts shall be made strictly interchangeable. All steel
sections before any work is done on them, shall be carefully levelled,
straightened and made true to detailed drawings, by methods which will
not injure the materials so that when assembled the adjacent matching
surfaces are in close contact throughout. No rough edges shall be
permitted in the entire structure.
8.00 DRILLING AND PUNCHING:

8.1 Before any cutting work is started, all steel sections shall be carefully
straightened and trued by pressure and not by hammering. They shall
again be trued after being punched and drilled.
8.2 Holes for bolts shall be drilled or punched with a jig but drilled holes
shall be preferred. The following maximum tolerance of accuracy of
punched holes is permissible.
a) Holes must be perfectly circular and no tolerance in this respect is
permissible.
b) The maximum allowable difference in diameter of the holes on the
two sides of plates or angle is 0.8-mm i.e., the allowable taper in
punched holes should not exceed 0.8 mm on diameter.
8.3 All burrs left by drills or punch shall be removed completely. When the
tower members are in position the holes shall be truly opposite to each
other. Drilling or reaming to enlarge defective holes shall not be
permitted.

537456407.doc Page 49
8.4 The strain plate holes shall be chamfered properly and sharp edges
removed.
9.00 GALVANISING:
Fully galvanised towers and stubs galvanised from the top up to 300
mm below ground level shall be used for the lines. Galvanising of the
member of the towers shall conform to IS: 2629-1966 and IS: 4759-
1968. All galvanised members shall withstand tests as per IS: 2633-
1972. For fasteners, the galvanising shall be done after all fabrication
work is completed, except that the nuts may be tapped or re-run after
galvanising. Spring washers shall be electro-galvanised as per Grade 4
of IS: 1573-1070.

10.00 FASTENERS: BOLTS, NUTS AND WASHERS:

10.1 All bolts and nuts shall conform to IS: 6639 –1972 or IS: 12427 –
1988 as applicable and shall be of approved makes only. All bolts and
nuts shall be galvanised and shall have hexagonal heads and nuts. The
heads shall be forged out of the solid, truly concentric, and square with
the shank, which must be perfectly straight. The following makes are
approved:
1. M/s. GKW, Calcutta.
2. M/s. Raj Enterprises, Indore.
3. M/s. Agarwal Industries, Howrah.
4. M/s. Bharat Industries, Howrah.
5. M/s. NEXO Industries, Ludhiana.
6. M/s. Indian Steel & Wire Products (ISWP), Jamshedpur.
10.2 Fully threaded bolts shall not be used. The length of bolts shall be
such that the threaded portion will not extend into the place of contact
of the members. All bolts shall be threaded to take the full depth of the

537456407.doc Page 50
 nut and threaded enough to permit firm gripping of the members, but
not further. It shall be ensured that the threaded portion of each bolt
protrudes not less than 3 mm and not more than 8 mm when fully
tightened. All nuts shall fit hand tight to the bolt. Threads of bolts and
nuts shall have a neat fit and shall be such that they can be turned with
finger through out the length of the threads of bolts and they shall be
capable of developing full strength of the bolts.
10.3 Flat and tapered washers shall be provided wherever necessary.
Spring washers shall be provided for insertion under all nuts. These
washers shall be of steel electro-galvanised, positive lock type and as
specified in Bill of Materials.
10.4 The contractor shall furnish bolt schedules giving thickness of
members connected, the nut and the washer, the length of shank, the
threaded portion of bolts and sizes of holes and any other detail of this
nature.
10.5 The bolts shall be of class 5.6 and nuts shall be of property class
5. The ultimate shear stress and bearing stress on bolts shall be 3160
Kg/Sq.cm and ultimate bearing stress shall be as per IS.
10.6 To obviate bending stress in bolts or to reduce it to minimum, no
bolt shall connect aggregate thickness of more than three (3) times its
diameter.
10.7 Bolts at the joints shall be so staggered that nuts may be tightened
with spanners without fouling.
10.8 The minimum bolt spacing and rolled edge distance and sheared
edge distances of sections from the centres of bolt holes to be
maintained are given in Table below:

537456407.doc Page 51
 Diameter Hole Minimum Minimum Minimum
of bolts diameter bolt rolled sheared edge
(mm) (mm) spacing(mm) distance distance
(mm) (mm)
16 17.5 40 20 23
12 13.5 32 16 20

11.00 TOWER ACCESSORIES:

11.1 Step Bolt Ladders:

Each tower shall be provided with step bolts on one of the main legs, of
not less than 16 mm diameter and 175 mm long, spaced not more than
450 mm apart and extending from about 3.5 metres above the ground
level to the top of the tower. Each step bolt shall be provided with two
nuts on one end to fasten the bolt securely to the tower and button head
at the other end to prevent the feet from slipping away. The step bolts
shall be capable of withstanding a vertical load not less than 1.5 KN and
shall be used as a ladder for climbing. The step bolts shall conform to
IS 10238 and shall have a hexagonal head.
11.2 Anti-climbing devices:

Fully galvanised barbed wire type anti-climbing device shall be provided

at a height of approximately 3 metres as an anti-climbing measure.
Four layers of barbed wires will be provided each inside and outside the
tower in horizontal plane, spacing between the layers being 140 to 150
mm. The angle pieces with 12 mm x 12-mm notches for accommodating
barbed wire shall be supplied with the towers along with provision for
suitable bolt holes on leg members for fitting the angles. The barbed
wire shall conform to IS-378 (1978). The anti-climbing devices shall in
general conform to Fig-8 of IS-5613 (Part-II/Sec-I).
11.3 Insulator strings and ground wire clamp attachments:

537456407.doc Page 52
 a) For the attachment of suspension insulator strings a suitable
swinging hanger on the tower shall be provided so as to obtain
requisite clearance under extreme swinging conditions and free
swinging of the string. The hanger shall be designed to withstand an
ultimate tensile strength of more than 90 KN.
b) For ground wires at suspension towers suitable ‘U’ Bolts strong
enough to withstand the full designed loads shall be provided to
accommodate the hook of the ground wire suspension clamps.
c) At tension towers, horizontal strain plates of suitable dimensions on
the underside of each power cross-arm tip and at the top ground wire
peak shall be provided for taking the ‘D’ shackles of the tension
insulator strings or groundwire tension clamps, as the case may be.
11.4 Caution Plates, Number Plates, Circuit Plates and Bird Guards:

Each tower shall be fitted with Number Plates, Caution Plates (Danger
Boards), Circuit plates and phase plates. These shall be provided at
appropriate level from the ground level (about 2.5 m to 3.5 m from
ground level) so that the man standing at the foot ground tower will be
able to clearly identify the same. These plates shall be 2 mm thick and
vitreous enameled on both back and front.
The letters, figures and the conventional skull and bones on danger
plates are in signal red on the front side. On the number plate, the
number of the tower location preceded by the letters defining the type of
the tower shall be inscribed. Phase plates shall be coloured red, yellow
and blue to indicate the phase of the conductor. The letters on number
plates shall be in red against white background. The number plates
shall confirm to Fig-5 of IS: 5613 (Part-II/Sec-I). Similarly the plates
and circuit plates to Figs. 6 & 7 in the said IS. The danger notice plates

537456407.doc Page 53
 shall confirm to IS: 2551. Bird guards shall be of the saw tooth type
and confirm to Fig.10 of IS (5613 Part-II/Sec-I).
11.5 Earth Bonds:

Earth bonds shall generally conform to drawing No.ECC(P)/MISC. 10

attached hereto and shall be supplied in lengths of 300 mm and 450
mm for use on suspension and tension towers respectively. These earth
bonds shall be designed to carry a minimum current of 100 Amps.
11.6 Earthing:

Normal and counter poise earthing:

This shall be in accordance with clauses 11.0 and sub-clauses there of

as per IS:5613 Part-2/Sec-2, corresponding to figure 6 and where the
desired tower footing resistance cannot be achieved, then it shall be by
counter poise earthing corresponding to fig-9 in the said IS.
11.7 Stub Setting Template:

Stub setting templates shall be arranged for by the contractor at his own
cost for all types of towers with or without extensions.
Stub templates for standard towers and towers with extensions shall be
of the adjustable type. All stub templates shall be painted with anti-
corrosive paints. The number of stub templates to be fabricated shall be
decided by the contractor to coincide with the approved erection
programme.

12.00 PACKING:

12.1 The material shall be boxed or bundled for transport as per IS 802 (Part-
II) – Clause – 11 and sub-clauses thereof. However

537456407.doc Page 54
 a) Angles shall be packed in bundles securely wrapped four times
around at each and every foot with No. weight of any bundle shall
not exceed approximately 450 Kg and the length of any individual
member not more than 6000 mm.
b) Cleat angles, brackets, filler plates and similar small loose pieces
shall be nested and bolted, together in multiples and securely wired
together through holes, wrapped round at least four times with No.9
SWG wire with ends twisted tightly. Gross weight of each bundle
shall not exceed approximately 70 Kgs.
c) The correct number of bolts, nuts and washers plus 10% excess for
each tower, extensions, cross arms, attachment to cross arms, etc.
shall be packed in heavy gunny bags accurately tagged in accordance
with the contents. 4 number of such bags shall be packed in a solid
box of 22 mm thick lumbered work with paneled ends securely nailed
and further reinforced with 22 mm x 75 mm battens round the sides,
at the ends with 25 mm wire No.18 SWG gauge iron band stretched
entirely around the battens with ends over lapping at least 150 mm.
The gross weight of each box shall not exceed approximately 70 Kgs.
All packaging shall be subject to the approval of the owner.
12.2 Marking of packings:
Each bundle or package shall have the following markings on it.
a) The name designation of the consignee.
b) Ultimate destination as required by the owner.
c) The relevant marks and number of tower members, or reference
number of bolts, nuts and small components like gusset plates,
various attachments, etc for easy identification.

537456407.doc Page 55
 The marking shall be stenciled in indelible ink on the top members in
the bundles of tower steel and on wooden boxes or gunny bags
containing smaller components.
Detailed despatch instructions shall be sought for by the contractor
from the owner at least four weeks ahead of the schedule date of
despatch.

13.0 TOWER FOUNDATIONS:

No design of foundation is envisaged in the specification. Detail
foundation drawing for each type of Tower, for all types of soil, will be
furnished to the successful bidder, by KPTCL. However, for the purpose
of quoting, the foundation quantities per tower are tabulated in Bid
Proposal Sheets.

In case of any other type of foundation other than given in the

specification is required then the contractor shall design the required
foundations and send the same to the owner for approval. The designs
shall be in accordance with IS-4091 with latest amendments. The factor
of safety to be adopted shall be 2.0 under Broken and conditions 2.5 for
normal conditions. The owner will supply the drawings of foundations
for Normal towers, 3M and 6M extension only for which the volumes are
indicated in the Bid proposal sheets. For other types such as 9M, 12M,
15M, 18M extensions and special river crossing towers etc., the tenderer
shall design the required foundations and indicate the ceiling volumes
and weights in the Data requirement sheets and Bid proposal for all
types of soils.

537456407.doc Page 56
 In respect of Black cotton soil, the foundations shall be designed for wet
conditions only i.e.-for Wet Black cotton soil only. However, for
excavations, payment shall be made based on the rates for Normal dry if
the soil is dry and based on the rates quoted for wet black cotton soil if
the soil is wet.

SECTION – IIIB
(VOLUME – II)
537456407.doc Page 57
 TECHNICAL SPECIFICATIONS
FOR

FABRICATION AND GALVANISATION OF

66KV D/C NARROW BASE TOWERS (KPTCL
DESIGN)

537456407.doc Page 58
 VOLUME – II

SECTION–IIIB

DETAILED TECHNICAL SPECIFICATIONS FOR FABRICATION AND

GALVANISATION OF 66KV D/C NARROW BASE TOWERS (KPTCL DESIGN)

(GENERAL)

1.0 Scope:
The scope of the work includes the supply
of 66KV D/C Narrow Base towers which includes the
following
a. Fabrication & Galvanization of steel sections
b. Assembly of proto-type and offer the same for
inspection by KPTCL
c. Supply of 16mm dia Galvanized Bolt & Nuts
conforming to class 5.6 of IS:12427
d. Supply of tower accessories like step bolts.
Hangers, D-shackle, flexible copper bonds,
number plate, phase plate, circuit plate and
danger plate etc.
e. Packing and dispatch

2.0 66KV D/C Narrow Base Towers :

No design of towers is envisaged

in the specification. KPTCL has developed 66KV
D/C Narrow Base tower type ‘DA’, ‘DC’ & ‘DD’
suitable for ACSR COYOTE conductor for normal span
of 250 Mts.
The weight of Normal tower with
stub, ‘+3M’ & ‘+6M’ body extensions, stub setting
template and bolts & nuts for all three types of
towers has been furnished in the specification to
enable the bidder to quote.
The bidder has to fabricate the
towers strictly as per the structural drawing.
The structural drawings along with the Bill of
Materials pertaining to all the three type of
towers will be furnished to the successful bidder

537456407.doc Page 59
 after awarding the contract. However the line
diagram showing the configuration, dimensions and
size of steel section of all the three types of
towers are enclosed with the specification.

Foundations:

The foundation design for all three type of

towers for various types of soil have been
developed by KPTCL and volumes of concrete, earth
excavation and steel reinforcement is furnished in
the specification. The foundation drawings will
be furnished to the successful bidder after
awarding the contract. The bidder shall strictly
follow the foundation drawings and cast the
foundation accordingly.

DESIGN PARAMETERS of 66KV D/C NARROW BASED

TOWERS

Technical details

Conductor & ground wire AAAC 7/3.15m

used “Moose” m GW
Normal span in M 140 140
Wind Span in M 140 140
Weight Span in M (NC)
a) Max 210 210
b) Min. 70 -210
Maximum Sag in M 4.401 3.076
Tension at 320 C, Still
1227 373
air in kg
Max. Dgn. Tension at
2000 730
320 C, FW (kg)
Maximum Temp in deg.C 85 53
Design wind pressure
75 91
(kg/sq.m)

537456407.doc Page 60
 BASE WIDTH OF THE NORMAL TOWER
TYPE .

The ‘Back to Back’ width of the tower at Plinth

Level are

Particulars ‘A’type ‘C’ type ‘D’

type
Base width of the 1.4 1.6 1.8
Normal tower in M.

The weight of Normal Tower, Extension pieces and

the summary of steel sections adopted for each
type of tower are tabulated as follows

Section summary of weights for 66KV D/C

Narrow based towers- KPTCL design

Sl Type of tower
No. NB-DA NB-DC NB-DD
Section
(Wt. In (Wt. In (Wt. In
Kg) Kg) Kg)
Stub
1 150x150x16 - - 498.19
2 150x150x12 - 376.45 -
3 100x100x8 161.80 - 55.18
4 100x100x6 - 41.95 -
65x65x6 17.17 - -
Total
179 418.40 553.37
NORMAL TOWER
1 45x45x5 804.09 330.5 314.03
2 50x50x5 - 606.0 -
3 50x50x6 252.44 - 360.00
4 60x60x5 - - 204.95
5 65x65x6 129.16 274.2 727.11
6 75X75x8 123.78 - -
7 90x90x8 212.63 248.7 245.99
8 100X100X8 226.27 - -

537456407.doc Page 61
 9 130x130x10 - 497.2 -
10 130x130x12 - - 551.45
11 150x150x12 - 576.55 -
12 150x150x16 - - 841.16
13 2mm
thickness
plate - 2.36 -
14 4mm
thickness
plate - - 5.43
15 6mm
thickness
plate 42.34 60.00 59.248
16 8mm
thickness
plate 33.64 - -
17 10mm
thickness
plate - 6.0 5.72
18 12mm
thickness
plate - 61.75 112.84
19 16mm
thickness
plate - 46.76 -
Total 1824.39 2710.02 3427.928
STUB SETTING TEMPLATE
1 150X150X16 - - 140.19
2 150X150X12 - 87.04 -
3 100X100X8 40.66 - -
4 65X65X6 - 85.17 94.19
5 45x45x5 8.85 81.11 101.7
Total 200.23 253.32 336.08
+3 M BODY EXTENSION
1 150x150x16 - - 429.03
2 150X150X12 - 325.96 -
3 130X130X10 36.72 -
4 130X130X12 - - 43.62
5 100X100X8 145.00 - -
6 90x90x8 13.65 - -
537456407.doc Page 62
 7 65x65x6 - - 166.07
8 50X50X5 - 167.65 -
9 45x45x5 159.91 - 109.35
10 8mm
thickness
plate 14.29 - -
11 12mm
thickness
plate - 33.01 33.01
Total 332.85 563.43 781.08
+6 M BODY EXTENSION
1 150X150X16 - - 859.05
2 150X150X12 - 652.69 -
3 130X130X12 - - 43.62
4 130X130X10 - 36.72 -
5 100X100X8 290.31 - -
6 90x90x8 13.65 - -
7 65x65x6 - - 336.47
8 50X50X5 - 352.78 -
9 45x45x5 330.88 53.46 218.7
10 6mm
thickness
plate - 3.81 -
11 8mm
thickness
plate 4.29 - -
13 12mm
thickness
plate - 33.01 33.01
Total 649.13 1132.47 1490.85

FOUNDATION VOLUMES

Type Earth M20 M10 Steel

Tower Type of exvn.
Soil Cmtr Cmtr Cmtr Kgs
NBDA+0M, NDS 32.67 5.44 0.45 198.4
PSS 50.43 7.34 0.72 313
537456407.doc Page 63
 FSS 48 7.1 0.68 288
Wet 48 7.1 0.68 288
WBC 52.9 7.61 0.76 323
DFR 16.38 4.35 0.33 168.74
SFR 28.02 7.14 0.57 268.4

NBDC+0M, NDS 63.48 11.77 0.92 492.37

PSS 94.08 16.65 1.4 774
FSS 97.49 16.07 1.45 820
Wet 90.75 15.95 1.35 735
WBC 99.18 17.37 1.48 877
DFR 34.24 10.03 0.7 481.9
SFR 58.18 18.33 1.25 842.9

NBDD+0M, NDS 84.3 17.61 1.25 886

PSS 126.75 25.56 1.92 1264
FSS 130.68 26.35 1.98 1342
Wet 122.9 24.8 1.86 1197
WBC 138.7 27.97 2.1 1556
DFR 55.96 17.02 1.15 802
SFR 95.22 27.24 1.92 1349

2.1 APPLICABLE STANDARDS:

Notwithstanding anything contained in the succeeding clauses the design,
fabrication, galvanizing and supply of towers and tower accessories shall
conform to the following Bureau of Indian Standard Specifications (BIS or
IS) with their latest amendments thereof:

IS- Number Particulars

IS 209 Zinc
IS 278 Specifications for Barbed wires.
Course and fine aggregates from natural
IS 388
sources and concrete
Mild steel and medium tensile bars and hard
IS 432
drawn steel wire for concrete reinforcement

537456407.doc Page 64
 Code of practice for plain and reinforced
IS 456
concrete.
Code of practice for use of structural steel
IS 800
in building construction
Use of structural steel in overhead
IS 802 (Part-1/Sec-1)
transmission line towers
– 1995
Materials, Loads and Permissible stresses
Fabrication, Galvanizing, Inspection and
IS 802 (Part-2) – 1977
Testing
Dimensions for rolled steels, beams,
IS 808 – 1989
columns, channel and angle sections
IS 1239 – 1968–Part-I Mild Steel Tubes
Hexagonal head bolts, screws and nuts of
IS 1363 (Part – 3) – 1992
product grade C.
Mechanical properties and test methods for
IS 1367 (Part – 6) – 1980
nuts with specified loads
IS 1367 (Part – 13) Hot dip galvanized coatings on threaded
– 1985 fasteners
Electroplated coatings of Zinc on iron and
IS 1573 – 1986
steel
Dimensions for steel plates, sheets strips and
IS 1730 – 1989
flats
IS-Number Particulars

Recommended practice for hot dip

IS 2629
galvanizing of steel & iron
Steel general structural purposes (Low,
IS 2062 – 2006
Medium & High strength qualities)
IS 2551 – 1982 Danger Notice Plates
Methods of testing of uniformity of Zinc
IS 2633 – 1972
coating on Zinc coated articles
IS 3043 Code of practice for earthing
Single coil rectangular section spring
IS 3063 – 1972
washers for bolts, nuts and screws
IS 3757 – 1985 High strength structural bolts
Code of practice for high strength bolts in
IS 4000 – 1992
steel structures
Code of practice for design and construction
IS 4091
of foundation, For transmission line towers.
Hot dip zinc coatings on structural steel and
IS 4759 – 1984
other allied products
IS 5358 Hot dip galvanized coating on fasteners.

537456407.doc Page 65
 Code of practice for design installation and
IS 5613 (Part-2/Sec-I) maintenance of overhead lines (Part-2 –
–1985 Lines above 11 kV and up to and including
220 kV)
IS 5624 – 1970 Foundation bolts
IS 6610 – 1972 Heavy washers for steel structures
IS 6623 – 1985 High strength structural nuts (first revision)
IS 6639 – 1972 Hexagonal bolts for steel structures
Hardened and tempered washers for high
IS 6649 – 1983 strength structural bolts and nuts (first
revision)
Method determination o f weight of zinc
IS 6745
coating Of zinc coated iron and steel articles
IS 10238 – 1982 Step bolts for steel structures
IS 12427 – 1988 Transmission line tower bolts

Reference
/Abbr Name and address from which
eviat the standards are available
ion
BUREAU OF INDIAN STANDARS,
Manak Bhavan,
IS
New Delhi
INDIA
CANADIAN STANDARDS
ASSOCIATION
CSA 178,Rexdale Boulevard
Ontario
CANADA
BRITISH STANDARDS
British Standard Institution
BS
Pentonvile Road
U.K.

537456407.doc Page 66
 DEUTSCHES INSTITUTE FIIR NOR
Gurggarafenstrasse 4-10
DIN
Post Fach 1107
BERLIN-30

3.0 MATERIALS:

3.1 STRUCTURAL STEEL:

12.1 ISS steel sections of tested quality in conformity with IS-2062-2006 (for
both MS and HT steel) with dimensional and section properties
conforming to IS 808-1976 Part V & VI shall be used in the design of
tower members, stubs and stub setting templates. No individual member
length shall more than 6000mm. Tower designs shall be made with only
rationalized steel sections. However during fabrication if any particular
section is not available the same shall be substituted by a higher section at
no extra cost. However, design approvals for such substitution shall be
obtained from the purchaser.

12.3 It shall be the Contractor’s responsibility to arrange for procurement of

structural steel. No extra payment shall be made, in case the Contractor
uses superior quality structural steel for fabrication of tower members due
to any reasons whatsoever.
3.2 BOLTS:
In accordance with sub-clauses 5.2.1 to 5.2.4 of IS 802 (Part-1/Sec-1),
only 16 mm dia bolts shall be used for the entire tower assembly.
3.3 NUTS:
In accordance with sub-clauses 5.3.1 to 5.3.2 of IS 802 (Part-1/Sec-1).
3.4 WASHERS:

In accordance with sub-clauses 5.4.1 to 5.4.2 of IS 802 (Part-1/Sec-1

3.5 GALVANIZATION:
3.6 In accordance with sub-clauses 5.5.1 to 5.5.3 of IS 802 (Part-1/Sec-1)
3.7 OTHER MATERIALS:

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 The other materials to be used in the construction and erection of the tower
are the tower accessories such as number plates, circuit plates, phase
plates, danger boards, earthing materials, anti-climbing devices. These are
detailed separately under supply of tower accessories.

3.0 FABRICATION:

3.1 The details of fabrication of towers shall be in conformity with IS:802

(Part – II) : 1978 except to the extent modified herein.
3.2 Butt splices shall be used and the inside angle and outside plate shall be so
as to transmit the load and the inside cleat angle shall not be less than half
the thickness of heavier member connected plus 2 mm. Lap splice may be
used for connecting members of unequal size. The inside angle of lap
splice shall be rounded at the heel to fit the fillet of the outside angle. All
splices shall develop full stress in the members connected through bolts.
But as well as lap splice shall be made as close to the main panel point as
possible.
3.3 Joints shall be so arranged as to avoid eccentricity as far as possible. The
use of gusset plates for joining tower members shall be avoided as far as
possible. However, where the connections are such that the elimination of
the gusset plates would result in eccentric joints or where more than three
members are joining at a particular point, gusset plates and spacer plates
may be used in conformity with modern practices. The thickness of the
gusset plates, required to transmit stress, shall not be less than that of
members connected.
3.4 The use of filler in connection shall be avoided as far as possible. The
diagonal web members in tension may be connected entirely to the gusset
plate where necessary to avoid the use of filler and it shall be connected at
the point of inter-section by one or more bolts.

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 3.5 The tower structures shall be accurately fabricated to bolt together easily at
site without any undue strain on the bolts.
3.6 No angle member shall have the two leg flanges brought together by
closing the angle.
3.7 The structure shall be such that all parts shall be accessible for inspection
and cleaning. Drain holes shall be provided at all points where pockets of
depressions are likely to hold water.
3.8 All similar parts shall be made strictly interchangeable. All steel sections
before any work is done on them, shall be carefully leveled, straightened
and made true to detailed drawings, by methods which will not injure the
materials so that when assembled the adjacent matching surfaces are in
close contact throughout. No rough edges shall be permitted in the entire
structure.

4.00 DRILLING AND PUNCHING:

4.1 Before any cutting work is started, all steel sections shall be carefully
straightened and trued by pressure and not by hammering. They shall
again be trued after being punched and drilled.
4.2 Holes for bolts shall be drilled or punched with a jig but drilled holes shall
be preferred. The following maximum tolerance of accuracy of punched
holes is permissible.
c) Holes must be perfectly circular and no tolerance in this respect is
permissible.
d) The maximum allowable difference in diameter of the holes on the two
sides of plates or angle is 0.8-mm i.e., the allowable taper in punched
holes should not exceed 0.8 mm on diameter.
4.3 All burrs left by drills or punch shall be removed completely. When the
tower members are in position the holes shall be truly opposite to each

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 other. Drilling or reaming to enlarge defective holes shall not be
permitted.
4.4 The strain plate holes shall be chamfered properly and sharp edges
removed.

5.0 GALVANISING:
Fully galvanized towers and stubs galvanized from the top up to 300 mm
below ground level shall be used for the lines. Galvanizing of the member
of the towers shall conform to IS: 2629-1966 and IS: 4759-1968. All
galvanized members shall withstand tests as per IS: 2633-1972. For
fasteners, the galvanizing shall be done after all fabrication work is
completed, except that the nuts may be tapped or re-run after galvanizing.
Spring washers shall be electro-galvanized as per Grade 4 of IS: 1573-
1070.

6.0 FASTENERS: BOLTS, NUTS AND WASHERS:

6.1 All bolts and nuts shall conform to IS: 6639 –1972 or IS: 12427 – 1988 as
applicable and shall be of approved makes only. All bolts and nuts shall
be galvanized and shall have hexagonal heads and nuts. The heads shall
be forged out of the solid, truly concentric, and square with the shank,
which must be perfectly straight. The following makes are approved:
7. M/s. GKW, Calcutta.
8. M/s. Raj Enterprises, Indore.
9. M/s. Agarwal Industries, Howrah.
10. M/s. Bharat Industries, Howrah.
11. M/s. NEXO Industries, Ludhiana.

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 12. M/s. Indian Steel & Wire Products (ISWP), Jamshedpur.
6.2 Fully threaded bolts shall not be used. The length of bolts shall be such
that the threaded portion will not extend into the place of contact of the
members. All bolts shall be threaded to take the full depth of the nut and
threaded enough to permit firm gripping of the members, but not further.
It shall be ensured that the threaded portion of each bolt protrudes not less
than 3 mm and not more than 8 mm when fully tightened. All nuts shall fit
hand tight to the bolt. Threads of bolts and nuts shall have a neat fit and
shall be such that they can be turned with finger through out the length of
the threads of bolts and they shall be capable of developing full strength of
the bolts.
6.3 Flat and tapered washers shall be provided wherever necessary. Spring
washers shall be provided for insertion under all nuts. These washers shall
be of steel electro-galvanized, positive lock type and as specified in Bill of
Materials.
6.4 The contractor shall furnish bolt schedules giving thickness of members
connected, the nut and the washer, the length of shank, the threaded
portion of bolts and sizes of holes and any other detail of this nature.
6.5 The bolts shall be of class 5.6 and nuts shall be of property class 5. The
ultimate shear stress and bearing stress on bolts shall be 3160 Kg/Sq.cm
and ultimate bearing stress shall be as per IS.
6.6 To obviate bending stress in bolts or to reduce it to minimum, no bolt shall
connect aggregate thickness of more than three (3) times its diameter.
6.7 Bolts at the joints shall be so staggered that nuts may be tightened with
spanners without fouling.

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 The minimum bolt spacing and rolled edge distance and sheared edge distances of
sections from the centres of bolt holes to be maintained are given in Table below:

TABLE –3
(Clause12.02)

Dia of Hole Min.Bolt Min.Rolled Min. sheared edge

bolts dia spacing distance distance (mm)
(mm) (mm) (mm) (mm)
16 17.5 40 20 23
20 21.5 48 25 28

Bolts sizes mentioned above shall only be used. The

minimum width of flanges without bolt holes shall be
30 mm.

7.0 TOWER ACCESSORIES:

7.1 STEP BOLT LADDERS:

Each tower shall be provided with step bolts on one of the main legs, of
not less than 16 mm diameter and 175 mm long, spaced not more than 450
mm apart and extending from about 3.5 metres above the ground level to
the top of the tower. Each step bolt shall be provided with two nuts on one
end to fasten the bolt securely to the tower and button head at the other end
to prevent the feet from slipping away. The step bolts shall be capable of
withstanding a vertical load not less than 1.5 KN and shall be used as a
ladder for climbing. The step bolts shall conform to IS 10238 and shall
have a hexagonal head.
7.2 ANTI-CLIMBING DEVICES:

Fully galvanized barbed wire type anti-climbing device shall be provided

at a height of approximately 3 meters as an anti-climbing measure. Four
layers of barbed wires will be provided each inside and outside the tower
in horizontal plane, spacing between the layers being 140 to 150 mm. The

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 angle pieces with 12 mm x 12-mm notches for accommodating barbed
wire shall be supplied with the towers along with provision for suitable
bolt holes on leg members for fitting the angles. The barbed wire shall
conform to IS-378 (1978). The anti-climbing devices shall in general
conform to Fig-8 of IS-5613 (Part-II/Sec-I).
7.3 INSULATOR STRINGS AND GROUND WIRE CLAMP

ATTACHMENTS:

d) For the attachment of suspension insulator strings a suitable swinging

hanger on the tower shall be provided so as to obtain requisite
clearance under extreme swinging conditions and free swinging of the
string. The hanger shall be designed to withstand an ultimate tensile
strength of more than 90 KN.
e) For ground wires at suspension towers suitable ‘U’ Bolts strong enough
to withstand the full designed loads shall be provided to accommodate
the hook of the ground wire suspension clamps.
f) At tension towers, horizontal strain plates of suitable dimensions on the
underside of each power cross-arm tip and at the top ground wire peak
shall be provided for taking the ‘D’ shackles of the tension insulator
strings or ground wire tension clamps, as the case may be.

7.4 CAUTION PLATES, NUMBER PLATES, CIRCUIT PLATES AND

BIRD GUARDS:

Each tower shall be fitted with Number Plates, Caution Plates (Danger
Boards), Circuit plates and phase plates. These shall be provided at
appropriate level from the ground level (about 2.5 m to 3.5 m from ground
level) so that the man standing at the foot ground tower will be able to
clearly identify the same. These plates shall be 2 mm thick and vitreous
enameled on both back and front.

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 The letters, figures and the conventional skull and bones on danger plates
are in signal red on the front side. On the number plate, the number of the
tower location preceded by the letters defining the type of the tower shall
be inscribed. Phase plates shall be colored red, yellow and blue to indicate
the phase of the conductor. The letters on number plates shall be in red
against white background. The number plates shall confirm to Fig-5 of IS:
5613 (Part-II/Sec-I). Similarly the plates and circuit plates to Figs.6 & 7 in
the said IS. The danger notice plates shall confirm to IS: 2551.Bird guards
shall be of the saw tooth type and confirm to Fig.10 of IS (5613 Part-
II/Sec-I).

7.5 EARTH BONDS:

Flexible Copper Earth bonds shall generally conform to drawing

No.ECC(P)/MISC. 10 attached hereto and shall be supplied in lengths of
300 mm and 450 mm for use on suspension and tension towers
respectively. These earth bonds shall be designed to carry a minimum
current of 100 Amps.

7.6 EARTHING:

Normal pipe type and counter poise earthing:

This shall be in accordance with clauses 11.0 and sub-clauses there of as

per IS:5613 Part-2/Sec-2, corresponding to figure 6 and where the desired
tower footing resistance cannot be achieved, then it shall be by counter
poise earthing corresponding to fig-9 in the said IS.
7.7 STUB SETTING TEMPLATE:

Stub setting templates shall be arranged for by the contractor at his own
cost for all types of towers with or without extensions.

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 Stub templates for standard towers and towers with extensions shall be of
the adjustable type. All stub templates shall be painted with anti-corrosive
paints. The number of stub templates to be fabricated shall be decided by
the contractor to coincide with the approved erection programme.

8.0 PACKING:

8.1 The material shall be boxed or bundled for transport as per IS 802 (Part-II)

– Clause – 11 and sub-clauses thereof. However

d) Angles shall be packed in bundles securely wrapped four times around

at each and every foot with No. weight of any bundle shall not exceed
approximately 450 Kg and the length of any individual member not
more than 6000 mm.
e) Cleat angles, brackets, filler plates and similar small loose pieces shall
be nested and bolted, together in multiples and securely wired together
through holes, wrapped round at least four times with No.9 SWG wire
with ends twisted tightly. Gross weight of each bundle shall not
exceed approximately 70 Kgs.
f) The correct number of bolts, nuts and washers plus 10% excess for
each tower, extensions, cross arms, attachment to cross arms, etc. shall
be packed in heavy gunny bags accurately tagged in accordance with
the contents. 4 number of such bags shall be packed in a solid box of
22 mm thick lumbered work with paneled ends securely nailed and
further reinforced with 22 mm x 75 mm battens round the sides, at the
ends with 25 mm wire No.18 SWG gauge iron band stretched entirely
around the battens with ends over lapping at least 150 mm. The gross
weight of each box shall not exceed approximately 70 Kgs. All
packaging shall be subject to the approval of the owner.

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 8.2 MARKING OF PACKINGS:
Each bundle or package shall have the following markings on it.
d) The name designation of the consignee.
e) Ultimate destination as required by the owner.
f) The relevant marks and number of tower members, or reference
number of bolts, nuts and small components like gusset plates, various
attachments, etc for easy identification.
The marking shall be stenciled in indelible ink on the top members in the
bundles of tower steel and on wooden boxes or gunny bags containing
smaller components.
The contractor from the owner shall seek for detailed dispatch instructions
at least four weeks ahead of the schedule date of dispatch.

9.0 The bidder shall assess the type and total quantities of the towers, tower
accessories and all other line materials required for completion of the line
and furnish the same in the relevant BPS of specification. The bids will be
evaluated based on the quantity furnished by the bidder. The payment will
be restricted to the quantity so assessed by the bidder. All the materials and
works required for the completion of the above project shall be invariably
furnished in the BPS.

The purchaser reserves the right to order for final quantities at the rates
quoted in the bid, which shall be valid through out the tendency of the
contract.

The unit weight of each type of tower, stubs, and extension pieces shall be
furnished by the bidder. The weight of tower shall mean the weight of the
tower calculated by using the black section (un-galvanized) weight of steel
members of sizes indicated in the approved fabrication drawings and bill
of materials, without taking in to consideration the reduction in weights
due to holes, notch cuttings, bevel cuttings, etc., but taking in to
consideration the weight of special fittings.

21.0 TESTS:

21.1 TEST FOR GALVANISATION:

Galvanization of the members of the tower
shall withstand tests as per IS 2633.

22.0 INSPECTION:

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 22.1 Proto-type assembly:
The proto-type assembly of the complete tower
along with body extensions shall be offered
for inspection by the Engineers of KPTCL and
the mass fabrication shall be taken only
after the successful proto-inspection.
22.2 The supplier shall keep the purchaser
informed well in advance of the commencement
of manufacture, progress of manufacture
thereof and fabrication of various tower parts
at various stages, so that arrangements could
be made for inspection by the purchaser.

22.3 The acceptance of any batch of items shall in

no way relieve the supplier of any of his
responsibilities for meeting all the
requirements and intent of this specification
and shall not prevent subsequent rejection if
any item of that back is later found
defective.

22.4 The purchaser or his authorized

representatives shall have free access at all
reasonable times to all parts of the
supplier’s works connected with the
fabrication of the material covered under the
contract for satisfying
themselves that the fabrication is
being done in accordance with the
provisions of this specification.

22.5 Unless specified otherwise, inspection shall

be made at the place of manufacture prior to
dispatch and shall be conducted so as not to
interfere unnecessarily with the operation of
the work.

22.6 Should any member of the structure be found

not to comply with the approved design, it
shall be liable for rejection. No member once

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 rejected shall be resubmitted for inspection,
except in cases where the purchaser of his
authorized representative considers that the
defects can be rectified.

22.7 Defects which occur during fabrication shall

be made good with the consent of and
according to the procedure to be laid down by
the purchaser.

22.8 All gauges and templates necessary to satisfy

the purchaser for conducting tests shall be
made available at the test site by the
supplier.

22.9 The correct grade and quality of steel shall

be used by the supplier. To ascertain the
quality of steel, the purchaser may at his
discretion get the material tested at an
approved Laboratory.

22.10 The time frame for executing the work is

also indicated in this schedule. The supplier
has to match the supply and delivery of stubs,
tower-pats etc., to complete the work within
the time schedule desired by the purchaser.

22.11 SCHEDULE OF PRICES:

The prices for design of tower, design of
foundation, developing the structural and shop
drawings, fabrication and galvanization of
proto type tower, proto type testing of tower,
etc., shall be furnished in the relevant
schedule.

23.0 DESIGN PARTICULARS:

Tower design data and ceiling weights proposed

to be used by the bidder shall be furnished in

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 Schedule – Schedule of Guaranteed Technical
Particulars given in Section DRS

537456407.doc Page 79
 SECTION – IVA
(VOLUME – II)

TECHNICAL SPECIFICATIONS
FOR

POWER CONDUCTORS ACSR

537456407.doc Page 80
 VOLUME-II

SECTION-IV

TECHNICAL SPECIFICATION FOR POWER CONDUCTOR FOR

TRANSMISSION LINES

1.0 SCOPE
2.0 STANDARDS
3.0 PRICIPAL PARAMETERS
4.0 GENERAL TECHNICAL REQUIREMENTS
5.0 TESTS
6.0 INSPECTION
7.0 QUALITY ASSURANCE PLAN
8.0 PACKING AND FORWARDING

TEST PROCEDURES

1.0 SURFACE CONDITION TEST

2.0 UTS TEST ON STANDARD CONDUCTOR
3.0 CORONA EXTINCTION VOLTAGE TEST
4.0 RADIO INTERFERENCE VOLTAGE TEST
5.0 DC RESISTANCE TEST ON STRANDED CONDUCTOR
6.0 STRESS – STRAIN TEST
7.0 CHEMICAL ANALYSIS OF ZINC
8.0 CHEMICAL ANALYSIS OF ALUMINIUM AND STEEL
9.0 VISUAL AND DIMENSIONAL CHECK ON DRUMS
10.0 VISUAL CHECK FOR JOINTS, SCRATCHES ETC.
11.0 DIMENSIONAL CHECK OF STEEL AND ALUMINIUM STRANDS
12.0 CHECK FOR LAY-RATIOS OF VARIOUS LAYERS
13.0 GALVANIZING TEST
14.0 TORSION AND ELONGATION TESTS ON STEEL STRANDS
15.0 BREAKING LOAD TEST ON WELDED ALUMINIUM STRAND

537456407.doc Page 81
 VOLUME – II
SECTION – IVA
TECHNICAL SPECIFICATION FOR POWER CONDUCTOR FOR
TRANSMISSION LINES

1.0 Scope:
1.1 This specification provides for design, manufacture, engineering,
inspection and testing before despatch, packing and delivery F.O.R.
(destination) of aluminium conductors steel reinforced (ACSR) for
overhead transmission purposes specified herein.

1.2 The conductor 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.
2.0 Standards:
2.1 Except as modified in this specification they shall conform to the
following Indian Standards, which shall mean latest revisions,
amendments thereof. Equivalent International and Internationally
recognized standard to which some of these standards generally
correspond are also listed below:

537456407.doc Page 82
 Sl. Indian International
Title
No. Standards Standards
1 IS: 209 Specification for zinc BS: 3436
IS: 398 Specification for IEC: 209
Part-I to aluminium conductors BS: 215
2 (Part-II)
Part-V (As for overhead transmiss-
relevant) ion purpose
Reels and Drums for
3 IS: 1778 BS: 1559
Bare Conductors
Method of Tensile Testing
4 IS: 1521 ISO/R89
of steel wire
Recommended practice
5 IS: 2629 for Hot Dip Galvanizing of
Iron and Steel
Method of Testing
6 IS: 2633 Uniformity of coating of
zinc coated Articles
Galvanised coating on ASTM A-472
7 IS: 4826 729
round steel wire
Method of Determination
of weight of zinc coating
8 IS: 6745
of zinc coated Iron and BS: 443
Steel Articles
EC grade Aluminium rod
9 IS: 1841 produced by rolling
(second Revision)
EC grade Aluminium rod
produced by continuous
10 IS: 5484
casting and rolling (first
revision)
Methods of determination
of weight of zinc coating
11 IS: 6754
of zinc coated Iron and
steel Articles.
Specification for Drake
12 C-49 CSA
ACSR

537456407.doc Page 83
2.2 The standards mentioned above are available from:

Reference
Name and Address
Abbreviation
British Standards, British Standards
BS Institution, 101, Pentonvile Road,
N-19-ND – UK
International Electro-technical
Commission, Bureau Central de la
Commission, Electro Technique
IEC/CISPR
International, 1 Rue de verembe,
Geneva, SWITZERLAND

Bureau of Indian Standards, Manak

BIS Bhavan, 9, Bahadur Shah Zafar Marg,
New Delhi-110 001 INDIA
International Organization for
Standardization, Danish Board of
ISO Standardization, Danish
Standardizing Sraat, Aurehoegvej-12,
DK-2900, Heelprup, DENMARK
National Electric Manufacture
NEMA Associate, 115, East 44 Street, New
th

York NY 10017 U.S.A

CSA Canadian Standards Assn.

However, in an event where the Bidder offers ACSR conductor

conforming to standards equivalent to or better than the above, the
salient points of comparison between the standards adopted and the
standards quoted herein shall be detailed in relevant schedule. Two
copies of authenticated English version of such standards shall be
furnished along with the offer.

537456407.doc Page 84
3.0 Principal Parameters:
3.1 The details of conductor are tabulated below:
26/4.442 30/2.79 26/2.5 mm
mm mm Aluminium
Stranding and wire
Aluminium Aluminium 7/1.9 mm
diameter
7/3.45 mm 7/2.79 mm Steel
Steel (Drake) Steel (Lynx) (Coyote)
a) Number of Strands (Not applicable) (Not applicable)

Steel Centre. 1 1 1
I Steel Layer 6 6 6
I Al. Layer 10 12 10
II Al. Layer 16 18 16
b) Sectional area of
aluminium (Sq.mm) 402.8 183.4 131.7
c) Total sectional area
(Sq.mm) 468.40 226.2 151.6
d) Overall diameter (mm) 28.13 19.53 15.86
e) Approximate weight
(kg/km) 1623.5 844 521
f) Calculated D.C
resistance at 200C 0.0715 0.1589 0.2214
(ohm/km)
g) Minimum UTS (Kg) 14175 7950 4625
h) Modulus of Elasticity
0.773 0.787 0.773
(Kgs/Sq.cm x 106)

The details of aluminium strand are as follows:

a) Minimum breaking
load of strand before 262 105 88
stranding (Kg)
b) Minimum breaking
load of strand after 249 100 84
stranding (Kg)
c) Maximum DC
resistance of strand at 1.842 4.700 5.671
200C (ohm/km)

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 The details of steel strand are as follows:

i. Minimum breaking
load of strand before 1251 819 403
stranding (Kg)
ii. Minimum breaking
load of strand after 1188 778 383
stranding (Kg)
iii. Minimum weight of
259 230 210
zinc coating (gm/sq.m

4.0 General Technical Requirement:

4.1 The conductor shall be suitable for satisfactory operation under the
tropical climatic conditions given in the project synopsis.
4.2 Physical constants of materials:
4.2.1 Physical constants for Hard-drawn Aluminium.
4.2.2 Resistivity: The resistivity of aluminium depends upon its purity and
its physical condition. For the purpose of this specification the
maximum value permitted is 0.028264 Ohm.sq.mm/mt 20 0C, and
this value has been used for calculation of the maximum permissible
value of resistance.
NOTE: It is not intended to check the resistivity from the measured values of
resistance.
4.2.3 Density: At a temperature of 200C the density of hard drawn
aluminium has been taken as 2.703 g/cubic cm.
4.2.4 Constant-Mass Temperature Co-efficient of Resistance: At a
temperature of 200C the constant-mass temperature co-efficient of
resistance of hard drawn aluminium measured between two potential

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 points rigidly fixed to the wire, the metal being allowed to expand
freely.
4.2.5 Co-efficient of linear expansion: The coefficient of linear expansion
for hard drawn aluminium at 00C has been taken as 0.004/0C has
been taken as 23.0 x 10-6/0C. This value holds good for all practical
purposes over the range of temperature from 0 0C to highest safe
operating temperature.
4.3 Physical constant for Galvanised steel wires:
4.3.1 Density: At a temperature 200C, the density of galvanised steel wire is
to be taken as 7.80 g/cm3.
4.3.2 Co-efficient of Linear Expansion: In order to obtain uniformity in
calculations a value of 11.5 x 10 -6/0C may be taken as the value for
the co-efficient of Linear Expansion of galvanized steel wires used for
the cores of steel-reinforced aluminium conductors.
4.4 Materials:
4.4.1 The conductors shall be manufactured from EC grade aluminium rod
suitably hard-drawn on wire drawing machines. The aluminium rods
used shall comply with IS: 1841 and IS: 5484. The mechanical and
electrical properties of aluminium wire shall comply with the
requirements given in relevant standard.
4.4.2 Galvanised steel wire shall be drawn from high carbon
steel rods produced by either acidic or basic open-
hearth process, electric furnace process or basic
oxygen process. The mechanical and electrical
properties of wire shall comply with the requirements
given in relevant standard. The chemical composition
of high carbon steel wire is given below for guidance
only.

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 Element Percentage Composition

Carbon 0.50 to 0.85

Manganese 0.50 to 1.10
Phosphorous Not more than 0.035
Sulphur Not more than 0.045
Silicon 0.10 to 0.35

4.4.3 The zinc used for galvanising shall be electrolytic high-grade zinc not
less than 99.95% purity. It shall conform to and satisfy all the
requirements of IS: 209 Galvanizing may be done by hot process.
Natural grease may be applied between the layers of wires.
NOTE: Lithium soap grease corresponding to Grade-II of IS: 7623
(Specification for lithium soap greases) is suitable for such
application.
4.5 Freedom from Defects:
4.5.1 The wires shall be smooth and free from all imperfections such as
spills, splits, slag inclusion, die marks, scratches, pittings, blow-
holes, projections, looseness, overlapping of strands, chipping of
aluminium layers etc and all such other defects, which may hamper
the and mechanical/ electrical properties of the conductor. Special
care should be taken to keep away dirt, grit etc during stranding.
4.6 Wire sizes:
4.6.1 Nominal size:
The aluminium and galvanised steel wires for the stranded conductor
covered by this standard shall have diameters specified in clause 3.1.
The diameter of the steel wires shall be measured over the zinc
coating.

4.6.2 Tolerances on normal size:

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4.6.2.1 Aluminium Wires: A tolerance of + 1% is permitted on the nominal
diameter of conductor respectively.
4.6.2.2 Galvanized steel earthwire: A tolerance of + 2% is permitted on the
nominal diameter.
NOTE: In order to maintain the circularity of the wires the tolerance
allowed in 4.6.2.1 and 4.6.2.2 shall apply to both the
measurements at right angles taken at the same cross-section
as per Clause 2.2 of IS:398 (Part-II) (Second Revision with
Amendments 1 to 30).
4.7 Joints in Wires:
4.7.1 Aluminium Wires: No joints shall be permitted in the aluminium
wires in the outermost layer of the ACSR Conductor. Joints in the
inner layers are permitted, in addition to those made in the base rod
or wire before final drawing, but no two such joints shall be less than
15 meter apart in the complete stranded conductor. Such joints shall
be made by cold pressure butt-welding.
NOTE: Joints are not permitted in the outermost layer of the
conductor in order to ensure a smooth conductor finish and
reduce radio interference levels and corona losses on the extra
high voltage lines.
4.7.2 Galvanized steel wires: There shall be no joints except those in the
base rod or wire before final drawing, in steel wires forming the core
of the steel-reinforced aluminium conductor.

NOTE: Joints are not permitted in the steel wires after final drawing
in order to avoid reduction in the breaking strength of the
conductor that may occur as a result of failure of the joints.
4.8 Stranding:

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4.8.1 The wires used in the construction of galvanised steel reinforced
aluminium conductor shall before stranding, satisfy all the relevant
requirements of this specification.
4.8.2 The lay ratio of the different layers shall be within the limits given in
the following tables:

LAY RATIO OF ALUMINIUM CONDUCTORS,

GALVANISED STEEL-REINFORCED
(Drake, Lynx and Coyote)

Maximum Minimum
1. ACSR DRAKE
a) Steel Wire 28 18
b) Aluminium
i. 10 Wire layer 14 10
ii. 16 Wire layer 16 10
2. ACSR LYNX
a) Steel Wire 30 20
b) Aluminium
i. 12 Wire layer 21 14
ii. 18 Wire layer 14 11.25
3. COYOTE ACSR
a) Steel Wire 30 20
b) Aluminium
i. 10 Wire layer 21 14
ii. 16 Wire layer 14 11.25

Note: The details of ACSR Coyote and Lynx may be ignored as they are not in the scope.

NOTE: For the purpose of calculation, the mean lay ratio shall be
taken as the arithmetic mean of the relevant minimum and
maximum values given in this table.

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4.8.3 In all constructions, the successive layers shall have opposite
directions of lay, the outermost layer being right-handed. The wires
in each layer shall be evenly and closely stranded.
4.8.4 In conductors having multiple layers of aluminium wires, the lay ratio
of any aluminium layer shall not be greater than the lay ratio of the
aluminium layer immediately beneath it.

4.9 Standard Length:

4.9.1 The standard length of the Conductor shall be in Standard length of
1500 meters for Drake. However, the bidder is at to offer a higher
standard length. A tolerance of +5% on the standard length offered
by the bidder shall be permitted. All lengths outside this limit of
tolerance shall be treated as random lengths.
4.9.2 Random lengths will be accepted provided no length is less than 70%
of the standard length specified and the total quantity of such
random lengths shall not be more than 5% of the total quantity
ordered.
4.9.3 Bidder shall also indicate the maximum single length, above the
standard length, he can manufacture in the guaranteed technical
particulars. This is required for special stretches like river crossing
etc. The purchaser reserves the right to place orders for the above
length on to the extent of 10% of the total ordered quantity the same
terms and conditions applicable for the standard lengths during the
pendency of the contract.
5.0 Tests:
5.1 The type, acceptance, routine tests and tests during manufacture shall
be carried out on the conductor. For the purposes of this clause:

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5.1.1 Type tests shall mean those tests, as per IS, which are to be carried
out to prove the design, process of manufacture and general
conformity of the material to this specification. These tests shall be
carried out on samples prior to commencement of commercial
production against the order. The Bidder shall indicate his schedule
for carrying out these tests in the offer.
5.1.2 Acceptance Tests shall mean those tests, which are to be carried out
on samples taken from each lot offered for predespatch inspection, for
the purposes of acceptance of that lot.
5.1.3 Routine Tests shall mean those tests, which are to be carried out on
each strand/spool/length of the conductor to check requirements,
which are likely to vary during production.
5.1.4 Tests during manufacture shall mean those tests, which are to be
carried out during the process of manufacture by the supplier to
ensure the desired quality of the end product to be supplied by him.
5.1.5 The norms and procedure of sampling for these tests will be as per
the Quality Assurance Programme to be mutually agreed to by the
supplier and the purchaser as per relevant clause of General
Conditions of Contract.
5.1.6 The standards and norms to which these tests will be carried out are
listed against them. Where a particular test is a specific requirement
of this specification, the norms and procedures of the test shall be as
specified in Annexure-II or as mutually agreed to between the
supplier and the purchaser in the Quality Assurance Programme.
5.1.7 For all type and acceptance tests, the acceptance values shall be the
values guaranteed by the bidder in the “Guaranteed Technical
Particulars”, Volume-III of his proposal or the acceptance value

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 specified in this specification, whichever is more stringent for that
particular test.
5.2 Type tests:
The following type tests shall be conducted once on each
sample/samples of conductor for every 500 KM of production from each
manufacturing facility.
a) UTS test on Stranded Conductor: Ref. Test Procedure
b) Corona extinction voltage test (dry): - do-
c) Radio interference voltage test (dry): - do-
d) DC resistance test on stranded
Conductor : - do-
e) Stress-strain Test : - do-
5.3 Acceptance Tests:
a) Visual and dimensional check on: Ref. Test Procedure
Drum
b) Visual check for joints, scratches :
Etc. and lengths of conductor - do -
c) Dimensional check on steel and :
Aluminium strands - do -
d) Check for lay ratios of various :
Layers - do -
e) Galvanizing test on steel strands : - do -
f) Torsion and Elongation test on : - do -
Steel strands
g) Breaking load test on steel and :
Aluminium strands - do -
h) Wrap test on steel and aluminium:
Strands - do -

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 i) DC resistance test on aluminium :
Strands - do -
j) UTS test on welded joints of :
Aluminium strand - do -
NOTE: All the above tests except test mentioned at (j) shall be
carried out on aluminium and steel strands after stranding
only.
5.4 Routine Tests:
a) Check to ensure that the joints are as per specification.
b) Check that there are no cuts etc on the strands.
c) All acceptance tests as mentioned in Clause 5.3 above shall be
carried out on each coil.
5.5 Tests during Manufacture:
a) Chemical analysis of zinc used : Ref. Test Procedures
For making galvanising
b) Chemical analysis of aluminium : - do -
Used for making aluminium strands
c) Chemical analysis of steel used : - do -
For making steel strands
5.6 Testing Expenses:
5.6.1 The testing charges for the type tests specified shall be indicated
separately in the prescribed schedule.
5.6.2 The Bidder shall indicate the type test charges for each type test
separately. In case the same are not mentioned then the charges are
deemed to have been included in the quoted rates of materials.
5.6.3 In case of failure in any type test, the Bidder is either required to
modify the design of the material or repeat the particular type test
three times successfully at his own expenses. The decision of the

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 purchaser in this regard shall be final and binding. The type tests
are to be conducted irrespective of whether the same have been
conducted earlier or not.
5.6.4 Bidder shall indicate the laboratories in which he proposes to
conduct the type tests. He shall ensure that the tests can be
completed in these laboratories within the time schedule guaranteed
by him in the appropriate schedule.
5.6.5 The entire cost of testing for the acceptance and routine tests and
tests during manufacture specified herein shall be treated as
included in the quoted unit price of conductor, except for the
expenses of the inspector/ purchaser’s representative.
5.6.6 The prices quoted by the bidder towards conductance of type test
shall be taken into consideration for bid evaluation.
5.7 Additional Tests:
The purchaser reserves the right of having at his own expenses any
other test(s) of reasonable nature carried out at supplier’s premises,
at site, or in any other place in addition to the aforesaid type,
acceptance and routine tests to satisfy himself that the material
comply with the specifications.
5.8 Sample Batch for type testing:
5.8.1 The supplier shall offer at least three (3) drums for selection of
samples required for conducting all the type tests.
5.8.2 The supplier is required to carry out all the acceptance tests
successfully in the presence of purchaser’s representative before
despatch.
5.9 Test Reports:
5.9.1 Four copies of type test reports shall be furnished to the Purchaser
within one month of conducting the tests. One copy will be returned

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 duly certified by the purchaser to the supplier within three weeks
thereafter and on receipt of the same supplier shall commence with
the commercial production of the conductor.
5.9.2 Four copies of acceptance test reports shall be furnished to the
purchaser. One copy will be returned, duly certified by the Purchaser
and only thereafter shall the conductor be despatched.
5.9.3 All records of routine test reports shall be maintained by the supplier
at his works for periodic inspection by the purchaser.
5.9.4 All test reports of tests conducted during manufacture shall be
maintained by the supplier. These shall be produced for verification
as and when required for by the purchaser.
5.10 Test Facilities:
5.10.1 The following additional test facilities shall be available at Supplier’s
works:
a) Calibration of various testing and measuring equipment including
tensile testing machine resistance measurement facilities, burette,
thermometer, barometer etc.
b) Standard resistance for calibration of resistance bridges.
c) Finished conductor shall be checked for length verification and
surface finish on separate rewinding machine at reduced speed
(variable from 8 to 16 metres per minute). The rewinding facilities
shall have appropriate clutch system and free of vibrations, jerks
etc with transverse layering facilities.
6.0 Inspection:
6.1 The Purchaser’s representative shall at all times be entitled to have
access to the works and all places of manufacture where conductor shall
be manufactured and the representative shall have full facilities for
unrestricted inspection of the supplier’s works raw materials and

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 process of manufacture for conducting necessary tests as detailed
herein.
6.2 The supplier shall keep the purchaser informed in advance of the
time of starting and of the progress of manufacture of conductor in
its various stages so that arrangements can be made for inspection.
6.3 No material shall be despatched from its point of manufacture before
it has been satisfactorily inspected and tested, unless the inspection
is waived off by the purchaser in writing. In the later case also, the
conductor shall be despatched only after satisfactory testing for all
tests specified herein has been completed.
6.4 The acceptance of any quantity of material shall in no way relieve the
supplier of any of his responsibilities for meeting all requirements of
the specification, and shall not prevent subsequent rejection if such
material is later found to be defective.
6.5 At least 5% of the total number of drums subject to minimum of two
in any lot put up for inspection, shall be selected at random to
ascertain the length of conductor by following method:
“At the works of the manufacturer of the conductor, the conductor
shall be transferred from one drum to another at the same time
measuring its length with the help of a graduated pulley &
Cyclometer. The difference in the average length thus obtained and as
declared by the Supplier in the packing list shall be applied to all the
drums if the conductor is found short during checking.”
7.0 Quality Assurance Plan:
7.1 The Bidder shall invariably furnish following information along with his
offer, failing which his offer shall be liable for rejection.
i) Statement giving list of important raw materials names of sub-
suppliers for the raw materials, list of standards according to which

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 the raw materials are tested, list of tests normally carried out on raw
materials in presence of Bidder’s representative, copies of test
certificates.
ii) Information and copies of test certificates as in (i) above in respect of
bought out material.
iii) List of manufacturing facilities available.
iv) Level of automation achieved and list of areas where manual
processing exists.
v) List of areas in manufacturing process, where stage inspections are
normally carried out for quality control and details of such tests and
inspections.
vi) List of testing equipments 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 deviation from specified test requirements.
7.2 The supplier shall within 30 days of placement of order submit following
information to the purchaser.
i. List of raw materials sub-suppliers selected from those furnished
along with offer.
ii. Type test certificates of the raw material.
iii. Quality Assurance Plan (QAP) with hold points for Purchaser’s
inspection. The quality assurance plan and Purchaser’s hold
points shall be discussed between the Purchaser and supplier,
before the QAP is finalized.
7.3 The supplier shall submit the routine test certificates of raw material
at the time of routine testing on the conductor.
8.0 Packing & Forwarding:

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8.1 The Conductor shall be supplied in non-returnable strong wooden
drums provided with lagging of adequate strength, and displacement
during transit, storage and subsequent handling and stringing
operations in the field. The drums shall generally conform to IS:
1778-except otherwise specified hereinafter.
8.2 The drums shall be suitable for wheel mounting and for jetting off the
conductor under a minimum controlled tension of the order of 5 KN.
8.3 The Bidder should submit the proposed drum drawings along with
the bid. However, the same shall be in line with the requirements as
stated herein. After placement of the Letter of Award, the supplier
shall submit four copies of fully dimensioned drawing of the drum he
wished to supply, for Purchaser’s approval before taking up
manufacturing of Conductor. After getting approval from the
purchaser, supplier shall submit 30 more copies of the approved
drawing to Purchaser for further distribution and field use at
Purchaser’s end.
8.4 All wooden components shall be manufactured out of seasoned
softwood free from defects that may materially weaken the component
parts of the drums. Preservative treatment for anti-termite/anti-
fungus (Aldrime/Aldruse) shall be applied to the entire drum with
preservatives of a quality, which is not harmful to the conductor.
8.5 The flanges shall be of two/three ply construction with each ply at
right angles to the other and nailed together. The nails shall be
driven from the inside face flange, punched and then clenched on the
outer face. The tolerance in thickness of each ply shall be + 3 mm
only. There shall be at least 3 nails per plank of ply with maximum
nail spacing of 75 mm. Where a slot is cut in the flange to receive the

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 inner end of the conductor, the entrance shall be in the line with the
periphery of the barrel.
8.6 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 battens 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.
8.7 Barrel studs shall be used for construction of drums. The flanges
shall be holed and the barrel supports slotted to receive them. The
barrel studs shall be threaded over a length on either end, sufficient
to accommodate washers, spindle plates and nuts for fixing flanges at
the required spacing. Barrel studs should be tack welded with the
nuts after tightening.
8.8 Normally, the nuts on the studs shall stand protrude of the flanges.
All the nails used on the inner surface of the flanges and the drum
barrel shall be countersunk. The ends of barrel shall generally be
flushed with the top of the nuts.
8.9 The inner cheek of the flanges and drum barrel surface shall be
painted with a bitumen-based paint.
8.10 Before reeling, cardboard or double corrugated or thick bituminised
waterproof bamboo paper shall be secured to the drum barrel and
inside of flanges or the drum by means of a suitable commercial
adhesive material. The paper should be dried before use. Medium
grade Kraft paper shall be used in between the layers of the
conductor. After reeling the conductor, the exposed surface of the
outer layer of conductor shall be wrapped with thin polythene sheet
across the flanges to preserve the conductor from dirt, grit and

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 damage during transportation and handling and also to prevent
ingress of rain water during storage/transport.
8.11 A minimum space of 125 mm shall be provided between the inner
surface of the external protective layer and outer layer of the
conductor.
8.12 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
exposed sharp edges or allow the battens to be released due to
corrosion.
8.13 Outside the protective layer, there shall be minimum of two binders
consisting of hoop iron/galvanized steel wire. Each protective layer
shall have two recesses to accommodate the binders.
8.14 The conductor ends shall be properly sealed and secured with the
help of U-nails on one side of the flanges. The end securing shall be
done by taking out at least 500 mm of steel core on either end by U-
nails. The composite conductor shall be hinged by use of galvanized
steel wire/ aluminium wire at three locations at least 75 mm apart or
more covered with PVC adhesive tape so as to avoid loosening of
conductor layers in transit and handling.
8.15 Only one length of conductor shall be wound on each drum.
8.16 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) Manufacturer’s name and address.
d) Drum Number.

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 e) Size of conductor.
f) Length of conductor in meters.
g) Gross weight of drum with conductor.
h) Weight of empty drum with lagging.
i) Arrow marking for unwinding.
TEST PROCEDURES
1.0 Surface Condition Test:
A sample of the finished conductor having a minimum recommended
length of 5 meters with compression type dead and clamps compressed
on both ends in such a manner as to permit the conductor to take its
normal straight line shape, shall be subject to a tension of 50% of the
UTS of the conductor. The surface shall not depart from its cylindrical
shape nor shall the strands move relative to each other so as to get out
of place or disturb the longitudinal smoothness of conductor. The
measured diameter at any place shall be not less than the sum of the
minimum specified diameters of the individual aluminium and steel
strands.
2.0 UTS Test on Stranded Conductor:
Circles perpendicular to the axis of the conductor shall be marked at
two places on a sample of conductor of minimum 5-meter length
suitably compressed with dead end clamps at either end. The load shall
be increased at a steady rate up to specified 50% of UTS and held for
one minute. The circles drawn shall not be distorted due to Relative
movement of strands. Thereafter the load shall be increased at a steady
rate to the minimum UTS specified in clause 3.1 (h) and held for one
minute. The applied load shall then be increased until the failing load is
reached and the value recorded.
3.0 Corona Extinction Voltage Test:

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 One sample of conductor of 5-meter length shall be strung. Incase of
twin conductor, two samples shall be arranged with the actual sub-
conductor spacing between them. This sample assembly when
subjected to power frequency voltage shall have a corona extinction
voltage of not less than 176 kV (rms) for 220 kV system line to ground
under dry condition. There shall be no evidence of corona on any part of
sample when all possible sources of corona are photographed in a
darkened room. The test shall be conducted without corona control
rings. The voltage shall be corrected for standard atmospheric
conditions.
4.0 Radio Interference Voltage test:
Under the conditions as specified in (2) above, the conductor samples
shall have a radio interference voltage level below 1500 micro volts at
one MHz when subjected to 50 Hz AC voltage of 1.1 times maximum line
to ground voltage under dry condition. This test may be carried out
with corona control rings and arcing horns.
5.0 D.C. Resistance test on Stranded Conductor:
On a conductor sample of minimum 5-meter length two contact clamps
shall be fixed with a pre-determined bolt torque. The resistance shall be
measured by a Kelvin double bridge by placing the clamps initially zero
meter 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 20 0C as per Clause No.12.8 of IS: 398
(Part-V). The resistance corrected at 20 0C shall conform to the
requirements of this specification.
6.0 Stress-Strain Test:

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6.1 This test is contemplated only to collect the creep data of the conductor
from the supplier. A sample of conductor of minimum 10-meters length
shall be suitably compressed with dead end clamps.
6.2 Test set-up:
6.2.1 The test sample shall be supported in a trough over its full length and
the trough adjustment so that the conductor will not be lifted by more
than 10 mm under tension. This shall be ascertained by actual
measurement.
6.2.2 The distance between the clamp and the sleeve mouth shall be
monitored with calipers during the test to ensure that, after the test, it
does not change by more than 1 mm + 0.1 mm from the value before the
test.
6.2.3 The conductor strain shall be evaluated from the measured
displacements at the two ends of the gauge length of the sample. The
gauge reference targets shall be attached to the clamps, which lock the
steel and aluminium wires together. Target plates may be used with
dial gauges or displacement transducers and care shall be taken to
position the plates perpendicular to the conductor. Twisting the
conductor, lifting it and moving it from side-to-side by the maximum
amounts expected during the test should introduce no more than 0.3
mm error in the reading.
6.3 Test Loads for complete conductor.
The loading conditions for repeated stress-strain tests for complete
conductor shall be as follows:
6.3.1 1-KN load shall be applied initially to straighten the conductor. The
load shall be removed after straightening and then the strain gauges are
to be set at zero at zero tension.

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6.3.2 For non-continuous stress-strain data, the strain readings at 1 KN
intervals at lower tensions and 5 KN intervals above 30% of UTS shall be
recorded.
6.3.3 The sample shall be reloaded to 50% of UTS and held for 1 hour.
Readings are to be noted after 5, 10, 15, 30, 45 and 60 minutes during
the hold period. The load shall be released after the hold period.
6.3.4 Reloading up to 70% of UTS shall be done and held for 1 hour.
Readings are to be noted after 5, 10, 15, 30, 45 and 60 minutes. The
load shall then be released.
6.3.5 Reloading up to 85% of UTS shall be done and held for 1 hour.
Readings are to be noted after 5, 10, 15, 30, 45 and 60 minutes and
then the load shall then be released.
6.3.6 Tension shall be applied again and shall be increased uniformly until
the actual breaking strength is reached. Simultaneous readings of
tension and elongation shall be recorded up to 90% of UTS at the
intervals described under Clause 6.3.5.
6.4 Test Loads for Steel Core only:
The loading conditions for repeated stress-strain tests for the steel core
of ACSR shall be as follows:
6.4.1 The test shall consist of successive application of load applied in a
manner similar to that for the complete conductor at 30%, 50%, 70%
and 85% of UTS.
6.4.2 The steel core shall be loaded until the elongation at the beginning of
each hold period corresponds to that obtained on the complete
conductor at 30%, 50%, 70% and 85% of UTS respectively.
6.5 Stress Strain Curves:
The design stress-strain curve shall be obtained by drawing a smooth
curve through the 0.5 and 1-hour points at 30%, 50% and 70% of UTS

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 loadings. The presence of any aluminium slack that can be related to
any observed extrusion entering the span from the compression dead
ends shall be removed from the lower ends of the design curves. Both
the laboratory and design stress-strain curves shall be submitted to the
Purchaser along with test results. The stress-strain data obtained
during the test shall be corrected to the standard temperature i.e. 20 0C.
7.0 Chemical Analysis of Zinc:
Samples taken from the zinc ingots shall be
chemically/spectrographically analyzed. The same shall be in
conformity to the requirements stated in this specification.
8.0 Chemical Analysis of Aluminium and Steel:
Samples taken from the Aluminium ingots/coils/strands shall be
chemically/spectrographically analyzed. The same shall be in
conformity to the requirements stated in this specification.

9.0 Visual and Dimensional Check on drums.

The drums shall be visually and dimensionally checked to ensure that
they conform to the requirements of this specification.
10.0 Visual Check for Joints, Scratches etc:
Conductor drums shall be rewound in the presence of the inspector.
The inspector shall visually check for scratches, joints, etc and that the
conductor generally conforms to the requirements of this specification.
11.0 Dimensional check of steel and aluminium strands:
The individual strands shall be dimensionally checked to ensure that
they conform to the requirements of this specification.
12.0 Check for Lay-ratios of various Layers:

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 The lay-ratios of various layers shall be checked to ensure that they
conform to the requirements of this specification and clause No.9.4 &
9.5 of IS-398 (Part-V).
13.0 Galvanizing Test:
The test procedure shall be as specified in IS: 4826. The material shall
conform to the requirement of this specification.
14.0 Torsion and Elongation Tests on Steel Strands.
The test procedures shall be as per clause No.12.6.1 and 12.6 of IS:398
(Part-V). In torsion test, the number of complete twists before fracture
shall not be less than 18 on a length equal to 100 times the standard
diameter of the strand. In case test sample length is less or more than
100 times the standard diameter of the strand, the minimum number of
twist will be proportionate to the length and if number comes in the
fraction then it will be rounded off to next higher whole number. In
elongation test, the elongation of the strand shall not be less than 4%
for a gauge length of 200 mm.

15.0 Breaking load test on welded Aluminium strand:

Two Aluminium Wires shall be welded as per the approved quality plan
and shall be subjected to tensile load. The welded point of the wire shall
be able to withstand the minimum-breaking load of the individual
strand guaranteed by the supplier.

*****

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537456407.doc Page 108
 SECTION – IVB
(VOLUME – II)

TECHNICAL SPECIFICATION
FOR
ACCR HTLS (HIGH TEMPERATURE LOW SAG)
CONDUCTOR
- EQUIVALENT TO ACSR COYOTE

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 VOLUME – II
SECTION – IVB
TECHNICAL SPECIFICATION FOR HTLS CONDUCTOR

1. GENERAL INFORMATION:

1.0 Preamble:

KPTCL has decided to uprate the following ring mains in Bangalore city by
replacing the existing ACSR COYOTE by equivalent ACCR ( Aluminum
Conductor Composite Reinforced) HTLS (High Temperature Low Sag)
Conductor (which can carry double the current with the same sag at
maximum temperature) on the existing towers. The intermediate supports
(Narrow Base Tower / High Tensile Tubular Mono-Pole) shall be used only in
case of long spans to get the adequate clearances.

a. Between 220/66/11KV Hebbal & ITI Sub-station, Bangalore East.

b. Between 66KV Peenya – Brundhavan S/C line (2.999 Kms).
c. Between 220/66KV Peenya Sub-station and Byaadarahalli.
d. Between 220/66KV Peenya Sub-station and 66kV Peenya-D.G.Plant DC
3& 4 line, 8 pole structure near Chikkabettahalli village

The above lines are passing through thickly populated Residential &
Commercial plots along the narrow streets and hence at most care must be
taken by the contractor during Releasing & Stringing of the conductor
without causing any damage to the property. The bidders are advised to
compulsorily carry out the walk-over survey/ route-inspection to
familiarize with the work before quoting. The preliminary and detailed
survey has been conducted by KPTCL and all the necessary data such as
tropo-sheet extract, route profile & tower schedule will be furnished to the
successful contractor.

1.1 Design details of the existing 66KV D/C tower:

The existing 66KV D/C towers of the ring mains are designed and
commissioned almost 32 to 40 years back.
The following are the design parameters of the tower:

a. Type of tower : Lattice type, Pylon tower

b. Normal Span : 275 M
c. Wind Span : 302 M

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 d. Weight Span : 412 M
e. Conductor used : ACSR Coyote
f. Ground wire used : 7/3.15 mm, 110 KG
g. Maximum design tension of conductor at 32 deg FW (43 kg/M2):1546 Kg
h. Tension of Power Conductor at 32 deg No Wind condition : 1156 Kg
i. Maximum Sag at 55 deg C No Wind condition : 5.1 M
j. Height of bottom conductor at tower : 10.8 M
k. Code according to which the tower is designed : as per old code IS:802
l. Factor of Safety in the design, Normal condition : 2.0
Broken Wire Condition : 1.5

2.0 Scope of the Work:

a. Supply & Stringing of ACCR HTLS conductor & Releasing of ACSR

COYOTE.
b. Supply & Installation of necessary conductor accessories.
c. Replacement of Insulator Hardware wherever required.
d. Supply & Erection of steel Mono-pole / Lattice type Narrow Base towers
if absolutely required.
e. Releasing of the existing ACSR COYOTE conductor and stringing of
ACCR HTLS conductor simultaneously so that the conductor do not
touch / damaged the obstacles below the line.

3.0 Description of High Temperature Low Sag (HTLS) Conductor and its
Technical Requirements
3.1 The HTLS Conductor shall be capable of providing the specified ampacity at
a continuous operating conductor temperature higher than that of the
maximum permissible operating temperature of the existing ACSR COYOTE
Conductor without exceeding the level of maximum permissible sag of the
existing ACSR COYOTE Conductor AT 55 0 C ie., 5.1M for HTLS conductor
for a continuous operating temperature of the conductor .
The physical and operating performance requirements of the transmission
line after its uprating by means of re-conductoring with HTLS conductor are
mentioned below. The bidder shall offer HTLS conductor complying with the
specified requirements. The Bidder shall indicate particulars of the proposed
conductor in the relevant GTP schedule of BPS alongwith calculations to
establish compliance with the specified requirements.
3.2 Current Carrying Capacity / Ampacity Requirements

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3.2.1 HTLS conductor shall be suitable to carry minimum 50 Hz alternating
current of 720 Amperes under the ambient conditions & maximum
conductor sag specified below while satisfying other specified technical
requirements/ parameters.
Ambient temperature: 40 deg C

Solar Absorption coefficient =0.5

Solar Radiation = 1045 watt/sq.m

Emisitivity Constant= 0.5

Wind velocity = 0.6m/sec

Maximum Conductor sag for 275M span at steady state conductor

temperature and nil wind corresponding to 50 Hz alternating current of 720
Amperes under ambient conditions specified above should be within 5.1M.

The calculations for Ampacity shall be based on IEEE Standard 738.

The bidder in his bid shall furnish calculations for the ampacity based on
the above Standard for the proposed HTLS conductor.
3.2.2 The design of conductor shall be suitable for operation at a steady state
conductor temperature experienced for a AC current flow of 720 Amperes
under the above ambient conditions based on ampacity calculations
mentioned above. The bidder shall also indicate the maximum permissible
conductor temperature for continuous operation without any deterioration
of its electrical, mechanical & metallurgical properties. The bidder shall also
furnish the maximum permissible conductor temperature for short term
operations including permissible duration of such short term operation.
3. 3 Technical Particulars of HTLS Conductor
The HTLS conductor shall meet the following minimum
requirements:
Overall diameter of Not exceeding 16.0 mm and
complete conductor
Approx. mass of Less than or equal to 521 kg/Km
complete conductor (kg/m)
Direction of lay of outer layer Right Hand

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 The bidder shall indicate the technical particulars and details of the
construction of the conductor in the relevant schedule of GTP. The bidder
shall also guarantee the DC resistance of conductor at 20 deg C and AC
resistance at the calculated temperature corresponding to 50Hz alternating
current flow of 720 amperes at specified ambient conditions (maximum
continuous operating temperature).
The bidder shall submit the supporting calculations for the AC resistance
indicating details & justifications of values of temperature coefficient of
resistance & DC to AC resistance conversion factor(s) with due reference to
construction / geometry of the conductor.
3.4 Sag-Tension Requirements

3.4.1 The HTLS conductor shall meet the following sag tension
requirements for ruling span of 275M

Particulars Limiting value

≤1156 kgs & Not exceeding
Tension at every day condition 25% of UTS of proposed
(32°C, no wind) conductor
Sag at maximum continuous
operating temp (corresponding
to 720 amperes at ambient conditions
specified at 1.2.1) ≤5.1M
Tensions under Condition-I  
≤1546 kgs & not exceeding
50% of UTS of proposed
Tension at 32°C, full wind (43 kg/m2) conductor
≤1567 kgs & not exceeding
Tension at 10°, 2/3 wind pressure 50% of UTS of proposed
(28.6kg/m2) conductor

Sag-Tension calculations at various conditions mentioned above using

parabolic equations and any other method shall be submitted along with
the bid. These calculations shall also include calculations for determination
of transition / knee point temperature.

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 The bidder shall also furnish sag & tensions under no wind for various
temperatures starting from 10 deg C to maximum continuous operating
temperature in steps of 5 degC .

3.4.2 After award of the contract, the Supplier shall submit Sag-Tension
calculations corresponding to various conditions given above for all the
existing spans and spans ranging from 50M to 400M in intervals of 50M.
3.4.3 Besides above, the Supplier shall also furnish details of creep
characteristics in respect of HTLS conductor based on laboratory
investigations/ experimentation (creep test as per IEE1138) conducted on
similar type of conductor and shall indicate creep strain values
corresponding to 1 month, 6 month, 1 year & 10 year creep at everyday
tension & at maximum continuous operating temperature.
3.5 Workmanship
3.5.1 All the conductor strands shall be smooth, uniform and free from all
imperfections, such as spills and splits, cracks, die marks, scratches,
abrasions, rust etc.

3.5.2 The finished conductor shall be smooth, compact, uniform and free from all
imperfections including kinks (protusion of wires), wire cross over, over
riding, looseness (wire being dislocated by finger/hand pressure and/or
unusual bangle noise on tapping), material inclusions, white rust, powder
formation or black spot (on account of reaction with trapped rain water
etc.), dirt, grit etc.

3.6 Joints in Wires

3.6.1 Aluminium Alloy Wires
3.6.1.1 During stranding, no Aluminium Alloy wire welds shall be made for the
purpose of achieving the required conductor length.
3.6.1.2 No joints shall be permitted in the individual wires in the outer most layer
of the finished conductor. However joints are permitted in the inner layer(s)
of the conductor unavoidably broken during stranding provided such
breaks are not associated with either inherently defective wire or with the

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 use of short lengths of Aluminium Alloy wires. Such joints shall not be
more than four (4 ) per conductor length and shall not be closer than 15
meters from joint in the same wire or in any other Aluminium Alloy wire of
the completed conductor. A record of such joints for each individual length
of the conductor shall be maintained by The Contractor for Employers
review.
3.6.1.3 Joints shall be made by cold pressure butt welding and shall withstand a
stress of not less than the breaking strength of individual strand
guaranteed.
3.6.2 Core Wires
There shall be no joint of any kind in the finished wire entering into the
manufacture of the strand. There shall also be no joints or splices in any
length of the completed stranded core
3.7 Tolerances
Manufacturing tolerances on the dimensions to the extent of one percent
shall be permitted for individual strands and the complete conductor.
3.8 Materials
The materials used for construction of the conductor shall be such that the
conductor meets the specified technical and performance requirements.
3.8.1 Outer layer
3.8.1.1 The material of outer layer of HTLS conductor shall be of high temperature
resistant aluminum alloy added with zirconium or any other suitable
element(s) etc. to electrolytic aluminium having purity not less than 99.5%
and a copper content not exceeding 0.04%.The strands shall be
manufactured through appropriate manufacturing process to ensure
consistant electrical mechanical and metallurgical properties under
continuous high temperature operation. Bidder shall guarantee the
chemical composition in the schedule GTP of BPS and also furnish
description of the manufacturing process in the Bid.
3.8.1.3 Fully annealed type (0 tempered) alluminium/ alloy strands shall not be
accepted owing to its lower abrasion resistance .
3.8.3 Core
The core wire strand(s) shall be of galvanized steel wires/ aluminium clad
steel wires / galvanized invar wires/ aluminium clad invar wires/
composite materials etc and shall have properties conforming to the
technical performance requirements of the finished conductor. Bidder shall
furnish properties and composition of the core wire strand(s)in the
schedule GTP of BPS.

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 The zinc used for galvanizing in case of steel /invar core shall be
electrolytic High Grade Zinc of 99.95% purity. It shall conform to and
satisfy all the requirements of IS:209. The minimum mass of zinc coating
shall be as per requirements of Class-1 coating as per IEC-888.
The aluminium cladding of invar/ steel wires shall be with aluminum
having purity not less than 99.5 % and shall be throghly bonded to the core
wire strand(s). The minimum thickness of aluminium cladding shall be
0.07mm to achieve a minimum conductivity of 14% of IACS.
Where composite material for core is offered, the materials shall be of such
proven quality that its properties are not adversely influenced by the
normal operating conditions of a 66 kV transmission line in tropical
environment conditions as experienced by the existing line. The bidder
shall provide adequate details including specifications/test
reports/operating experience details/performance certificates etc. in
support of the suitability of the offered materials.
3.9 Conductor Length
3.9.1 The contractor after his survey of the existing line shall determine the most
appropriate individual conductor lengths to be manufactured & supplied
keeping in view tower schedules, section lengths, special crossings etc. and
the drum schedules shall be submitted to Employer for review & approval.
3.9.2 The bidder shall also indicate the maximum single length of HTLS
Conductor, he can manufacture in the guaranteed technical particulars of
offer.

3.10 Evaluation of Ohmic Losses & Differential Price Loading

CAPITALISATION OF LOSSES
KPTCL will capitalise the losses as offered by the Bidders commensurate
to the ratings offered by each of them in their “Augmentation
Programme”. The savings in losses will need to clearly demonstrate with
calculations by the bidder. Such loss capitalisation will be averaged by
admitting the loss over 25 years.

- The bidder will have to establish at the instance of KPTCL

the losses declared by him in the bid. The I2R losses must be specified

- The bidder will have to establish the mechanical and electrical

compatibility of the system offered by him with that of the KPTCL line
parameters.

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 - The level of Augmentation achieved by the Bidder with its progresses
will be duly considered and capitalised in the evaluation process of the
award in the tender.

3.10.1 Based on the conductor parameters guaranteed by the bidders, average

ohmic losses for different conductors offered by the bidders shall be
calculated as per the following:

Average Ohmic Loss = Loss Load factor x Line Length x (Specified

maximum Operating Current)2 x AC resistance corresponding to the
maximum operating temperature

For 4 kms D/C 66 kV Line, considering, loss factor = 0.48, maximum

specified operating current of 720 Amp;

Average Ohmic loss (kW)

= 0.48 x 4 x (720)2 x Rac/1000

= 995.328 x Rac

Where Rac is the AC resistance per Km guaranteed by the bidder at

temperature corresponding to the specified maximum operating current.

Differential price evaluation for the conductors offered by the bidders shall
be carried out considering the average ohmic losses calculated as above
and considering Rs.1,52,600 per kW.

The best parameter of loss (lowest ohmic loss for conductor) corresponding
to lowest AC resistance quoted among bidders by any technically
responsive and qualified bidder shall be taken as basis and that quoted by
the particular bidder shall be used to arrive at differential price to be
applied for each bid.

4.0 Tests and Standards

4.1 Type Tests

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4.1.1 Type Tests on Stranded Conductor/ Stranded wire
The following tests shall be conducted once on sample/samples of
conductor from each manufacturing facility:
(i) On complete Conductor
a) DC resistance test on stranded
: As per Annexure-A
conductor
b) UTS test on stranded conductor : As per Annexure-A
c) Radio interference voltage test
: As per Annexure-A
(dry)
d) Corona extinction voltage test
: As per Annexure-A
(dry)
e) Stress- Strain test on stranded
: IEC 1089
conductor and core at room
temperature
f) Stress-strain test on stranded
conductor and core at elevated As per Annexure-A
temperature
g) High temperature endurance & : As per Annexure-A
creep test on stranded conductor
h) Sheaves Test : As per Annexure-A

i) Axial Impact Test : As per Annexure-A

j) Crush Strength Test : As per Annexure-A

k) Torsional Ductility Test : As per Annexure-A

l) Aeolian Vibration Refer Annexure-A of

Section-III

m) Temperature Cycle Test Refer Annexure-A of

Section-III

(ii) On Conductor Strand/core

a) Heat resistance test on
: As per Annexure-A
Aluminium Alloy strands
b) Bending test on core : As per Annexure-A

c) Compression test on core : As per Annexure-A

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 d) Coefficient of linear expansion on : As per Annexure-A
core/ core strands

4.2 Acceptance Tests

a) Visual and dimensional check on

: As per Annexure-A
drum
b) Visual check for joints scratches : As per Annexure-A
etc. and length measurement of
conductor by rewinding
c) Dimensional check on core : As per Annexure-A
strands/composite core and
Aluminium Alloy strands
d) Check for lay-ratios of various : As per Annexure-A
layers
e) Galvanising test on core strands : As per Annexure-A
f) aluminum thickness on
aluminium clad wires
g) Torsion and Elongation tests on : As per Annexure-A
core strands/composite core
h) Breaking load test on core strands : As per Annexure-A
and Aluminium / Aluminium
Alloy strands
i) Wrap test on core strands and : As per IEC:888 &
Aluminium Alloy strands IES:889

j) Minimum conductivity test on : As per IEC : 889

thermal resistant Aluminium Alloy
strands
k) Procedure qualification test on : As per Annexure-A
welded joint of Aluminium Alloy
strands
l) Heat resistance test on Aluminium : As per Annexure-A
Alloy strands
m) Ageing test on filler (if applicable) : As per Annexure-A
n) Minimum conductivity test on : As per Annexure-A
aluminium clad core strands

Note All the above tests except (j) shall be carried out on
: Aluminium / Aluminium Alloy and core strands after
stranding only.

4.3 Routine Test

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 a) Check to ensure that the joints are as per Specification
b) Check that there are no cuts, fins etc., on the strands.
c) Check that drums are as per Specification
d) All acceptance tests as mentioned above to be carried out
on each coil

4.4 Tests During Manufacture

a) Chemical analysis of zinc used for : As per Annexure-
galvanizing A
b) Chemical analysis of Aluminium alloy : As per Annexure-
used for making Aluminium Alloy A
strands
c) Chemical analysis of core : As per Annexure-
strands/composite core A

4.5 Testing Expenses

4.5.1 The break-up of the testing charges for the type tests specified shall be
indicated separately.
4.5.2 Bidder shall indicate the laboratories in which they propose to conduct the
type tests. They shall ensure that adequate facilities are available in the
laboratories and the tests can be completed in these laboratories within the
time schedule guaranteed by them.
4.5.3 In case of failure in any type test the Supplier is either required to
manufacture fresh sample lot and repeat the entire test successfully once
or repeat that particular type test three times successfully on the sample
selected from the already manufactured lot at his own expenses. In case a
fresh lot is manufactured for testing then the lot already manufactured
shall be rejected.
4.5.4 The entire cost of testing for the acceptance and routine tests and Tests
during manufacture specified herein shall be treated as included in the
quoted unit price of conductor, except for the expenses of the
inspector/Employer's representative.
4.5.5 In case of failure in any type test, if repeat type tests are required to be
conducted, then all the expenses for deputation of Inspector/Employer's
representative shall be deducted from the contract price. Also if on receipt
of the Supplier's notice of testing, the Employer's representative does not
find material/ testing facilities to be ready for testing the expenses incurred
by the KPTCL for redeputation shall be deducted from contract price.

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4.5.6 The Supplier shall intimate the KPTCL about carrying out of the type tests
along with detailed testing programme at least 3 weeks in advance (in case
of testing in India) and at least 6 weeks in advance (in case of testing
abroad) of the schedule date of testing during which the Employer will
arrange to depute his representative to be present at the time of carrying
out the tests.
4.6 Additional Tests
4.6.1 KPTCL reserves the right of having at his own expenses any other test(s) of
reasonable nature carried out at Supplier’s premises, at site or in any other
place in addition to the aforesaid type, acceptance and routine tests to
satisfy himself that the materials comply with the Specifications.
4.6.2 The Employer also reserves the right to conduct all the tests mentioned in
this specification at his own expense on the samples drawn from the site at
Supplier’s premises or at any other test centre. In case of evidence of non
compliance, it shall be binding on the part of Supplier to prove the
compliance of the items to the technical specifications by repeat tests, or
correction of deficiencies, or replacement of defective items all without any
extra cost to the Employer.
4.7 Sample Batch for Type Testing
4.7.1 The Supplier shall offer material for selection of samples for type testing
only after getting Quality Assurance Plan approved from Employer’s Quality
Assurance Deptt. The sample shall be manufactured strictly in accordance
with the Quality Assurance Plan approved by Employer.
4.7.2 The Supplier shall offer at least three drums for selection of sample
required for conducting all the type test.
4.7.3 The Supplier is required to carry out all the acceptance tests successfully
in presence of Employer’s representative before sample selection.
4.8 Test Reports
4.8.1 Copies of type test reports shall be furnished in at least three copies along
with one original. One copy will be returned duly certified by the Employer
only after which the commercial production of the material shall start.
4.8.2 Record of routine test reports shall be maintained by the Supplier at his
works for periodic inspection by the Employer’s representative.
4.8.3 Test Certificates of tests during manufacture shall be maintained by the
Supplier. These shall be produced for verification as and when desired by
the Employer.
4.9 Inspection

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4.9.1 The Employer’s representative shall at all times be entitled to have access
to the works and all places of manufacture, where conductor shall be
manufactured and representative shall have full facilities for unrestricted
inspection of the Supplier’s works, raw materials and process of
manufacture for conducting necessary tests as detailed herein.
4.9.2 The Supplier shall keep the Employer informed in advance of the time of
starting and of the progress of manufacture of conductor in its various
stages so that arrangements can be made for inspection.
4.9.3 No material shall be dispatched from its point of manufacture before it has
been satisfactorily inspected and tested, unless the inspection is waived off
by the Employer in writing. In the latter case also the conductor shall be
dispatched only after satisfactory testing for all tests specified herein have
been completed.
4.9.4 The acceptance of any quantity of material shall in no way relieve the
Supplier of any of his responsibilities for meeting all requirements of the
Specification, and shall not prevent subsequent rejection it such material is
later found to be defective.
4.10 Test Facilities
4.10.1 The following additional test facilities shall be available at the Supplier’s
works:
a) Calibration of various testing and measuring equipment including
tensile testing machine, resistance measurement facilities, burette,
thermometer, barometer etc.
b) Standard resistance for calibration of resistance bridges.
c) Finished conductor shall be checked for length verification and surface
finish on separate rewinding machine at reduced speed (variable from 8 to
16 meters per minute). The rewinding facilities shall have appropriate
clutch system and free of vibrations, jerks etc. with traverse laying
facilities.
4.11 Packing
4.11.1 The conductor shall be supplied in non-returnable, strong, wooden/painted
steel/hybrid (painted steel cum wood) drums provided with lagging of
adequate strength, constructed to protect the conductor against all damage
and displacement during transit, storage and subsequent handling and
stringing operations in the field. The Supplier shall select suitable drums
for supply of conductor and shall be responsible for any loss or damage to
conductor and/or drum during transportation handling and storage due to
improper selection of drum or packing.

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4.11.2 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.
4.11.3 The Bidder should submit their proposed drum drawings along with the
bid.
4.11.4 One conductor length only shall be wound on each drum.
4.11.5 The conductor ends shall be properly sealed and secured on the side of one
of the flanges to avoid loosening of the conductor layers during transit and
handling.
4.11.6 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) Manufacturer’s name and address.
(d) Drum number
(e) Size of conductor
(f) Length of conductor in meters
(g) Arrow marking for unwinding
(h) Position of the conductor ends
(i) Distance between outer-most Layer of conductor and the inner surface
of lagging.
(k) Barrel diameter at three locations & an arrow marking at the location of
the measurement.
(l) Number of turns in the outer most layer.
(m) Gross weight of drum after putting lagging.
(n) Tear weight of the drum without lagging.
(o) Net weight of the conductor in the drum.
(p) CIP/MICC No.
The above should be indicated in the packing list also.

4.12 Verification of Conductor Length

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 The Employer reserves the right to verify the length of conductor after
unreeling at least ten (10) percent of the drums in a lot offered for
inspection.
4.13 Standards
4.13.1 The conductor shall conform to the following Indian/International
Standards, which shall mean latest revisions, with amendments/changes
adopted and published, unless specifically stated otherwise in the
Specification.
4.13.2 In the event of the supply of conductor conforming to standards other than
specified, the Bidder shall confirm in his bid that these standards are
equivalent to those specified. In case of award, salient features of
comparison between the standards proposed by the Supplier and those
specified in this document will be provided by the Supplier to establish
their equivalence.

Sl. Indian Title International

No. Standard Standard
1. IS: 209-1992 Specification for zinc BS:3436-1986

2. IS: 398-1982 Specification for Aluminium IEC:1089-1991

Conductors for Overhead BS:215-1970
Transmission Purposes
3. IS:398-1990 Aluminum Conductor Galvanised BS;215-1970
Part-II Steel Reinforced IEC:1089-1991
4. IS:398-1992 Aluminum Conductor Galvanised IEC:1089-1991
Part-V Steel- Reinforced For Extra High BS:215-1970
Voltage (400 KV) and above
5. IS : 1778- Reels and Drums for Bare BS:1559-1949
1980 Conductors
6. IS : 1521- Method of Tensile Testing of ISO 6892-1984
1991 Steel Wire
7. IS : 2629- Recommended Practice for
1990 Hot Dip Galvanising of Iron
and Steel
8. IS : 2633- Method of Testing Uniformity
1992 of Coating on Zinc Coated
Articles
9. IS : 4826- Galvanised Coating on IEC : 888-1987
1992 Round Steel Wires BS:443-1969
10. IS : 6745- Methods of Determination BS:433-1969
1990 of Weight of Zinc Coating ISO 1460 - 1973
of Zinc Coated Iron and

537456407.doc Page 124

 Steel Articles
11. IS : 8263- Method of Radio Interference IEC:437-1973
1990 Tests on High Voltage NEMA:107-1964
Insulators CISPR
12. IS : 9997- Aluminium Alloy Redraw IEC 104 - 1987
1988 Rods
13. Zinc Coated steel wires for IEC : 888-1987
stranded Conductors
14. Hard drawn Aluminium wire IEC : 889-1987
for overhead line conductors
15. IS:398 Aluminium Alloy stranded IEC : 208-1966
(Part-IV) conductor BS-3242-1970
16. Aluminium clad steel wires IEC:1232
17. Method of measurement of IEC:468
resistivity of metallic materials
18 Ampacity IEEE738
19. Creep

The standards mentioned above are available from:

Reference Abbreviation Name and Address

BS British Standards,
British Standards Institution
101, Pentonvile Road,
N - 19-ND
UK

IEC/CISPR International Electro technical Commission,

Bureau Central de la Commission, electro
Technique international, 1 Rue de verembe,
Geneva
SWITZERLAND.
BIS/IS Beureau Of Indian Standards.
Manak Bhavan,
9, Bahadur Shah Zafar Marg,
New Delhi - 110001.
INDIA

ISO International Organisation for Standardization.

Danish Board of Standardization
Danish Standardizing Sraat,
Aurehoegvej-12
DK-2900, Heeleprup,
DENMARK.

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 NEMA National Electric Manufacture Association,
155, East 44th Street.
New York, NY 10017
U.S.A.

5.0 ANNEXURE-A
5.1.0 Tests on Conductor
5.1.1 UTS Test on Stranded Conductor
Circles perpendicular to the axis of the conductor shall be marked at two
places on a sample of conductor of minimum 5 m length between fixing
arrangement suitably fixed by appropriate fittings on a tensile testing
machine. The load shall be increased at a steady rate upto 50% of
minimum specified UTS and held for one minute. The circles drawn shall
not be distorted due to relative movement of strands. Thereafter the load
shall be increased at steady rate to minimum UTS and held 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.
5.1.2 D.C. Resistance Test on Stranded Conductor
On a conductor sample of minimum 5m length two contact-clamps shall be
fixed with a predetermined bolt torque. The resistance shall be measured
by a Kelvin double bridge or using micro ohm meter of suitable accuracy by
placing the clamps initially zero metre and subsequently one metre 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 20 0C as per
IS:398-(Part-IV)/(Part-V). The resistance corrected at 20deg C shall conform
to the requirements of this Specification.
5.1.3 Coefficient of linear expansion for core/core strands
The temperature and elongation on a sample shall be continuously
measured and recorded at interval of approximately 15 degree C from 15
degree C to maximum continuous operating temperature corresponding to
rated current(720A) by changing the temperature by suitable means.
Coefficient of linear expansion shall be determined from the measured
results.

5.1.4 Breaking load test on Aluminium Alloy & Core strands and
D.C Resistance test on Aluminium Alloy wire
The above tests shall be carried out as per IEC: 888/889 and the results
shall meet the requirements of the specification.

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5.1.5 Wrap test on Core strand
The wrap test on steel strands shall be meet the requirements of IEC: 888.
In case of aluminium clad core wire, the same shall be wraped around a
mandel of diameter of five times that of the strand to form a helix of eight
turns. The strand shall be unwrapped. No breakage of strand shall
occurred.
5.1.6 Heat Resistance test on Aluminium Alloy wire
Breaking load test as per clause 1.5 above shall be carried out before and
after heating the sample in uniform heat furnace at 280 degC (+5/-3 degC)
temperature for one hour. The breaking strength of the wire after heating
shall not be less than the 90% of the breaking strength before heating.
5.1.7 Chemical Analysis of Aluminium Alloy and Core
Samples taken from the Aluminium and core coils/strands shall be
chemically/spectrographically analysed. The same shall be in conformity to
the particulars guaranteed by the bidder so as to meet the requirements
stated in this Specification.

5.1.8 Visual and Dimensional Check on Drums

The drums shall be visually and dimensionally checked to ensure that they
conform to the approved drawings.
5.1.9 Visual Check for Joints, Scratches etc.
Conductor drums shall be rewound in the presence of the Employer. The
Employer shall visually check for scratches, joints etc. and that the
conductor generally conform to the requirements of this Specification. Ten
percent (10%) drums from each lot shall be rewound in the presence of the
Employer's representative.
5.1.10 Dimensional Check on Core Strands and Aluminium Alloy Strands
The individual strands shall be dimensionally checked to ensure that they
conform to the requirement of this Specification.
5.1.11 Check for Lay-ratios of Various Layers
The lay-ratios of various layers shall be checked to ensure that they
conform to the guaranteed values furnished by the Contractor.

5.1.12 Procedure Qualification test on welded Aluminium Alloy strands.

Two Aluminium Alloy wire shall be welded as per the approved qualityplan
and shall be subjected to tensile load. The breaking strength of the welded
joint of the wire shall not be less than the guaranteed breaking strength of
individual strands.

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5.1.13 Chemical Analysis of Zinc
Samples taken from the zinc ingots shall be chemically/ spectrographically
analysed. The same shall be in conformity to the requirements stated in the
Specification.
5.1.14 Galvanising Test
The test procedure shall be as specified in IEC : 888. The material shall
conform to the requirements of this Specification. The adherence of zinc
shall be checked by wrapping around a mandrel four times the diameter of
steel wire.
5.1.15 Torsion and Elongation Tests on Core Strands
The test procedures shall be as per clause No. 10.3 of IEC 888. In torsion
test, the number of complete twists before fracture shall not be less than
18 on a length equal to 100 times the standard diameter of the strand. In
case test sample length is less or more than 100 times the stranded
diameter of the strand, the minimum number of twists will be proportioned
to the length and if number comes in the fraction then it will be rounded off
to next higher whole number. In elongation test, the elongation of the
strand shall not be less than 1.5% for a gauge length of 250 mm.

5.1.16 Bending test on aluminium clad core strand

A sample of aluminium clad invar strand measuring 30 cm in length shall
be subject to bending with help of a vise. The vised length of wire should be
5 cm and radius of bend 4.8 mm. The bending should be first 90 degrees
left and 90 degree right. After this operation the strand should cut at the
bending point. There should be no separation of core and aluminium at the
bending point after this operation.

5.1.17 Compression test on aluminium clad strand

A sample of aluminium clad core strand 10 mm in length is to be

compressed by a plate with a load of 3600 kgs. The aluminium and core
strand should not break.

5.1.18 Aluminium conductivity test on aluminium clad strand

Resistivity test as per IEC-468 shall be conducted to confirm minimum

conductivity as per specification requirement.

5.1.19 Minimum conductivity test on thermal resistant aluminium alloy

strands

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 Resistivity test as per IEC-468/IEC 889 shall be conducted to confirm
minimum conductivity as per specification requirement.

5.1.20 Stress-strain test at elevated temperature

Stress-strain test as per IEC-1089 shall be conducted keeping conductor
temperature at designed maximum temperature.

5.1.21 High Temperature endurance & creep test

A conductor sample of at least 20 m length shall be strung at tension

equal to 25 % of conductor UTS. The conductor temperature shall be
increased to designed maximum temperature in steps of 20 deg. C and
thermal elongation of the conductor sample shall be measured & recorded
at each step. Further, the temperature of the conductor shall be
maintained at maximum continuous operating temperature (+10 Deg. C)
for 1000 hours. The elongation/creep strain of the conductor during this
period shall be measured and recorded at end of 1 hour, 10 hour, 100 hour
and subsequently every 100 hour upto 1000 hours time period. After
completion of the above, the conductor sample shall be subjected to UTS
test as mentioned above at clause 1.1 of Annexure-A.

The supplier shall furnish details of creep characteristic in respect of the

conducted based on laboratory test and other laboratory investigations/
experimental conducted on similar type of conductor and shall indicate
creep strain values corresponding to 1 month, 6 month, 1 year, 10 year &
20 year creep at everyday tension & continuous designed temperature.

5 Axial Impact Test.

The conductor sample shall be suspended vertically and load applied by

dropping a 650 Kg from an elevation of 4 meters above the sample. The
impact velocity shall be not be less than 8 m/sec. with an intial pre-tension
of 200 kgs. The curve for load vs time shall be recorded and recorded load
of failure for core shall not be less than UTS of core.

5.1.23 Crush Strength Test

A section of conductor is to be crushed between two six inch steel platens.

Load shall be held at 350 Kgs for 1 minute and then released. All the
strands shall be subsequently disassembled and tensile tested. All the
strands shall exhibit full strength retention

5.1.24 Torsional Ductility Test

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 After removing the outer layer aluminium/ aluminium alloy strands, the
conductor shall be loaded to 25% of UTS and than loaded in increasing
steps of +/-180 deg, the core shall withstand atleast 16 such rotation.

5.1.25 Sheaves Test (if required)

The conductor sample of minimum length of 35 meter shall be tensioned at

22 % of the UTS and shall be passed through pulleys having diameter of
32 times that of the conductor with angle of 20 deg. between the pulleys.
The conductor shall be passed over the pulleys 36 times a speed of 2
m/sec. After this test UTS test on the conductor shall be carried out.

*****

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 SECTION – V
(VOLUME – II)

TECHNICAL SPECIFICATIONS
FOR

GSS GROUND WIRE (7/3.15mm)

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 VOLUME-II
SECTION-V
TECHNICAL SPECIFICATION FOR GROUND WIRE (7/3. 15mm)

1.0 SCOPE

2.0 STANDARDS

3.0 MATERIALS

4.0 SIZES AND CONSTRUCTIONS

5.0 LENGTHS AND JOINTINGS

6.0 TEST AND TEST CERTIFICATE

7.0 PACKING AND MARKING

8.0 SAG AND TENSION CHARTS

537456407.doc Page 132

 VOLUME II

SECTION – V

TECHNICAL SPECIFICATIONS FOR GROUNDWIRE (7/3.15mm)

SCOPE:

1.0 This Specification provides for the manufacture, testing before despatch
supply and delivery of 7/3.15mm ground wire 1100 NEWTON/Sq.mm
quality (grade 3 as per IS 12776 of 1989 for the purpose of earthing and
protection of power transmission lines as per the particulars given in
Appendix – I attached. The ground wire shall consist of standard
galvanised steel wires. The other applicable standards are IS-209/2979,

IS-1521/1972, IS-1755/1961, IS-1778/1961,

IS-2633/1972, IS-4826/1979, IS-6745/1972,
IS-5714/1979, IS-6594/1977, IS-1766/1983,
IS-182/1972.

2.0 STANDARDS:
The ground wire shall comply in all respects with the latest edition of IS
12776/1989 (with latest amendments).

3.0 MATERIALS:
The materials offered shall be of best quality and workmanship. The steel
wire (strands) shall be manufactured from steel produced by the suitable
process. The steel wire shall not contain sulphur and phosphorous
exceeding 0.05% each.
The steel wire shall be evenly and uniformly coated with Zinc complying
with IS-209/1979 specification for Zinc (revised)-99.99% grade and zinc
coating shall conform to heavy type coating as per IS-4826/1979

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 including latest amendments, IS-2633/1972 and IS-6745/1972. The
individual wires after galvanising shall be smooth, free of inequalities,
spills or splits before stranding.

4.0 SIZES AND CONSTRUCTION:

The sizes and physical properties of the ground wire shall be as given in
Appendix-I. The lay of the strands shall be of lengths given in the
appendix and the wires shall be so stranded together that when an evenly
distributed pull is applied at the end of completed strands, each wire will
take an equal share of the pull.

5.0 LENGTHS AND JOINTINGS:

The ground wire may be supplied in the standard length of 2 Kms.

However, random lengths of ground wire up to a minimum of 10 (ten)
percent may be allowed.
The length of strand, which may be supplied without joints. In the
individual wires comprising it, depends on the lengths of wire, which may
be carried by the bobbin in a normal stranding machine. The normal
lengths of strands which shall be supplied without joints in individual
wires, excluding welds made in the rod before drawing shall be as given
in Appendix-I. The lengths may be exceeded by agreement between the
manufacturer and Owner. Joints are not permitted either in the
individual strand wires or in completed strand.
Each coil shall be warranted to contain no weld joints or splice. The wire
shall be free from scale, irregularities, imperfections, flaws, splits and
other defects. The zinc coating shall be smooth even and bright.

6.0 TEST AND TEST CERTIFICATE:

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 Samples from each lot shall be tested for ascertaining the conformity to
the requirements of the ground wire, specified herein. The coils selected
shall be tested for lengths of the lay joints. The lot shall be declared
conforming to the requirements of these characteristics if all the coils are
found satisfactory. One test specimen from each wire of the strand shall
now be drawn from every selected coil and subjected to tensile test,
ductility test and coating test. One test specimen of the completed strand
shall now be drawn from every selected coil and subjected to tensile
strength. The lot shall be declared conforming to the requirements of
these characteristics if all the test specimen satisfy the relevant
requirement.
All the coils of the galvanised strand of the same grade, diameter, and
construction, manufactured under similar conditions shall be grouped to
constitute one lot.

6.01 CHEMICAL ANALYSIS:

One sample shall be drawn from the lot for chemical analysis. Unless
otherwise agreed to between the owner and the supplier, the chemical
analysis shall be carried out.

6.2 TENSILE TEST:

The wire when tested in accordance with the IS-1521 or any one-gauge length
of 100 mm, shall have the minimum-breaking load of strand as specified in
Appendix-I, shall be as follows. The tensile strength of the finished strand
shall not be less than 95% of the aggregate of the single wires.

6.03 DUCTILITY TEST:

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 The wire shall be subjected to wrapping test in accordance with IS-1755.
When wrapped eight times round its own dia and on being subsequently
straightened, the wire shall not break or split.

6.4 COATING TEST:

The uniformity of zinc coating shall be tested as per IS-2633. The wire shall
withstand the number of dips specified in Appendix-I or as per latest edition of
IS-4826 and IS-6745/1972.

6.5 TOLERANCE ON WIRE DIAMETER:

The tolerance shall be +0.06 and –0.03 in millimeter as per clause 6.1 of IS-
12776/1989.

6.06 CHEMICAL ANALYSIS:

Shall be conducted on a sample drawn from each lot as per clause 8.1.4 of IS-
2141/1979.

6.07 ACCEPTANCE TEST:

The acceptance tests shall be conducted as per the scale of sampling specified
in standard IS-12776/1989.
Samples from each lot shall be tested for ascertaining the conformity to the
requirements of this specification. The number of coils to be selected shall be
in accordance with Clause-10 of the of IS 12776/1989. The lot shall be
declared in conformity with the requirements of the following tests are
satisfied. The length of the test sample shall be not less than 5 (five) metres.
i. Length and lay of joints.
ii. Ductility Test.
iii. Tolerance on wire diameter.
iv. Tensile and Elongation test.
v. Galvanising test.

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 vi. Electrical resistance as per BS 182 – 1972 and
BS 5714 – 1979.
The above acceptance tests should be conducted in the presence of the
Purchasers representative. Three copies of manufacturer’s tests
certificate shall be submitted by the contractor to the owner for approval
immediately after such tests have been conducted on the G.S. strands
and the wire. No separate charge shall be payable for these type and
acceptance tests.
The owner reserves the right to inspect the material at manufacturer’s
works before despatch.

7.0 PACKING AND MARKING:

The ground wire shall be supplied in non-returnable reels or drums of
non-perishable or treated wood conforming to IS-1778/1961 Specification
for reels and drums for the same wires. Each coil shall be provided with
a label fixed firmly on the inner part of the coil bearing the following
information.
a) Trade mark, name if any.
b) Name of the manufacturer.
c) Type of wire-size and length of wire.
d) Net weight of the wire.
e) Tare weight and
f) No. of lengths on the reel or drum.

8.0 SAG AND TENSION CHARTS:

The successful tenderer shall submit seven copies of stringing charts for
earth wire showing initial and final sags and tensions for various
temperatures and spans. One set of chart shall be in ink or tracing.

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 APPENDIX – I

Details of ground wire (1100 Newton/Sq.mm quality) grade 3 as per

IS-12776/1989.

1. Stranding and wire diameter: 7/3.15mm

2. Single wire before stranding
a) Diameter Nominal: 3.15mm
Maximum: +3.23mm
Minimum: - 3.07mm
b) Minimum breaking load: 8.57 KNf
3. Lay length
i. Maximum : 265 mm
ii. Minimum : 123 mm
4. Minimum breaking load of
Stranded wire : 58.45 KNf
5. Percentage elongation at
break on complete strand : Min.4%
6. Minimum ultimate tensile
strength of individual strand : 1100 N/Sq.mm
7. Nominal overall diameter of
stranded wire : 9.45mm
8. Zinc coating
a) Duration and No. of dips : 1. Min dip 3.
b) Weight of coating : 260 Gms/Sq.mm
9. Normal length without joint

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 or weld in the same wire : 1000 Metres

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 SECTION – VI (A)
(VOLUME – II)

TECHNICAL SPECIFICATIONS
FOR

DISC INSULATORS

&

LONG ROD INSULATORS

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 VOLUME-II

SECTION-VI (A)
TECHNICAL SPECIFICATION FOR DISC / LONG ROD INSULATORS FOR
USE ON TRANSMISSION LINES

1.0 SCOPE

2.0 STANDARDS

3.0 PRINCIPAL PARAMETERS OF PORCELAIN DISC INSULATORS

4.0 GENERAL TECHNICAL REQUIREMENTS

5.0 TECHNICAL DESCRIPTION OF LONG ROD INSULATORS

6.0 GENERAL TECHNICAL REQUIREMENTS AND LONG ROD INSULATORS

7.0 MATERIAL DESIGN AND WORKMEN SHIP

8.0 TESTS

9.0 INSPECTION

10.0 DOCUMENTATION

11.0 PACKING AND FORWARDING

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 VOLUME – II
SECTION – VI (A)

TECHNICAL SPECIFICATION FOR DISC / LONG ROD INSULATORS FOR

USE ON TRANSMISSION LINES
(120KN & 90KN EMS)

1.0 SCOPE:
1.1 This specification provides for design, manufacture, engineering, inspection and
testing before dispatch, packing and delivery F.O.R. (destination) DISC
INSULATORS / LOG ROD INDULATORS as per technical requirements
furnished in this specification. These insulators are to be used in suspension and
tension insulator strings for suspension and anchoring of conductors on EHV
transmission towers of KPTCL.

1.2 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
judgement, is not in full accordance therewith.

2.0 STANDARDS
2.1 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 Internationally recognized standards to which same
of these standards generally correspond are also listed below:

Sl. Indian
Title International standard
No. Standard
Method for chemical analysis of
1 IS: 206
slab zinc
2 IS: 209 Specification for Zinc BS:3436
Porcelain insulators for overhead BS:137 (I&II)
3 IS:731 power lines with the nominal IEC:274
voltage greater than 1000 V. IEC:383
IS:2071 Method of High voltage Testing
Part(I)
4
Part (II)
Part(III)
5 IS:2121 Specification of Conductors and

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 Earth-wire Accessories for
Overhead Power lines
Part (I) Armour Rods, Binding-Wires and
Tapes for conductors
6 IS:2486 Specification for Insulator fittings
for overhead power lines with a
nominal voltage greater than 1000V
General Requirements and Tests
Part (I) Dimensional Requirements BS:3288
Part (II) Locking Devices IEC:120
Part (III) IEC:372
7 IS:2629 Recommended practice for hot dip
galvanization for iron and steel
8 IS: 2633 Testing for Uniformity of Coating
of Zinc Coated Articles
9 IS:3138 Hexagonal bolts and nuts IS0/R 947 and
IS0/R 272
10 IS:3188 Dimensions for Disc Insulators IEC:305
11 IS:4218 Metric Screw Threads IS0/R 68-1969 R 26-
1963, R262-1969 and
R 965-1969
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 IEC:437
Insulators NEMA Publication
No.107/1964 CISPR
14 IS:8269 Methods for switching impulse test IEC: 506
on HV insulators
15 Thermal Mechanical performance IEC:575
test and mechanical performance
test on string insulator units.
16 IEC Long rod insulators IEC-433

2.2 The Standards mentioned above are available from:

Reference
Name and Address
Abbreviation

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 British Standards, British Standards
BS institution, 101, Pentonvile Road, N-19, ND,
UK
International Electro technical Commission
Bureau Central de la Commission Electro
IEC/CISPR
Technique International 1, Rue de verembe
Geneva Switzerland
Bureau of India Standards,
Manak Bhavan,
IS
9, Bahadur Shah Zafar Marg,
New Delhi – 110 001 India
International Organisation for standardization
Danish Board of Standardization
ISO Dansk Standardisering Street,
Aurehoegvej – 12 DK – 2900
DENMARK
National Electric Manufactures Association
NEMA 155, East 44th Street, New York,
NY 10017 USA.

2.3 Insulators conforming to any other international standards are also acceptable
provided always that such standards are equivalent to or better than the
corresponding standards specified in 2.1 above However in such an event the
salient points of Comparison between the standards adopted and the standards
quoted herein shall be detailed in the appropriate schedule. Two copies authentic
English version of such standards shall be submitted along with the offer.
3.0 PRINCIPAL PARAMETERS:
3.1 Details of disc Insulators:
3.1.1 The insulator strings shall consist of standard discs for a three
phase. 50 HZ, effectively earthed 220 or 110 or 66KV transmission
system in a moderately polluted atmosphere. The discs shall be
cap and pin, ball and socket type.

3.1.2 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:

537456407.doc Page 144

 Minimum Electro-mechanical
No. of
Sl. Size of disc creepage Strength of
Type of String Standard
No. insulator(mm) distance of each Insulator string in
discs
disc (mm) KN
220 KV

01 Single Suspension 255x 145 320 13 90

02 Double Suspension 255x145 -do- 2x13 2x90

03 Single Tension 255x145 320 15 120

04 Double Tensile -do- -do- 2x15 2x120

110 KV

01 Single Suspension 255x145 320 7 90

02 Double Suspension -do- -do- 2x7 2x90

03 Single Tension 255x145 320 8 90

04 Double Tensile -do- -do- 2x8 2x90

66KV

01 Single Suspension 255x145 320 4 90

02 Double Suspension -do- -do- 2x4 2x90

03 Single Tension 255x145 320 5 90

04 Double Tensile -do- -do- 2x5 2x90

4.0 GENERAL TECHNICAL REQUIREMENTS :

4.1 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, foreign matter, imperfections or other defects which might render it
in any way unsuitable 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 versification.

4.2 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
co-efficient of expansion as that of the insulator shell. The thickness of the glaze shall

537456407.doc Page 145

 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 to 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.

4.3 METAL PARTS:

4.3.1 CAP AND BALL PINS:

Ball pins shall be made with drop forged steel and 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 material. 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.

4.3.2 SECURITY CLIPS:

The security clips shall be made of phosphor bronze or of stainless steel.
4.3.3 FILLER MATERIAL:
Cement to be used as a filler material shall be quick setting, fast curing port-land
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 it’s thickness shall be
as small and as uniform as possible.

4.4 MATERIAL DESIGN AND WORKMANSHIP:

4.4.1 GENERAL:
i. All raw materials to be used in the manufacture of these insulators shall be
subject to strict raw materials 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.
ii. The design, manufacturing, process and material control at various stages
be such as to give maximum working load, highest mobility, best

537456407.doc Page 146

 resistance to corrosion, good finish, elimination of sharp edges and corners
to limit corona and radio interference voltages.

4.4.2 INSULATOR SHELL:

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

4.4.3 METAL PARTS:

i. The Pin and cap shall be designed to transmit the mechanical stresses 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 string or when a
string is placed in position.

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

4.4.4 GALVANISING:
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 bright, continuous
and free from impurities such as flux, ash, rust strains, 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.

4.4.5 CEMENTING:
The insulator design shall be such that the insulating medium shall not directly
engage with hard metal. The surfaces of porcelain and coated with resilient paint
537456407.doc Page 147
 to offset the effect of difference in thermal expansions of these materials. A zinc
sleeve measuring 5mm thick and 20mm length shall be provided on the pin as
shown in the drawing Section-XII.

4.4.6 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:2468 (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 be 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 when 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 countersunk 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 it’s unlocked position shall not be less than 50N (5 Kg) or
more than 500 N (50 Kg).

4.5 BALL AND SOCKET DESIGNATION:

The dimensions of the balls and sockets for 90KN discs shall be of 16mm and for
120KN discs shall be of 20mm designation in accordance with the standard
dimensions state in IS:2486 (Part – II).

4.6 DIMENSIONAL TOLERANCE OF INSULATOR DISCS:

It shall be ensured that the dimensions of the insulators are within the limits
specified below:
a. diameter of Disc (mm)

Standard Maximum Minimum

120 kN Disc 255 266 244
90 kN Disc 255 266 244

b. Ball to Ball spacing

between discs (mm)
Standard Maximum Minimum
120 kN Disc 145 149 141
90 kN Disc 145 149 141

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4.7 INTERCHANGEABILITY :
The insulators inclusive of the ball and socket fit shall be of standard design
suitable for use with ware fittings of any make conforming to relevant standards.

4.8 CORONA AND RIV PERFORMANCE:

All surfaces shall be even, smooth, without cuts, sions or projections. No part
shall be subject to excessive localized pressure. The metal parts and lain shall not
produce any noise generating corona at all operating conditions.

4.9 SUITABILITY FOR LIVE LINE MAINTENANCE:

The insulators shall be compatible for use wit line or live line maintenance
technique that usual hot line operations can be out with ease, speed and safety.

4.10 FREEDOM FROM DEFECTS:

Insulators shall have none of the following defects:
i. Ball pin shake
ii. Cementing defects near the pin like small blow holes, small hair cracks,
lumps, etc.
iii. Sand fall defects on the surface of the insulator.

4.11 INSULATOR STRINGS:

4.11.1 TYPE AND RATING:

The insulator strings shall be formed with standard discs described in this
specification for use on 3 phase, 220/110/66KV, 50 Hz effectively earthed systems
in an with pollution level as indicated in project synopsis atmosphere. Suspension
insulator strings for use with suspension / tangent towers are to be fitted with discs
of 90 KN EMS rating while tension insulator strings for use with Anchor / Tension
towers are to be fitted with discs of 120/90 KN EMS rating.

4.11.2 STRING SIZE:

The size of the disc insulator, the number to be used in different types of strings,
their Electro-mechanical strength and minimum nominal creep age distance shall
be as given in clause 3.1.2.

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4.12 STRING CHARACTERISTICS:
4.12.1 The characteristic of the complete sting shall be as follows:

Suspension Tension
220KV 110KV 66KV 220KV 110KV 66KV
i. Lightning Impulse withstand voltage
(dry) KV peak. 1050 550 325 1050 550 325
ii. Power frequency withstand voltage
(wet) KV r.m.s. 460 230 140 460 230 140
iii. Corona extinction voltage – KV
(rms) 176 - - 176 - -
iv. Max. RIV for complete string
including corona rings, arcing horns, clamps 500 - - 500 - -
etc, at 1.1 times maximum line to ground
voltage (micro-volts)
v. Mechanical failing load for each sting 120 90 90 120 90 90
KN.
vi. No deformation load for each string - - - - - -
Kgf.
vii. Max. voltage across any disc. 13% 13% 13% 13% 13% 13%

4.12.2 Insulator units after assembly shall be concentric coaxial within limits as
permitted by Indian standards
4.12.3 The string design shall be such that when units coupled together there shall be
contact between shell of one unit and metal of the adjacent unit.

5.0 TECHNICAL DESCRIPTION OF PORCELAIN LONG ROD

INSULATORS.

5.1 DETAILS OF PORCELAIN LONG ROD INSULATORS:

5.1.1 The Insulator string shall consists of standard long rod insulators with normal sheds
for three phase 50 Hz, effectively earthed 220/110/66kv transmission system in a
lightly/medium polluted atmosphere. The insulators shall be long rod type with
Ball & Socket connection.

5.1.2 Insulator shall have normal sheds/alternate sheds with good self-cleaning properties.
Insulator shed profile, spacing projection etc. shall be strictly in accordance with
the recommendations of IEC-815

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5.1.3 Supplier quoting for long rod insulators made of electro porcelain shall also
supply intermediate ball pins and intermediate arcing horns along with long rod
insulators.

5.1.4 The prices of these items shall be considered as included in the price of long rod
insulators.

5.2 The size of long rod insulator, minimum creep age distance, the number to be used
in different type of strings, their electromechanical strength and mechanical
strength of insulator string along with hard ware shall be as follows.

Length of the Min. No.of EMS of

Sl Line string with long Creep individu Insulat
Type of String
No KV rod ins.(Cap to age al units / or
Cap) (mm) distance string (KN)
Single Suspn 1885 2080 1X2 90
Single Tension 2030 2400 1X2 120
1 220kV
Double Suspn 1885 2080 2X2 90
Double Tension 2030 2400 2X2 120
Single Suspn 1015 2240 1X1 90
Single Tension 1160 2560 1X1 90
2. 110kV
Double Suspn 1015 2240 2X1 90
Double Tension 1160 2560 2X1 90
Single Suspn 580 1280 1X1 90
Single Tension 725 1600 1X1 90
3. 66kV
Double Suspn 580 1280 2X1 90
Double Tension 725 1600 2X1 90

5.3 STRING CHARACTERISTICS:

The Characteristics of the complete string with long rod insulators shall be as
follows.

537456407.doc Page 151

 Sl No Particulars 220 KV 110 KV 66 KV
Lightning Impulse withstand
1 1050 550 325
voltage (dry) KV peak
Power frequency withstand
2 460 230 140
voltage (wet) KV rms
Corona extinction voltage – KV
3 176 - -
(rms)
Max. RIV for complete string
including corona rings, arcing
4 horns, clamps etc., at 1.1 times 500 - -
maximum line to ground voltage
(micro-volts)

6.0 GENERAL TECHNICAL REQUIREMENTS:

6.1 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, foreign matter, imperfections or other
defects which might render it in any way unsuitable 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.

6.2 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 co-efficient of expansion as that of the insulator shell. The
thickness of the glaze shall be uniform throughout and the color of the glaze shall
be brown. The glaze shall have a visible luster and smooth on surface and be
capable of to 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.

6.3 METAL PARTS:

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6.3.1 CAP AND BALL PINS:

Ball pins shall be made with drop forged steel and 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 material. 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.

6.3.2 METAL PARTS:

i. The Pin and cap shall be designed to transmit the mechanical stresses 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 string or when a string is placed in position.
ii. Metal caps shall be free from cracks, seams, shrinks, air holes, blow holes
and rough edges. All metal surfaces shall be perfectly smooth with no
projecting parts or irregularities which may cause corona. All load
bearing surfaces shall be smooth and uniform so as to distribute the
loading stresses uniformly. Pins shall not show any microscopically
visible cracks, inclusions and voids.

6.3.3 SECURITY CLIPS:

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

6.4 FILLER MATERIAL:

Cement to be used as a filler material shall be quick setting, fast curing port-land
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 it’s
thickness shall be as small and as uniform as possible.

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7.0 MATERIAL DESIGN AND WORKMANSHIP:

7.1 GENERAL:
i. All raw materials to be used in the manufacture of these insulators shall be
subject to strict raw materials 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.
ii. 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.

7.2 INSULATOR SHELL:

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

7.3 METAL PARTS:

i) The Pin and cap shall be designed to transmit the mechanical stresses 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 string or when a string is placed in position.

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

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7.4 GALVANISING:

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 bright, continuous
and free from impurities such as flux, ash, rust strains, 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.

7.4.1 CEMENTING

The insulator design shall be such that the insulating medium shall not directly
engage with hard metal. The surfaces of porcelain and coated with resilient paint
to offset the effect of difference in thermal expansions of these materials. A zinc
sleeve measuring 5mm thick and 20mm length shall be provided on the pin as
shown in the drawing Section-XII.

7.5 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:2468 (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 be
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 when 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 countersunk 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 it’s unlocked position
shall not be less than 50N (5Kgs) or more than 500 N (50 Kgs).

7.6 BALL AND SOCKET DESIGNATION:

The dimensions of the balls and sockets for 90KN Long Rod shall be of 16mm
and for 120KN Long Rod shall be of 20mm designation in accordance with the
standard dimensions state in IS:2486 (Part – II)

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7.7 DIMENSIONAL TOLERANCE OF INSULATOR UNITS:
It shall be ensured that the dimensions of the insulators are within the limits
specified below:
+ (0.04d + 1.5)mm when d<300mm
+ (0.025d+6)mm when d>300mm
Where d being the dimensions in millimeters for diameter, length or creep age
distance as the case may be.

However, no negative tolerance shall applicable for creep age distance.

7.8 Intermediate Ball Pin Designation

The dimensions of the intermediate ball pin shall be in accordance with standard
dimension stated in IEC 471

7.9 Interchangeability:
The long rod insulator with ball and socket connection shall be of standard
design suitable for use with the hardware fittings of any make conforming to
relevant IS/IEC standards.

8.0 TESTS:

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

8.2 TYPE TESTS:

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

8.3 ACCEPTANCE TESTS:

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

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

8.5 TESTS DURING MANUFACTURE:

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

8.6 TEST VALUES:

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

8.7 TEST PROCEDURES AND SAMPLING NORMS:

The norms and procedure of sampling for the above tests shall be as per the
relevant Indian standard or other internationally accepted standards. This will be
discussed and mutually agreed to between the supplier and purchaser before
placement of order. The standards and norms 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 and procedure for the same shall be
as specified in annexure IV attached hereto or as mutually agreed to between the
supplier and the purchaser in the Quality Assurance program.

8.8 TYPE TESTS:

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

8.8.1 On unit Disc 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:137

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 d) Impulse voltage withstand
Flashover test (dry) : IEC:383

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

f) RIV test (dry) : IS:8263

8.8.2 On Porcelain Long Rod Insulator unit.

g) Verification of dimensions : IEC -383

h) Thermal mechanical
Performance test : IEC:575

i) Power frequency voltage

withstand and flashover
(i) dry (ii) wet : IEC-383

j) Impulse voltage withstand

Flashover test (dry) : IEC:383

j) Visible Discharge test (dry) : IS:731

k) RIV test (dry) : IS:8263

8.8.3 On the complete insulator string with hardware fittings:

a) Power frequency voltage withstand ) BS:137(Part-I)
test with corona control rings )
and under wet condition
b) Switching surge voltage withstand )
test under wet condition
(400KV only) )
)
c) Impulse voltage withstand test ) IEC:383
under dry condition. )
)
d) Impulse voltage flashover test )
under dry condition )

e) Voltage distribution test )

f) Corona and RIV test under ) As per this

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 dry condition ) Specification
g) Mechanical strength test )
h) Vibration )

8.8.4 On the complete porcelain long rod insulator string with hardware
fittings :
i) Power frequency voltage withstand ) IEC-383
test with corona control rings )
and under wet condition )
j) Switching surge voltage withstand )
test under wet condition )
(400KV only) )

k) Impulse voltage withstand test ) IEC:383

under dry condition. )

l) Impulse voltage flashover test )

under dry condition )

m) Voltage distribution test )

n) Corona and RIV test under ) As per this
dry condition ) Specification
o) Mechanical strength test )
p) Vibration )

8.8.5 All the type tests given under clause No.6.8.1 shall be conducted on Single
suspension and Double tension Insulator strings along with hardware fittings.

8.9 ACCEPTANCE TESTS:

8.9.1 For Disc Insulators:
a) Visual Examination : IS:731
b) Verification of Dimensions : IS:731
c) Temperature cycle test IS:731
d) Galvanizing test
e) Mechanical performance test : IEC:575
f) Test on locking device for ball ) IEC: 372
and socket coupling Eccentricity test
(As per this specification)
h) Electro – mechanical )
strength test )

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 ) IS:731
g) Puncture test
8.9.2 For Porcelain Long rod Insulator:

a) Visual examination As per IEC 383

b) Verification of dimensions As per IEC 383

c)Temperature cycle test )

) IS:731/IEC-383
h) Galvanizing test )

i) Mechanical performance test : IEC:575

j) Test on locking device for ball : IEC: 372

and socket coupling

Eccentricity test ) As per this

) specification/IEC 383
n) Electro – mechanical )
strength test )
) IS:731/IEC 383
k) Puncture test )
)
l) Porosity test )

8.10 ROUTINE TEST :

8.10.1 For Disc Insulators:
a) Visual Inspection )
) IS:731
b) Mechanical Routine Test )
c) Electrical Routine Test ) IEC:383

8.10.2 For Porcelain Long rod Insulators:

d) Visual Inspection )
) IS:731/IEC 383
e) Mechanical Routine Test )
f) Electrical Routine Test ) IEC:383

8.11 TESTS DURING MANUFACTURE:

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 On all components as applicable

a) Chemical analysis of zinc used )

for galvanizing )

b) Chemical analysis, mechanical )

and metallographic test and )
magnetic particle inspection for )
malleable castings.

c) Chemical analysis, harness test ) As per the

and magnetic particle inspection ) Specification
for forgings

d) Hydraulic Internal pressure test )

on shell

e) Crack detection test for metal parts )

8.12 ADDITIONAL TEST:

The purchaser reserves the right for carrying out any other tests of a reasonable
nature at the works of the supplier 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 materials complies with the intent of
this specification.

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

8.14 TEST CHARGES AND TEST SCHEDULE:

8.14.1 TYPE TESTS:

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 The disc insulators offered shall be fully type tested as per this specifications.
The bids offering Disc Insulators not type tested will be rejected. These tests
must not have been conducted earlier than five years from the date of bid
opening. In case the equipment of the type and design offered, has already been
type tested, the bidder shall furnish four sets of type test reports along with the
offer. In case the type tests are conducted earlier than five years all type tests as
per the relevant standards shall be carried out by the successful bidder in the
presence of purchaser’s representative at free of cost. The purchaser reserves the
right to demand repetition of any or all the type tests in the presence of his
representatives. For this purpose, the bidder may quote relevant rates for carrying
out each type test. The prices quoted by the bidder towards conductance of type
test shall be taken into consideration for bid evaluation. For any change in the
design / type already type test and the design / type offered against this
specification the purchaser reserves the right to demand repetition tests without
any extra cost.

8.14.2 ACCEPTANCE AND ROUTINE TESTS:

All acceptance and Routine tests as stipulated here shall be carried out by the
supplier in the presence purchaser’s representative.
8.14.3 Immediately after finalization of the programme of type / acceptance / routine
testing, the supplier shall give sufficient advance intimation to the Owner, enable
him to depute his representative for witness the test.
8.14.4 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.
8.14.5 In case of failure of the complete string in any type tests, the manufacturer whose
product has failed in type tests, shall get the tests repeated at his cost. In case of
any dispute, assessment of the Purchasers to the items that has caused the failure
in any of the type tests shall be final and binding.

9.0 INSPECTION:
9.1.1 Purchaser and its representative shall at a times be entitled to have access to the
works and to all places of manufacture 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 for
conducting necessary tests and specified herein.
9.1.2 The supplier shall keep the Purchaser informed in advance of the time of starting
and progress of manufacture of insulators in various stages so that arrangements
could be made for inspection.
9.1.3 No material shall be dispatched from its point of manufacture unless the material
has been satisfactorily inspected and tested.

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 9.1.4 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 disc insulators are later found to be defective.

9.2 IDENTIFICATION MARKING:

9.2.1 Each disc insulator shall be legibly and indelibly marked with the trademark 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.

9.2.2 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.

9.3 Quality assurance plan:

9.3.1 The bidder hereunder shall invariably furnish following information’s along with his
offer, failing which the offer shall be liable for rejection.
i. Statement giving list of important raw materials, names of sub-suppliers
for the raw materials, list of standard, according to which the raw materials
are tested, list of tests, normally carried out on raw material in presence of
Bidder’s representative, copies of test certificates.
ii. Information and copies of test certificates as in (i) above in respect of
bought out material.
iii. List of manufacturing facilities available.
iv. Level of automation achieved and list of areas where manual processing
exists.
v. List of areas in manufacturing process, where stage inspections are
normally carried out in quality control and details of such tests and
inspections.
vi. Special features provided in the equipment to make it maintenance free.
vii. List of testing equipment 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.

9.3.2 The supplier shall within 30 days of placement of order submit the
following information to the owner.
i. List of raw materials and the names of sub-suppliers selected from those
furnished along with the offer.

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 ii. Type test certificates of the raw material and bought out accessories.
iii. Quality assurance plan (QAP) with hold points for purchasers inspection.
The QAP and purchaser’s hold points shall be discussed between the
Owner and the supplier before the QAP is finalised.
9.3.3 The supplier shall submit the routine test certificates of bought out items and raw
material at the time of routine testing of the finalized insulator.

10.0 Documentation:
10.1 The bidder shall furnish full description and illustrated catalogues of insulators
offered along with the offer.
10.2 TEST REPORTS:
i. Four copies of type test reports shall be furnished to the purchaser’s within
one month conducting the tests. One copy will be return duly certified by
the purchaser’s to the supplier within three weeks there afterwards and
receipt of the same supplier shall commence with the commercial
production of the concern material.
ii. Four copies of acceptance test reports shall furnished to the purchaser’s.
One copy will returned, duly certified by the purchaser’s and only there
after shall the materials be dispatched.
iii. All records of routine test reports shall maintained by the supplier at his
works for periodic inspection by the purchaser’s.
iv. All test reports of tests conducted during manufacture shall be maintained
by the supplier. These shall be produced for verification as and when
requested for by the purchaser.

11.0 PACKING & FORWARDING:

i. All disc insulators shall be packed in strong seasoned wooden crates. The
gross weight of the crates along with disc insulators shall not normally
exceed 200 kg. to avoid handling problem. Suitable lifting lugs shall be
provided on the crates in order to facilitate handling by cranes.
ii. The packing shall be of sufficient strength to withstand rough handling
during transit, storage at site and subsequent handling in the field.
iii. Suitable cushioning, protective padding, Dunn age or spacers shall be
provided to prevent damage or deformation during transit and handling.
iv. All packing cases shall be marked legibly and correctly so as to ensure
safe arrival at their destination and avoid the possibility of goods being lost
or wrongly dispatched on account of faulty packing and faulty or illegible
markings. Each wooden case / crate shall have all the markings stenciled
on it in indelible ink.

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 Annexure-A
TEST DETAILS
1.0 TESTS ON COMPLETE STRING WITH HARDWARE FITTINGS:
1.1 VOLTAGE DISTRIBUTION TEST:
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. The voltage across
any disc shall not exceed the values given in clause4-12.1

1.2 CORONA EXTINCTION VOLTAGE TEST (DRY):

The sample assembly when subjected to power frequency voltage shall have a
corona extinction voltage of not less than the value specified at clause 4.12.1 (iv)
under dry condition. There shall be no evidence of corona on any part of the
sample when all possible source of corona are photographed in a darkened room.

1.3 RIV TEST (DRY):

Under the conditions as specified in (2) above, the insulator string along with
complete hardware fittings shall have a radio interference voltage level below 500
micro volts at one MHz when subjected to 50 Hz AC voltage of 1.1 times
maximum line to ground voltage under dry condition. The test procedure shall be
in accordance with IS:8263/IEC:437

1.4 MECHNICAL STRENGTH TEST:

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 at steady 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.

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1.5 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 insulators shall be
subjected to the following tests as per relevant standards.

Test %age of units to be tested

Disc. Long Rod

a. Temperature cycle test followed by

mechanical performance test. 60 100
b. Puncture test 40 -
(for porcelain insulator only)

2. ON DISC INSULATOR UNITS/PORCELAIN LONG ROD

UNITS (As applicable):

2.1 Steep Wave Front Test (For Disc Insulator only):

Test following test shall be performed on 10 insulator units in case of disc

insulators selected at random from the lot offered for selection of sample for type
test.

a. Each insulator unit shall be subjected to five successive positive and

negative impulse flashovers with a wave having minimum effective rate of
rise of 2500 KV per micro seconds.

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 b. Each unit shall then be subjected to three dry power frequency voltage
flashovers.

Acceptance Criteria:

An insulator shall be deemed to have met the requirement of this test if, having
been successfully subjected to the ten impulse flashovers, the arithmetic mean of
the three subsequent dry/power frequency voltage flashover values equals or
exceeds 95% of the rated dry power frequency flashover voltage.

An insulator shall be deemed to have failed to meet the requirement of above

testing if,

a) It has not flash over when the oscillogram or peak voltage indicator shows
a marked reduction in voltage.

or

b) Any one of the subsequent three dry power frequency voltage flashover
value is less than 80% of the value specified.

Failure of any one unit either in the steep wave front or subsequent low frequency
voltage test shall cause for testing on double number of units.

2.2 Polarized Light Inspection (only for Glass Disc Insulator):

The disc insulator shall be held over a polarized light source and the stress lines
viewed thereon. There shall be no uneven stress distribution in the toughened
glass insulators. This shall be carried out on 100% glass shells.
2.3 Hydraulic Internal Pressure Test on Shells (only for Disc
Insulator):

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

2.4 Thermal Mechanical Performance Test:

Thermal Mechanical Performance Test shall be performed in accordance with

IEC-60383-1 Clause 20 with the following modifications:

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 1) The applied mechanical load during this test shall be 70% of the rated
electromechanical or mechanical value.
2) The acceptance criteria shall be

a) X greater than or equal to R + 35.

Where

X = Mean value of the individual mechanical failing load.

R = Rated electro-mechanical/mechanical failing load.
S= Standard deviation.

b) The minimum sample size shall be taken as 20 for disc insulator units and
5 units for long rod units.
c) The individual electromechanical failing load shall be at least equal to the
rated value. Also puncture shall not occur before the ultimate fracture.

2.5 Electromechanical/Mechanical Failing load Test:

This test shall be performed in accordance with clause 18 and 19 of IEC 383 with
the following acceptance.
i) X greater than or equal to R + 35
Where
X = Mean value of the individual mechanical failing load.
R = Rated electro-mechanical/mechanical failing load.
S= Standard deviation.
ii) The minimum sample size shall be taken as 20 for disc insulators units and 5
for long rod units. However, for larger lot size, IEC591 shall be applicable.
iii) The individual electro-mechanical failing load shall be at least equal to the
rated value. Also electrical puncture shall not occur before the ultimate fracture.
2.6 Residual Strength Test (For Disc Insulators only):
The above test shall be performed as per clause 4.4 and 4.5 of IEC 797 preceded
by the temperature cycle test, on both glass and porcelain disc insulators. The
Sample size shall be 25 and the evaluation of the results and acceptance criteria
shall be as per clause No.4.6 of IEC:797.

2.7 IR Measurements:
IR Measurement shall be carried out by the instrument operating at 1 KV DC. IR
value when measured under fair weather condition, shall not be less than 50 M-
ohm.

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2.8 Impact Test:

The Impact test shall be carried out in accordance with ANSI-C-29.2 Clause 8.2.8
with the following modification.

The breaking point of the pendulum shall be so adjusted that, when released the
copper nose will strike the outer rim of the shell or the most protruded rim of the
shell squarely in direction parallel to the axis of the unit and towards the cap.

The test specimen shall receive an impact of 7 N-m for 120 kN Disc & 10N-m for
160 kN Disc releasing the pendulum.

3 TESTS ON ALL COMPONENTS (As applicable)

3.1 CHEMICAL ANALYSIS OF ZINC USED FOR

GALVANIZING:
Sample taken from the zinc ingot shall be chemically analyzed as per IS:209.
The purity of zinc shall not be less than 99.95%.
3.2 TEST FOR FORGINGS:
The chemical analysis hardness tests and magnetic particle inspection for forgings
will be as per the international/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.

3.3 TEST ON CASTINGS:

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.

3.4 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.

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3.5 THERMAL MECHNICAL 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.

3.6 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 contract 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.

3.7 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.

537456407.doc Page 170

 SECTION – VI (B)
(VOLUME – II)

TECHNICAL SPECIFICATIONS
FOR
SILICON RUBBER COMPOSITE INSULATOR

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 VOLUME-II

SECTION-VI (B)
TECHNICAL SPECIFICATIONS FOR SILICON RUBBER COMPOSITE
INSULATOR FOR USE ON TRANSMISSION LINES

SPECIAL INSTRUCTION TO BIDDER

Please read the following instructions carefully before submitting

your bid.

1. All the drawings i.e., elevation, side view, plan cross sectional view

etc. in AutoCAD format and manuals in PDF format for offered

items shall be submitted . Also the hard copies as per specification

shall be submitted.

2. The bidder shall submit Quality Assurance Plan for manufacturing

process and field quality plan with the technical bid. The flow chart

of the manufacturing process with points of quality check clearly

indicated shall be submitted.

3. The bidder shall have to submit all the Design test and type test

reports for having designed and tested for the offered items. In

absence of this, evaluation shall be carried out accordingly as non-

submission of type test reports.

537456407.doc Page 172

 4. The bidder must fill up all the point of GTP for offered items/s.

Instead of indicating ‘refer drawing, or as per IS/IEC, the exact

value/s must be filled in.

5. All the points other than GTP, which are asked to confirm in

technical specifications must be submitted separately with the bid.

6. The bidder is required to impart training in view of manufacture,

assembly, erection, operation and maintenance for offered item, at

his works, to the person/s identified by KPTCL, in the event of an

order, free of cost. The cost of logistics will be borne by KPTCL.

7. Please note that the evaluation will be carried out on the strength

of content of bid only. No further correspondence will be made.

8. The bidder shall bring out all the technical deviation/s only as per

the specified annexure.

9. The bidder should indicate manufacturing capacity by submitting

latest updated certificate of a Chartered Engineer (CE).

537456407.doc Page 173

 QUALIFYING REQUIREMENT DATA

(For Supply)

Bidder to satisfy all the following requirements.

1) The bidder shall be Original Equipment Manufacturer (OEM). The

offered equipment have to be designed, manufactured and tested
as per relevant IS/IEC /ANSI with latest amendments.
2) The minimum requirement of manufacturing capacity of offered
type, size and rating of equipment shall be 7 times tender / bid
quantity. The bidder should indicate manufacturing capacity by
submitting latest updated certificate of a Chartered Engineer
(CE).
3) Equipment proposed shall be of similar or higher rating and in
service for a minimum period of THREE (3) years and satisfactory
performance certificate in respect of this is to be available and
submitted.
4) The bidder should clearly indicate the quantity and
Single Value Contract executed during last FIVE (5)
years, for the offered equipment. Bidder should have
executed one single contract during last five years
for the quantity equivalent to tender / bid. The
details are to be submitted in following format,
Sr ITEMS ORDER ITEM QUAN ORDER STATUS, IF REMAR
. SUPPLIE REFERE S TIT FULLY ORDER K
N D TO NCE No. Y EXECUTED UNDER
o & DATE YES/NO EXECUTIO
N

537456407.doc Page 174

5) Equipment offered shall have Type Test Certificates from accredited
laboratory (accredited based on ISO/IEC Guide 25 / 17025 or EN
45001 by the National accreditation body of the country where
laboratory is located), as per IEC / IS / technical specification. The
Type test reports shall not be older than FIVE years and shall be
valid up to the expiry of validity of offer.

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 VOLUME-II

SECTION-VI (B)
TECHNICAL SPECIFICATION FOR SILICON RUBBER COMPOSITE
INSULATORS FOR USE ON TRANSMISSION LINES

1. SCOPE

2. PRE-QUALIFYING REQUIREMENTS.

3. STANDARDS

4. SERVICE CONDITIONS

5. BASIC TECHNICAL PARAMETERS OF TRANSMISSION LINES.

6. PRINCIPAL PARAMETERS OF SILICON RUBBER COMPOSITE

NSULATORS

7. SPECIFIC TECHNICAL REQUIREMENTS OF SILICON RUBBER

COMPOSITE

8. VERIFICATION OF HOUSING MATERIALAL.

9. BALL AND SOCKET DESIGN

10. DIMENSIONAL TOLERENCE OF COMPOSITE INSULATORS.

11. INTERCHANGIABILITY

12. SUITABILITY FOR LIVE LINE MAINTENANCE.

13. CORONA & R I PERFORMANCE

14. WORKMANSHIP

15. MARKINGS

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 16. PACKING

17. INSPECTION,TESTS AND STANDARDS.

18. TEST REPORTS & DOCUMENTATION

19. TEST FECILITY

20. QUALITY ASSURANCE PLAN

21. DOCUMENTATION

22. DRAWINGS.

23. DEVIATIONS

24. MAINTENANCE.

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 VOLUME-II

SECTION-VI (B)
TECHNICAL SPECIFICATION FOR SILICON RUBBER COMPOSITE
INSULATORS FOR USE ON TRANSMISSION LINES
(120KN & 90KN EMS)

5.0 SCOPE:
1.3 This specification provides for design, manufacture, engineering,
inspection and testing before dispatch, packing and delivery F.O.R.
(destination) of SILICON RUBBER COMPOSITE as per
technical requirements furnished in this specification. These
insulators are to be used in suspension and tension insulator
strings for suspension and anchoring of conductors on EHV
transmission towers of KPTCL.

1.4 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.

The materials covered here under this specification shall be

supplied complete in all respects, including all components,
fittings and accessories which are necessary or are usual for their
efficient performance and satisfactory maintenance under the
various operating and atmospheric conditions. Such parts shall
be deemed to be within the scope of the Contract, whether
specifically included or not in the Specification or in the Contract
Schedules. The Supplier shall not be eligible for any extra
charges for such fittings, etc.

6.0 PRE- QUALIFYING REQUIREMENT:

The bidders should be original manufacturer of the Silicon Rubber
composite insulators and shall have all the facilities to
manufacture 90KN & 120KN and higher Size of Composite long

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 rod insulators. Traders are not eligible for the tenders offered by
KPTCL.

7.0 STANDARDS
7.1 Except as modified in this specification, the SILICON RUBBER
COMPOSITE insulators shall conform to the following Indian
standards which shall mean latest revisions and amendments.
Equivalent International and Internationally recognized standards
to which same of these standards generally correspond are also
listed below:

Indian
Sl. International
Standa Title
No. standard
rd
International Electro- IEC 60050 –
1 technical Vocabulary Chapter 471
Insulators
2 Method for chemical
IS: 206
analysis of slab zinc
3 IS: 209 Specification for Zinc BS:3436
Composite insulators
for A.C. Overhead
4 power lines with the IEC:61109-
nominal voltage 1992
greater than 1000 V.
Method of High IEC:60060-1 -
IS:207 voltage Testing General
1 definition& test
5 Part(I) requirements.
Part (II) IEC:60060-2 –
Part(III) Measuring
systems.
6 IS:212 Specification of
1 Conductors and
Earth-wire
Accessories for

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 Part (I) Overhead Power lines
Armour Rods,
Binding-Wires and
Tapes for conductors
7 IS:248 Specification for IEC: 575
6 Insulator fittings for
overhead power lines
with a nominal
voltage greater than BS:3288
Part (I) 1000V IEC:6020
Part (II) General IEC:60372
Part Requirements and
(III) Tests
Dimensional
Requirements
Locking Devices
8 IS:262 Recommended ISO:1459
9 practice for hot dip ISO:1460
galvanization for iron ISO:1461
and steel
9 IS: Testing for Uniformity
2633 of Coating of Zinc
Coated Articles
10 IS:313 Hexagonal bolts and IS0/R 947 and
8 nuts IS0/R 272
11 IS:318 Dimensions for Disc IEC:60305-
8 Insulators Characteristics
of insulator
units for O/H
lines with
nominal
Voltage above
1000 Volts.
12 IS:421 Metric Screw Threads IS0/R 68-1969
8 R 26-1963,
R262-1969
and R 965-
1969
13 IS:674 Determination of BS: 443-1969
537456407.doc Page 180
 5 weight of zinc coating ISO:1460
on zinc coated iron
and steel articles
14 IS:826 Methods of RIV Test IEC:60437
3 of HV Insulators NEMA
Publication
No.107/1964
CISPR
15 IS:826 Methods for switching IEC: 60506
9 impulse test on HV
insulators
16 Thermal Mechanical IEC: 60575
performance test and
mechanical
performance test on
string insulator units.
17 IEC Long rod insulators IEC-433
18 Salt Fog Pollution IEC-60507
Voltage Withstand
Test.
19 Residual strength of IEC- 60797
string Insulator Units
of Glass Or Ceramic
Material for Over head
lines after Mechanical
damage of the Di-
electric.
20 Guide for the Selection IEC- 60815
of insulators in respect
of polluted conditions.
21 Tests for insulators of IEC-60363.Part-
Ceramic materials or 1-Ceramic &
Glass for Over head Glass Units for
lines with a nominal a.c system-
Voltage greater than Definitions, Test
1000V. methods &
acceptance
criteria.
& Part 2-
Insulator strings

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 and sets for a.c
system.
22 Instruments & IEC :61083-1
Software used for
measurement in high
Voltage Impulse test –
Requirements of
Instruments
23 Impulse Puncture IEC- 61211.
testing in air – for
Ceramic or Glass or
Composite insulator for
O/H lines with nominal
voltage greater than
1000v.

3.2 The Standards mentioned above are available from:

Reference
Name and Address
Abbreviation
British Standards, British Standards
BS institution, 101, Pentonvile Road, N-19,
ND, UK
International Electro technical
Commission Bureau Central de la
IEC/CISPR Commission Electro Technique
International 1, Rue de verembe Geneva
Switzerland
Bureau of India Standards,
Manak Bhavan,
IS
9, Bahadur Shah Zafar Marg,
New Delhi – 110 001 India
International Organisation for
standardization
Danish Board of Standardization
ISO
Dansk Standardisering Street,
Aurehoegvej – 12 DK – 2900
DENMARK

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 National Electric Manufactures
Association
NEMA
155, East 44th Street, New York,
NY 10017 USA.

3.3 Insulators conforming to any other international standards are also

acceptable provided always that such standards are equivalent to or
better than the corresponding standards specified in 2.1 above
However in such an event the salient points of Comparison between
the standards adopted and the standards quoted herein shall be
detailed in the appropriate schedule. Two copies authentic English
version of such standards shall be submitted along with the offer.

4.0 SERVICE CONDITIONS:

Composite Insulators are to be for lines located near thermal power

stations using Coal, near sea coast which are getting polluted by
certain deposits from the sea, salt deposits in the water vapour from
cooling towers, coal dust & cement/fly ash. The lines covered under
this contract are to run in plains / undulating hilly terrain (Western
Ghats)/coastal areas/Polluted areas in the vicinity of Cement
factories,of Karnataka and shall be suitable for the hot and humid
tropical climatic conditions prevailing in the State. These are
furnished here below:
j) Peak ambient day temperature in still air – 50 0C.

k) Minimum night temperature – 100C.

l) Average maximum ambient day temperatures.

iii. June to January – 350C.
iv. February to May – 450C.

m) Relative humidity maximum – 90 % in coastal area; minimum

– 10 % in the Western Ghats and plains.

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 n) Maximum rainfall – 200 mm in the plains/6000 mm in the
coastal areas and the Western Ghats.

o) Average number of rainy days:- 120 between April and

November.

p) Average number of thunderstorm days/annum – 50 between

April and November.

q) Altitude above Mean Sea level – MTr..

iv. Varying from 0 to 250 m in the coastal areas.

v. Varying from 250 to 1000 m in the plains.
vi. 500 m in the Western Ghats.

r) Maximum wind speed.

iii. 39 m/sec in the coastal areas, the Western Ghats and the
plains of northeastern Karnataka ( Bidar, Gulbarga &
Raichur).

iv. 33 m/sec in the plains of northwestern and southern

Karnataka.

j) Seismic level i.e Earthquake Accelaration.

a) Horizontal Seismic Co-efficient
(acceleration )- g (Zone – 5).
b) a) Horizontal Seismic Co-efficient
(acceleration )- g (Zone – 5).

5.0 BASIC TECHNICAL PARAMETERS OF THE LINES:

A) Electrical System Data:

g) System Voltage (kV rms) 220 110 66
h) Maximum Voltage (kV rms) 245 123 72.5
i) Lightning impulse withstand
1050 550 325
voltage (dry & wet) (kVp)
j) Power frequency withstand
460 230 140
voltage (wet) (kVp)

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k) Power frequency withstand
510 265 165
voltage (dry) (kVp)
l) Short circuit level (KA)/duration 40/1 31.5/1
31.5/1 Sec
Sec Sec
B) Line Data:
i) Conductor: ACSR ACSR ACSR
j) Name DRAKE LYNX COYOTE
k) Conductor per phase Single Single Single
l) Spacing between the
conductors of same phase 4900 3100 2100
(Vertical) mm
m) Configuration
iii. Single Circuit Delta Right
angled Right angled triangle
Triangle
Vertical
iv. Double Circuit Vertical Vertical
n) Minimum ultimate tensile
14175 7950 4625
strength (kg)
o) Conductor tension at 320C
without external load
iii. Initial unloaded tension 35% 35% 35%
iv. Final unloaded tension 25% 25% 25%
C) Galvanized Steel Earthwire
( Ground Wire):
i) Size (strands and wire diameter)
7/3.15 7/3.15 7/3.15
(mm)
j) Location of earth wire One continuous earth wire to run
horizontally on the top of the towers and
conductors
k) System of Grounding Solidly Solidly
Solidly earthed
earthed earthed
l) Progressive shielding angle 300 300 300
m) Isokeraunic level 50 50 50
n) Tensile load in each earth wire The tension of earth wire & power
conductor are so co-ordinated such that
the earth wire Sag shall not be more than
90% of the corresponding Sag of power
conductor under still air condition for the
entire specified temperature range.
D) Towers:

537456407.doc Page 185

 a) Span length in metres: 320 320 275
b) Wind span in meters 352 352 302
c) Wind Load (Kg/sq.m) 130 130 130
d) Suspension Towers 20
Tension Towers 150, 300, 600
E) Insulators:
b) Type of Insulators SILICON RUBBER COMPOSITE INSULATOR

Arcing horns both on the conductor side

b) Lightning protection to insulator
and cross arm side

6.0 PRINCIPAL PARAMETERS:

6.1 Details of Silicon Rubber Composite Insulators:
GENERAL REQUIREMENT
The design, manufacturing, processes, tolerances and inspection of
composite insulators shall confirm to the following.
Language and units:
i. All correspondence, literature, drawings and markings shall
be in the English language.
ii. Dimensioning shall be in the SI (Metric System) units.
Manufacturer should mention the standard adopted for
Dimensioning & tolerance principals considered for design.
iii. The insulator shall consist of standard module for a three
phase. 50 HZ, effectively earthed 220 or 110 or 66KV
transmission system in a moderately polluted atmosphere. The
insulator shall be therefore suitable for satisfactory operation
under the tropical climatic onditions listed in the relevant
clause. The applicable design particulars of the insulator to be
used on these lines are furnished in the ‘System particulars’.
iv. The end fitting of the Composite Insulators shall be shall be
ball and socket type with necessary coupling arrangement such
that the Pin shall move freely in the sockets but they do not get
disengaged while in service under various operating and
atmospheric conditions. The length and other dimensions
should be such that it should be substituted by other
conventional type Porcelain insulators. The Composite Insulator
Units shall have ‘Ball’ fitting on the line side and ‘Socket’
fitting on the tower side.
The insulator shall be suitable for being installed in air
supported on suspension insulator hardware or anchored
through tension insulator hardware at the power cross arm of

537456407.doc Page 186

 single circuit, double circuit or multi-circuit line towers , as
such it should be substitution for the conventional porcelain
insulators.
v. The insulators shall have sheds of open aerodynamic profile
with good self cleaning properties. Insulator shed profile,
spacing, projection etc shall be strictly in accordance with the
recommendations of IEC:60815.
vi. The colour of housing material shall be Dark Brown ,
uniform and consistent.
vii. The insulator shall be designed to withstand high pressure
(3800KPa)/ (550psi) water washing from a 6mm diameter nozzle
from a distance of 3 meter between nozzle to Polymer insulator,
viii. The track resistance of the material used in the manufacture
of housing and weathersheds shall meet the requirements of
IEC 587 class 1A4.5 or 1B4.5.
ix. The end fittings shall be free from defects like pittings,
scalings, laps, folds. Cracks, shrinks, blow holes. Burrs or
rough edges etc. The fittings shall be attached to the core
through crimping process (controlled compression technique)
and shall be designed to transmit the mechanical load to the
core and develop uniform and consistent mechanical strength of
insulators. The metal surfaces shall be perfectly smooth with no
projecting parts or irregularities which may cause Corona .Ball
pins shall not show any microscopically visible cracks.
inclusions and voids. The end fittings shall not contain parts of
pieces joined together, welded, shrink fitted or manufactured by
any other process from more than one piece of material.
x. The ball and socket fittings shall be designed to transmit the
mechanical stresses to the core and develop uniform
mechanical strength in the insulator . The socket 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 ball shall move freely in the socket either uring
assembly of a string or during erection of a string or when a
string is placed in position.
xi. The Design, manufacturing Process and material control ay
various stages shall 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. The design of the insulator string
shall be such that all the stresses due to expansion or
contraction in any part of the insulator under rapid

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 temperatures fluctuation, which may be created due to
variation in the loads or fault of any nature , while in service
shall not lea to any type of deterioration. Flat surfaces and
corners shall not be allowed and shall be completely rounded
off.
xii. All raw materials to be used in the manufacture of insulators
shall be subject to strict raw material quality Control and to
stage testing 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 lifetime performance on
transmission lines.
xiii. For reference the Size of conventional Disc insulator, Section
length of 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 indicated in Table-1 and Table-2.

TABLE:1

Minimum Electro-
Size of disc creepage No. of mechanical
Sl. Type of
insulator(mm distance of Standard Strength of
No. String
) each disc discs Insulator string
(mm) in KN
220 KV

01 Single 255x 145 320 13 90

Suspension
02 255x145 -do- 2x13 2x90
Double
03 Suspension 255x145 320 15 120

04 Single Tension -do- -do- 2x15 2x120

Double
Tensile
110 KV

01 Single 255x145 320 7 90

Suspension
02 -do- -do- 2x7 2x90
Double
03 Suspension 255x145 320 8 90

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 04 Single Tension -do- -do- 2x8 2x90

Double
Tensile
66KV

01 Single 255x145 320 4 90

Suspension
02 -do- -do- 2x4 2x90
Double
03 Suspension 255x145 320 5 90

04 Single Tension -do- -do- 2x5 2x90

Double
Tensile

ELECTRICAL STRING CHARACTERISTICS FOR DISC INSULATOR STRING:

TABLE -2
viii. Lightning Impulse
withstand voltage 1050 550 325 1050 550 325
(dry) KV peak.
460 230 140 460 230 140
ix. Power frequency
withstand voltage (wet) KV 176 - - 176 - -
r.m.s.
x. Corona extinction 500 - - 500 - -
voltage – KV (rms)
xi. Max. RIV for complete
string including corona rings, 120 90 90 120 90 90
arcing horns, clamps etc, at 1.1
times maximum line to ground - - - - - -
voltage (micro-volts)
xii. Mechanical failing load 13% 13% 13% 13% 13% 13%
for each sting KN.
xiii. No deformation load for
each string Kgf.

xiv. Max. voltage across any

disc.

xiv. Section length of Silicon rubber Composite insulator string, minimum creepage
distance required, no. of units per string & EMS of each unit is tabulated in Table -3.

537456407.doc Page 189

 TABLE-3
Min. No.of
Section length
Creep Standard EMS of
Sl Line of insulator
Type of String age individual Insulator
No KV ( Soket to Ball
distanc units / (KN)
pin) (mm)
e string
Single Suspn 1885 4160 1 90
Single Tension 2030 4800 1 120
1 220kV Double Suspn 1885 4160 1X2 90 x 2
Double 2030 4800 1X2 120 x 2
Tension
Single Suspn 1015 2240 1 90
Single Tension 1160 2560 1 90
2. 110kV Double Suspn 1015 2240 1X2 90 x 2
Double 1160 2560 1X2 90 x 2
Tension
Single Suspn 580 1280 1 90
Single Tension 725 1600 1 90
3. 66kV Double Suspn 580 1280 1X2 90 x 2
Double 725 1600 1X2 90 x 2
Tension

Note: The section length of insulators mentioned above is the required length of
insulator corresponding to equivalent length of disc insulator string. The bidder may
offer insulator varying in length with that mentioned above. However, in such a case
the total length of string including hardware fittings shall be within the maximum
and minimum limits specified in the drawing (inclusive of tolerances on hardware and
insulator ) attached to this specification.

6.2 STRING CHARACTERISTICS:

The Electrical String Characteristics of the complete string with long rod insulators
shall be as tabulated in Table – 4 .

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 TABLE-4

Sl No Particulars 220 KV 110 KV 66 KV

Lightning Impulse withstand voltage
1 1050 550 325
(dry) KV peak
Power frequency withstand voltage
2 460 230 140
(wet) KV rms
3 Corona extinction voltage – KV (rms) 176 - -
Max. RIV for complete string
including corona rings, arcing horns,
4 500 - -
clamps etc., at 1.1 times maximum
line to ground voltage (micro-volts)

6.3 DRAWINGS:
5.2.1 The General arrangement drawings in respect of 220KV, 110KV & 66KV
strings mentioned above are enclosed at the end of this specification. These
drawings are attached only for the information and guidance of the
manufacturer.
5.2.2 The manufacturer shall furnish outline drawing of the insulator and component
drawing of end fittings, Corona control ring indicating all dimensions. All
drawings shall be neatly arranged and all drafting and lettering shall be
standard and legible. Dimensions shall be in SI units. The drawings shall give
the following information.
1) The bill of material indicating quantity, nature grade and reference standard
of the material used for various parts,
2) Technical details like Section length of insulator, dry arcing distance,
creepage distance, ball and socket designation, identification mark on the
insulator.
3) Mechanical characteristics like specified mechanical load (SML) , Routine test
load (RTL) and weight of insulator.
4) Electrical characteristics like One minute Power frequency withstand voltage
under dry and wet conditions, lightening impulse withstand voltage.
Switching surge impulse withstand voltage. Corona inception and extinction
voltage.
5) After award of contract the bidder shall submit 3 sets of drawings to CEE
(P&C) , Kaveri Bhavan , Bangalore, giving details as mentioned above for

537456407.doc Page 191

 scrutiny and approval. Once the drawings have been approved no alteration
or modification will be carried put without prior approval of the purchaser.
6.4 GALVANIZING:
All ferrous parts shall be hot dip galvanized in accordance with IS: 2629/ASTM A 153
to resist corrosion. The Zinc to be used for galvanizing shall conform to grade Zn 98
(purity = 99.95%) of IS:209. The Zinc coating shall be uniform, smooth, reasonably
bright continuous and free from impurities such as flux, ash, rush bstains, bulky white
deposits and blisters. Before ball fittings are galvanized , all die flashing on the shank
and on the bearing surface of the shall be carefully removed without reducing the
designed dimensional requirements,
The Galvanised end fittings shall withstand 4 one minute dips in standard CuSO 4
solution as per IS: 2633. The mass of Zinc coating shall not be less than 610gm/m 2 (86
micro m)

7.0 SPECEFIC TECHNICAL REQUIREMENTS:

DESIGN, WORKMANSHIP AND MATERIAL REQUIREMENT

7.1 GENERAL:

It is not the intent to specify completely herein all details of design

and construction of the insulators involved. However, the insulator
shall conform, in all respects to the highest standards of
Engineering an workmanship and shall fulfill the anticipated
performance in a manner acceptable to the purchaser who will
interpret the meaning of drawings and specifications and shall have
the power to reject any material which in his judgment. are not in
full accordance therewith.

7.2 Design:
Silicon rubber Composite insulator shall be designed to meet the
high quality, safety and reliability capable of withstanding a wide
range of system and environmental conditions mentioned in
section 3,4 & 5 above. Composite insulators shall consists of Three
Parts, at least two of which are insulating parts:-

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 a) Core- the internal insulating part designed to ensure the
mechanical characteristics.
b) Housing –the external insulating part which provides the
necessary creepage distance and protects the core from
weather. A shed provided in the housing is a projecting
part of the housing intended to increase the creepage
distance.
c) Metal end fittings - intended to transmit the mechanical load.

7.2.1 Core:
The core shall be glass-fibre reinforced epoxy resin rod (FRP) of high di-
eletric and mechanical strength. Both, glass fibre and Epoxy resin
matrix material shall be optimized in the FRP rod. Process used for
manufacturing should yield a uniform material structure and
optimum control and regulation of the quality-influencing
parameters such as homogeneity and uni-directionality of the
glass fibre across the cross section of the rod. Glass fibers with low
content in alkalies shall be boron free ‘E’glass or Boron free
Electrically corrosion resistance(ECR) glass. Use of resin with
hydrolysis trend due to water penetration should be prevented i. e.
matrix of the FRP rod shall be Hydrolysis resistant. Suitability of Epoxy
matrix as well as interface between matrix and fibres is to be
considered as design parameter to prevent brittle fracture. The FRP rod
should be void free and shall be manufactured through Pultrusion
process and shall not be of draw forming process.
7.2.2 Housing:
The core of the composite insulator shall be completely covered by a
continuous housing consisting of a seamless sheath & -weathershed of

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 silicon rubber compound. For moulding of entire weather shed
structure on to the rod, a one shot moulding process or extruded
process shall be employed to avoid multiple interfaces i.e. the housing
shall consist of one piece of housing using injection moulding principle
consisting of seamless silicon rubber sheath with sheds to cover the
entire core, to protect the rod against environmental influences like
Hydrolysis, U.V radiations, Corona & Ozone degradation, nd also to
external Pollution and humidity. The interface between the housing
and the Fibre reinforced glass rod shall be chemically bonded to
prevent contaminations and moisture ingress. The strength of the bond
shall be greater than the tearing strength of composite insulating
material used. The manufacturer shall follow non-destructive
technique (N.D.T) to check the quality of jointing of the housing
interface with the core. The technique being followed with detailed
procedure and sampling shall be furnished along with the bid.
Hardware i. e. metal fittings may be installed on the rod prior to
moulding of the shed controlling moulding lines. The base polymer
shall be 100% Silicon Rubber prior to the addition of reinforcing fillers.
The housing and weathersheds shall have Silicon contents of minimum
of 30% to 40% by weight. The Shore ‘A’ hardness of Silicon rubber
used in the manufacture of housing and weathersheds shall not be
less than 60.
The thickness of compounding material on core should be minimum 3
mm. The weather-sheds of the insulators shall be of alternate shed
profile. The weathershed shall be vulcanized to the sheath (extrusion
process) or moulded as part of the sheath (injection moulding process)
and free from imperfections. The vulcanization for extrusion process
shall be at high temperature and for injection moulding shall be at

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 high temperature and high pressure. Any seams/ burrs protruding
axially along the insulator, resulting from the injection moulding
process shall be removed completely without causing any damage to
the housing. The track resistance of housing and shed shall be class
1A 4,5 according to IEC 60587. Manufacturer should furnish a
description of its Quality Assurance Programme including fabrication,
testing and inspection for any material (i.e. rubber),
components(i.e.rod) or hardware (i.e.end fittings). If the manufacturer
has got fabricated or manufactured components of insulator by others,
the same should also be included.
Manufacturing methods and material composition documentation will
be a part of Technical Bid to be submitted along with offer. Insulator
should have hermetically sealed structure in which the housing
material is molded to cover the interface between the end fittings and
the FRP rod. This seal should never be broken during testing or
otherwise.
7.2.3 End fittings:

The composite insulators shall be socket and ball type with the
necessary coupling arrangement such that pin shall move freely in the
cap socket either during assembly of a insulators or during erection
of insulators or when a insulators is placed in position but do not get
disengaged while in service under various operating and atmospheric
conditions.
The socket & ball type metal end fittings shall be designed to transmit
the mechanical stresses to the to the core & the end fittings by
compression and develop uniform mechanical strength in the insulator
Material and methods used in the fabrication of metal parts shall be

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 selected to provide good toughness and ductility. Metal end fittings shall
be made from a quality malleable cast iron or forged steel with high
tensile quality and shall be hot dipped galvanized in accordance with IS
2629 & ASTM A-153. Ball pins shall be made with drop forged steel and
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 material. 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 dimensions
of the end fittings of insulators shall be in accordance with the standard
dimensions stated in IEC:60210/IS:2486-Part-II.
The attachment to the FRP rod shall be performed with a symmetrically
controlled crimping method control by acquistic method such as Co-
axial Compression process that compresses the metal radially onto the
rod without damage to the individual rod fibre or resin matrix or causing
crack the rod, while providing a strength equal to or greater than the
defined and specified ultimate strength to the insulator. The
manufacturer shall have in-process Aquostic emission arrangements to
ensure that there is no damage to the core during crimping. The
verification shall be in-process and done on each insulator. The
Compression technique used shall make the insulator fittings relatively
insensitive to dynamic stresses which, for example, are caused by
conductor vibrations. The interface point of the housing and the metal
end fittings shall be sealed by a flexible silicon elastomeric , metastable
compound or Silicone alloy compound sealant. The system of
attachment of the end fittings to the rod shall provide superior sealing

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 performance between housing and metal connection. The sealing must
be humidity proof and durable with time.
The material used in fittings shall be corrosion resistant. Nominal
dimensions of the pin, ball and socket interior shall be in accordance
with the standard shown at Clause No. 2.0 of this Specefication. No
joints in ball & socket will be allowed. Outer portion of ball or socket
should be Zinc sleeved with minimum 99.95% purity of electrolytic high
grade Zinc. 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.
The bidder shall specify the grade, composition and mechanical
properties of steel used for fittings.
The surface shall not crack or get chipped due to ageing effect under
normal and abnormal service conditions or while handling during
transit or erection.
The design of the fittings and the insulators shall be such that there is
no local corona formation or discharges likely to cause the interference
to either sound or vision transmission.
7.2.4 INTERPHASE ZONES:
Every insulator has, depending on the design and manufacturing
process, various inter face zones between the individual
components of the insulator, as well as within the composite
material, the RBGF or FRP rod. In all the zones the best possible
bonding must be achieved at the interface surface of the materials
being bonded so that no voids are created which can lead to the
occurrence of partial discharges in service, causing ageing and
damade to the insulation. As silicon does not readily bond to other
substrates, the composite surface shall be sprayed evenly with a

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 primer on a silicon basis before the silicone weathershed is poured.
In this way no additional layer is formed between the reinforced
epoxy –resin rod and the silicon weathershed. The process should
be such that, from both an electrical and a mechanical view no
problems concerning interface surfaces and intermediate layers
should occur.
In load transfer area, the metal fittings shall be given silicon covering.
This will ensure and gaureentee insulators resistance to hydrolysis at
the ends for a long period so that no moisture is able to penetrate into
the insulator and which otherwise leads to the well known negative
effects on the fibre glass rod.
7.2.5 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)/ IEC: 60372. The legs of the
security clips shall allow for spreading after installation to prevent
complete withdrawal from the socket. The locking device shall be
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 when 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
countersunk 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
it’s unlocked position shall not be less than 50N (5 Kg) or more than 500
N (50 Kg).

7.2.6 GRADING RINGS:

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 Grading rings shall be provided when system voltages are equal to or
greater than 220 KV. For 220 KV transmission, grading ring is to be
provided at energized end only. For 400 KV transmission, grading ring is
to be provided at both ends of a insulator.
All grading rings and brackets shall be designed as an integral part of
the insulator assembly with a positive mounting system that allows
mounting in only one position. The design of the grading ring shall be
such that ring can only be mounted with its orientation towards the
weathersheds for maximum RIV and corona control. Grading rings shall
be designed in such a manner that the rings can be readily installed and
removed with hot line tools without disassembling any other part of the
insulator assembly. The size and placement of the metallic grading rings
shall be designed to eliminate dry band arcing/Corona cutting/
exceeding of permissible electrical stresses of material in the vicinity of
the end fittings and shield the end fittings preventing Corona inception
at 115% of the nominal line to ground voltage. The supplier shall
furnish calculations along with the proposed placement and design of
corona ring in support of the above.
Grading ring height (is the distance from the end of the end fitting to the
top of corona ring) should be so selected that maximum field minimizes
& uniformly distributed along the insulator. Manufacturer should
provide reports of successful electrical field modeling testing for the
specific insulator design. The EFM should be three dimensional with
results containing drawing depicting the electric field in various colours,
each of a different voltage level. The result of this study should show
that the voltage field surrounding the composite insulator is optimum
along the entire length of insulator, with the effected hot end of the
insulator being a critical location. The threshold at which corona may or

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 may not be present should be defined as a figure in kV/mm for the
designed insulator.

8.0 VERIFICATION OF HOUSING MATERIAL

The manufacturer should provide written verification about housing
material, for which base polymer shall be 100% Silicon Rubber prior to
the addition of reinforcing fillers considered will provide satisfactory
performance in the particular environment mentioned atCl.No.3 & 4.
It shall meet following requirements :
 Be homogenous, impermeable, with no fissures, bubbles and
strange
materials inclusions.
 Be designed in order to avoid formation of localized discharges and
to
prevent interfaces humidy penetration.
 Be resistant to corona, UV radiation, ozone, atmospheric
contamination,
water penetration and power arcs.

9.0 BALL AND SOCKET DESIGNATION

The dimensions of the Ball and Socket shall be 16mm designation for
90KN and 20mm designation for 120KN insulators in accordance with
the standard dimensions stated in IEC: 60120/IS:2486(Part-II)

10.0 DIMENSIONAL TOLERANCE OF COMPOSITE INSULATORS:

The tolerance on all dimensions e.g. diameter, length and creepage
distance shall be allowed as follows:

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 ± (0.04 d + 1.5) mm. when d = 300 mm.
± (0.025 d + 6) mm. when d > 300 mm.

Where d being the dimensions in millimeters for diameter, length or

creepage distance as the case may be. However, no negative tolerance
shall be applicable to creepage distance.

11.0 INTERCHANGEABILITY:
The composite insulators including the ball socket connections shall be
standard design suitable for use with the hardware fittings of any make
conforming to relevant Indian standards.
The length and other dimensions should be such that it should be
substituted by other conventional type Porcelain insulators.

12. SUITABILITY FOR LIVE LINE MAINTENANCE

The insulators shall be compatible for use wet line or live line
maintenance technique that usual hot line operations can be carried out
with ease, speed and safety.

13. CORONA AND RI PERFORMANCE:

All surfaces shall be clean, smooth, without cuts, abrasions or
projections. No part shall be subjected to excessive localized pressure.
The insulator and metal parts shall be so designed and manufactured
that it shall avoid local corona formation and not generate any radio
interference beyond specified limit under the operating conditions.

14.0 WORKMANSHIP:

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 11.1 All the materials shall be of latest design and conform to the best
engineering practices adopted in the high voltage field. Bidders
shall offer only such insulators as are guaranteed by them to be
satisfactory and suitable for continued good service in Power
Transmission lines.
11.2 The design, manufacturing process and material control at various
stages shall be such as to give maximum working load, highest
mobility, best resistance to corrosion, good finish and elimination
of sharp edges and corners to limit Corona and Radio
interference..
11.3 The design of insulators shall be such that stresses due to
expansion and contraction in any part of the insulator shall not
lead to deterioration.
11.4 The core shall be sound and free from cracks and voids that may
adversely affect the insulators.
11.5 Wheather sheds shall be uniform in quality. They shall be clean,
sound, smooth and shall be free from defects and excessive
flashing at parting lines.
11.6 Metal end fittings surfaces shall be uniform, perfectly
smooth with no projecting parts or irregularities, without
sharp edges or corners which may cause corona and shall be
free of cracks, seams, air holes, blow holes and rough edges ,
flakes, slivers, slag, shrinkage defects and localized porosity.
All load bearing surfaces shall be smooth and uniform so as
to distribute the loading stresses uniformly. Pins shall not
show any microscopically visible cracks, inclusions and voids.
End fittings should be effectively sealed to prevent moisture

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 ingress, effectiveness of sealing system must be supported by
test documents.
11.7 All ferrous parts shall be hot dip galvanized to give a
minimum average coating of Zinc equivalent to 610gm/sqm or
87 micrn thickness and shall be in accordance with the
requirements of IS:2629/ISO 1461(E) . 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
bright, continuous and free from impurities such as flux, ash, rust
strains, bulky white deposits and blisters. The galvanized metal
parts shall be guaranteed to withstand at least four successive
dips each lasting for one (1) minute duration under the standard
Preece test. The galvanization shall be carried out only after any
machining.
15. MARKINGS:
Each Composite insulator shall be legibly and indelibly marked
with the following details as per IEC – 61109.
a. Name or trademark of the manufacturer.
b. Voltage and Type.
c. Month and year of manufacturing.
d. Minimum failing load / guaranteed mechanical
strength in kilo Newton followed by the work ‘KN’ to
facilitate easy identification.
e. Country of manufacturer.

16.0 PACKING:
All insulators shall be packed in strong corrugated box of
minimum 7 ply duly paletted or wooden crates. The gross weight of

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 the crates along with the material shall not normally exceed 100
kg to avoid hackling problem. The crates shall be suitable for
outdoor storage under wet climate during rainy season. The
packing shall be of sufficient strength to withstand rough handling
during transit, storage at site and subsequent handling in the
field. Suitable cushioning, protective padding, or Dunn age or
spacers shall be provided to prevent damage or deformation during
transit and handling. All packing cases shall be marked legibly
and correctly so as to ensure safe arrival at their destination and
to avoid the possibility of goods being lost or wrongly dispatched
on account of faulty packing and faulty or illegible markings. Each
wooden case / crate corrugated box shall have all the markings
stenciled on it in indelible ink.
The bidder shall provide instructions regarding handling and
storage precautions to be taken at site.

17.0 INSPECTION, TESTS AND STANDARDS:

17.1 INSPECTION:
Inspection includes the performance of acceptance, type and
design tests. KPTCL reserves the right to carry out design and type
tests to check conformity of the material with the proto type unit
previously approved.

Inspection includes the performance of acceptance, type and

design tests. KPTCL reserves the right to carry out design and type
tests to check conformity of the material with the proto type unit
previously approved.

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 KPTCL reserves the right to attend the tests and perform
inspections in any stage of the supply, appointing its inspectors
and following the approved manufacturing schedule. Inspection
and tests scheduled to happen during manufacture shall have
their dates informed to KPTCL at least 10 days in advance.
The manufacturer shall assure KPTCL’s inspector the right to
being fully acquainted with installations and apparatus, check
calibrations, be present at the tests, check results and in case of
doubt, perform new inspections and claim the repetition of any
test.

17.2 TESTS:
Insulators offered shall be manufactured with the same
configuration & raw materials as used in the insulators for which
Design & type test reports are submitted. the manufacturer shall
submit a certificate for the same . The design and type test reports
submitted shall not be more than five years old.
No material shall be dispatched from its point of manufacture
before it has been satisfactorily inspected, tested, and necessary
dispatch instructions are issued in writing, except for the cases
where waiver of inspection is granted by competent authority of
the Purchaser, and even in this case also written dispatch
instructions will be issued. Any dispatches before the issue of
Dispatch Instructions in writing will be liable for rejection and
non-acceptance of the materials by the consignee.
The acceptance of any quantity of material shall in no way relieve
the Bidder of any of his responsibilities for meeting all

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 requirements of the specification, and shall not prevent
subsequent rejection if such material is later found to be defective.
The sample taken from any numbers of crates for carrying out any
type of
tests will be to the suppliers account.
17.3 The following tests shall be carried out on the composite
insulators.

17.3.1 DESIGN TEST:

The design tests are intended to verify the suitability of the
design, materials and method of manufacture (Technology),i.e., to
prove the design, process of manufacture and conformity of the
core material, housing material, core assembly (core & end
fittings), interfaces and connections of sample insulators and
product with the insulator of this specification. These tests shall
be conducted on representative number of samples prior to
commence of commercial production. The bidder shall indicate his
schedule for carrying out these tests. When a composite insulator
is submitted to the design tests the results shall be considered
valid for the whole class of insulators which are represented by the
one tested and having the following characteristics.
 Same materials for the core and sheds and same methods of
attachment.
 Same material of the fittings ,the same design and the same
method of attachment.
 * Same or greater layer thickness of the shed material over
the core (including a sheath where used)
 same or smaller ratio of the highest system voltage to
insulation length.
 * same or smaller ratio of all mechanical loads to the
smallest core diameter between fittings highest system
voltage to insulation length.
 * same or greater diameter of the core.

the tested composite insulator shall be identified by a drawing

giving all the dimensions with the manufacturing tolerances.
Subsequently, if there are small variations in the design data of
not more than 15% for characteristics marked with ‘*’, the design
tests shall not be repeated.

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 17.3.2 PROTO TYPE or TYPE TESTS:
This shall mean those tests, which are to be carried to verify the
main characteristics of a composite insulator , which depend
mainly on its shape and size. Type tests shall be applied to
composite insulators, the class of which has passed the design
tests. They shall be repeated only when the type or material of the
composite insulator is changed.

17.3.3 ACCEPTANCE /SAMPLING TESTS:

The sampling tests are for the purpose of verifying other
characteristics of composite insulators, including those which
depend on the quality of manufacture and on the materials
used.This shall mean these tests which are to be carried on
insulator samples taken at random from each lot offered for pre-
dispatch inspection for the purpose of acceptance of the lot

17.3.4 ROUTINE TEST:

Tha aim of these tests is to eliminate composite insulators with
manufacturing defects.This shall mean those tests, which are to be
carried out on each insulator offered for acceptance to check the
requirements are likely to vary during production.

17.3.5 TESTS DURING MANUFACTURE:

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

17.3.6 TEST VALUES:

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

17.3.7 TEST PROCEDURES AND SAMPLING NORMS:

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 The norms and procedure of sampling for the above tests shall be
as per the relevant Indian standard or other internationally
accepted standards. This will be discussed and mutually agreed to
between the supplier and purchaser before placement of order.
The standards and norms 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 and
procedure for the same shall be as specified in annexure IV
attached hereto or as mutually agreed to between the supplier and
the purchaser in the Quality Assurance program.

17.4 DESIGN TESTS:

The design test are performed only once and results are recorded
in a test report as per IEC 1109 latest edition. Each part of the
four tests enlisted can be performed independently on new test
specimens when appropriate. The composite insulator of a
particular design will be qualified only when all isulator or test
specimens pass the design tests, in the given sequence defined as
under clause 5.1,5.2,5.3 and 5.4 of IEC 1109 an as per Annexure-
A,C & D of IEC:61109.
The summary of this tests.

Sl Description of the Relevant standard/ test

No Type Test procedure.
1 Tests on interface As per clause 5.1 of IEC
and connections of 61109 1992 and as per
metal fittings Anexxure-D of IEC 61109..
Test specimens and As per clause 5.1.1 of IEC
preliminary tests. 61109 1992.
Dry Power frequency As per clause 5.1.2 of IEC
tests 61109 1992.
Prestressing. As per clause 5.1.3 of IEC
61109 1992.

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 Sudden load release As per clause 5.1.3.1 of IEC
test. 61109 1992.
Thermal- mechanical As per clause 5.1.3.2 of IEC
test 61109 1992.
Water immersion test As per clause 5.1.3.3 of IEC
61109 1992.
Verification tests. As per clause 5.1.4 of IEC
61109 1992.
Visual examination As per clause 5.1.4.1 of IEC
61109 1992.
Steep-front impulse As per clause 5.1.4.2. of IEC
Voltage test. 61109 1992.
Dry Power frequency As per clause 5.1.4.3 of IEC
Voltage test.
61109 1992.
2 Assembled Core As per clause 5.2 of IEC
load 61109 1992 and as per
– Annexure –A & D of
time IEC:61109
test:
Test Specimens As per clause 5.2.1 of IEC
61109 1992.
Mechanical Load test As per clause 5.2.2 of IEC
61109 1992.
Determination of As per clause 5.2.2.1 of IEC
61109 1992.
average failing load of
the core of the
assembled insulator,
Control of slope of the As per clause 5.2.2.2 of IEC
strength-time curve of 61109 1992.
the insulator.
3 Test of Housing : As per clause 5.3 of IEC
61109 1992 and as per
Tracking and
Anexxure-D of IEC 61109..
erosion test & Multi

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 stress test :
Test Specimens. As per clause 5.3.1 of IEC
61109 1992.
Test procedure. As per clause 5.3.2 of IEC
61109 1992.
Test conditions. As per clause 5.3.3 of IEC
61109 1992.
Evaluation of the As per clause 5.3.4 of IEC
tests. 61109 1992.
4. Tests for the core As per clause 5.4 of IEC
material 61109 1992 and as per
Anexxure-D of IEC 61109..
Dye penetration test. As per clause 5.4.1 of IEC
61109 1992.
Test specimens As per clause 5.4.1.1 of IEC
61109 1992.
Performance of the As per clause 5.4.1.2 of IEC
61109 1992.
test
Acceptance criterion. As per clause 5.4.1.3 of IEC
61109 1992.
Water diffusion test As per clause 5.4.2 of IEC
61109 1992
Test Specimens As per clause 5.4.2.1 of IEC
61109 1992
Prestressing As per clause 5.4..2.2 of IEC
61109 1992
Voltage test As per clause 5.4.2.3 of IEC
61109 1992
5 Flammability test As per clause 5.5 of IEC
61109 1992
Test Specimens. As per clause 5.5.1 of IEC
61109 1992
Evaluation of the As per clause 5.5.2 of IEC
tests. 61109 1992
.
Additionally following tests shall be carried out or reports for the tests
shall be submitted after award of contract.
1) Pollution test for composite insulator as per IEC-507.
2) Power arc test.

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 3) Brittle facture test.
4) Radio interference test.
5) Torsion withstand test for insulators whose coupling do not give
total rotational freedom.

17.5 TYPE TESTS:

One insulator type is Electrically defined by arcing distance,
creepage distance, Shed inclination, Shed diameter and shed
spacing. The Electrical type test shall be performed only once on the
insulator satisfying the above criteria for one type and shall be
performed with arcing devices, if they are an intergral part of the
insulator type.
The Electrical type tests shall be repeated only when one or more of
the above characteristics is changed.
One insulator type is Mechanically defined by the Core diameter
and the method of attachment of the metal fittings. The mechanical
type tests shall be performed only once on insulators satisfying the
above criteria for each type. They shall be repeated only when one or
both of the above characteristics is changed.

Unless otherwise agreed, a tolerance of

± (0.04 d + 1.5) mm. when d < or = 300 mm.
± (0.025 d + 6) mm. when d > 300 mm with a maximum of
50mm.
is allowed on all dimensions for which specific tolerance are not
requested ( d being the dimension in millimeter).

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 Following Type tests shall be conducted on the
complete Long Rod Composite insulator with
Hardware Fittings
Sl Description of the Relevant standard/ test
No Type Test procedure.
ELECTRICAL TESTS:
1 As per IEC 61109 (Clause 6.1) Test
Dry Lightning procedure according to clause and
Impulse voltage sub clauses 7,9,10,14,15.1,15.2,
withstand test 17,18.1.2, 18.2,19 and 20 of IEC
383.
2 Wet Power frequency As per IEC 61109 (Clause 6.2) Test
test procedure according to clause and
sub clauses
7,9,12,13,14,15.1,17,18.1.2,
18.2,19 and 22 of IEC 383.
3 Wet Switching As per IEC 61109 (Clause 6.3) Test
impulse withstand procedure according to clause and
Voltage test sub clauses 7,9,11,
13,14,15.1,17,18.1.3, 18.2,19 and
21 of IEC 383.
Mechanical Tests
4 Mechanical Load- As per IEC 61109 (Clause 6.4)
time test Annexure -A and as per
 Long time amendment of IEC:6110-9 1995
mechanical Clause 6.4
withstand
 Short time
mechanical

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 withstand
5 Radio interference As per IEC 61109 (Clause 6.5)
test amendment -1 1995
6 Chemical composition
test for Silicon
content
7 Brittle fracture Annexure-A
resistance test -
8 Ageing test under Annexure C of IEC 61109
operating Voltage
simulating weather
conditions
(Accelerated Ageing
Test of 5000 hours)
10 Power frequency -IEC:383-1993
voltage withstand test
with corona control
rings/grading ring
and arcing horns
under wet condition
11 d) Vibration test -IEC:383-1993-Annexure-A

12 Recovery of -Annexure-A
Hydrophobicity test

All the above type test shall be conducted on Single ‘I’ suspension and

Double tension insulator along with hardware fittings.

i) Grading device test
ii) Electrical Field Modeling test(EFM)

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 The bidder shall submit type test reports as per IEC 61109 along with
the bid Additional type tests required if any shall be carried out by the
manufacturer, after award of contract for which no additional charges
shall be payable. In case, the tests have already been carried out, the
manufacturer shall submit reports for the same.
17.6 Sample Tests ( Acceptance Tests) –
When specified on a purchase order, sample tests shall
be performed as per ANSI C29.11& IEC:61109-1992.
Sl No Description of the Type Test Relevant standard/
test procedure.
1 Verification of Dimensions Clause 7.2 of IEC:61109
2 Verification of Locking System- Clause 7.3 of IEC:61109
applicable only in the event ball
and socket insulators is specified.
3. Verification of tightness of the Clause 7.4 of IEC:61109
interface between end fittings and
insulator housing
4. Mechanical Load test: Verification Clause 7.4 of IEC:61109
of the specified Mechanical Load and as per amendment
(SML) of IEC:61109 1995
clause 7.4
5. Galvanizing Test Clause 7.5 of IEC:61109

If any one insulator or metal part fails to comply with the sampling
tests, Re-testing procedure shall be as per Clause 7.6 IEC:61109.

17.7 Routine Tests:

The following tests shall be performed on every insulator produced as
per IEC:61109-1992.

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 (a) Identification of the Composite insulators: Each insulator shall
be marked with the name or trade mark of the manufacturer and
the year of manufacture. In addition, each insulator shall be
marked with the Specified Mechanical Load(SML). These markings
shall be legible and indelible.
(b) Mechanical Test: Every insulator shall withstand at ambient
temperature a tensile load equal to or greater than its Routine Test
Load (50% of the Specified Mechanical Load) for a period not less
than 10 seconds
(c) Visual Examination: Every insulator shall be examined to insure
its conformance to the manufacturer’s drawing as per Clause 8.2
of IEC:61109. Superficial polymer surface defects of an area less
than 25 square millimeters (total area not to exceed 0.2% of total
insulator surface area) and depth less than 1 mm shall be
acceptable.
17.8 Additional Tests
The Purchaser reserves the right of getting done any other test(s) of
reasonable nature carried out at Purchaser's premises, at site, or
in any other place in addition to the aforesaid type, acceptance
and routine tests to satisfy himself that the material comply with
the specifications. In such case all the expenses will be to
Suppliers account.
The owner also reserves the right to conduct all the tests
mentioned in this specification at his own expense on the samples
drawn from the site at suppliers premises or at any other test
centre. In case of evidence of non-compliance, it shall be binding
on the part of the supplier to prove the compliance of the items to
the technical specifications by repeat tests or correction of

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 deficiencies or replacement of defective items, all without any extra
cost to the owner.

17.9 Tests during Manufacturing:

Following tests shall also be carried out during
manufacturing on all components as applicable and
the reference standards according to which the
test shall be conducted are as follows.
Sl No Particulars of tests Reference standards
Raw material Inspection
Silicon Rubber
1 Tensile strength & Elongation ASTM D 412
2 Tear strength ASTM D 624
3 Hardness ASTM D2240
4 Resistance to track and erosion IEC-60587
5 Di-electric strength ASTM D 149
6 Silicone content test Between 30% to 40%
7 Resistance to weathering and UV ASTM G 53-93
8 Limiting Oxygen index ASTM D 2863
FRP rods
1 Dimensions As per drawing
2 Dye penetration test As per Cl. 5.4.1 of
IEC 61109
3 Water absorption test ASTM 570
4 Water diffusion test As per Cl. 5.4.2 of
IEC 61109
5 Hardness test ( Barcol) ASTM D 2583
6 % of Glass content, ASTM D 2584
7 Brittle fracture resistance test &
Flexural test, inter laminar shear &
tensile strength of FRP
Bonding Agent
1 Appearance and specific gravity Acceptance norms
0.836 to 0.880
Galvanized condition
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 1 Visual inspection & Dimension IS:2486
2 Uniformity of Zinc coating
3 Thickness of coating by Electometer
4 Chemical analysis of Zinc used for As per IS: 209
galvanization(Purity of Zinc)
Ball end Fittings(Forged steel)
1 Visual inspection & Dimension IS:2486 Part II
2 Failing Load test, Yield strength test As per IS:1608
bar, Tensile strength to test bar,
Hardness test
3 Chemical analysis, hardness tests and As per IS: 1608 &
magnetic particle inspection for IS:3703
forging.
Socket end fittings
1 Visual inspection & Dimension
2 Tensile test, Elongation , Hardness As per IS: 14329 &
IS: 1865.
3 `Chemical analysis, mechanical, As per IS 3703
metallographic test and magnetic
particle inspection for malleable
castings.
Security Clip
1 Visual inspection & Dimension As per IEC 60372
Cl.12
2 Resistance to bending test, Hardness & As per IEC 60372
Chemical analysis Cl.13
Corona Ring
1 Visual inspection & Dimension
2 Chemical analysis
In process Inspection
1 Visual inspection of Prime application Should be uniform
on the entire rod
2 Gauge checking for alignment after
crimping
3 SML check after crimping 50% of SML for 10 %

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 Sample Batch For Type Testing
The bidder shall offer material for sample selection for the type testing
only after Quality Assurance Plan approved by the General Manager
Procurement. The Bidder shall offer at least 10% of the ordered
quantity or 300 nos. whichever is higher, for selection of samples
required for conducting all the type tests.
The Bidder is required to carry out all the acceptance tests
successfully in the presence of Purchaser's representative before
dispatch of the selected sample to the testing laboratory for type test.

18.0 TEST REPORTS

18.1 Copies of type test reports shall be furnished in at least two (2)
copies along with one original. One copy shall be returned duly
certified by the Purchaser only after which the material already
inspected i.e. the materials manufactured for selection of
sample for type test, shall be dispatched on receipt of Dispatch
Instructions from the CEE(P&C),KPTCL, Kaveri Bhavan,
Bangalore
18.2 Record of routine test reports shall be maintained by the Bidder
at his works for periodic inspection by the purchaser’s
representative.
18.3 Test Certificates of test during manufacture shall be maintained
by the Bidder. These shall be produced for verification as and
when desired by the Purchaser.
19.0 TEST FACILITIES

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 The following additional facilities shall be available at Supplier's
works:
a) Calibration Reports from Government approved testing
laboratory of various testing and measuring equipment
including tensile testing machine, resistance measurement
facilities, burette, thermometer, barometer etc.

b) Finished insulator shall be checked for dimension verification

and surface finish separately.

c) The bidder should have all the routine and acceptance testing
facilities, in house in accordance with IEC:383 & 61109.
Manufacturers of foreign origin shall, in addition to the above,
also have arrangements in India, either at works of their
authorized representative/licenses or in the NABL lab. like
CPRI, IISC, ERDA etc. for conducting sampling test in
accordance with IEC : 383 & 1109.

20.0 QUALITY ASSURANCE PLAN

20.1 The bidder shall invariably furnish following information along
with his offer, failing which his offer shall be rejected.
i) Statement giving list of important raw materials, proposed to be
used in the manufacture of the insulator against this
Specification, names of sub suppliers for the raw materials, list
of standards according to which the raw materials are tested,
list of tests normally carried out on raw materials in presence of
Bidder's representative as routine and / or acceptance during
production and on finished goods, copies of test certificates.

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 ii) Information and copies of test certificates as in (i) above in
respect of bought out accessories.
iii) List of manufacturing facilities available.
iv) Level of automation achieved and lists of areas where manual
processing exists.
v) List of areas in manufacturing process, where stage inspections
are normally carried out for quality control and details of such
tests and inspections.
vi) List of testing equipment available with the Bidder for final
testing of Insulator specified. In the case if the Bidder does not
possess all the Routine and Acceptance testing facilities the
tender will be rejected.
vii) The Purchaser reserves the right for factory inspection to verify
the facts quoted in the offer. If any of the facts are found to be
misleading or incorrect the offer of that Bidder will be out
rightly rejected and he may be black listed.
viii) Special features provided to make it maintenance free.
ix) Bidder shall also submit the Field Quality Plan (FQP) along with
Technical Bid.
20.2 The bidder shall also submit following information to the purchaser
along with the technical Bid. .
i) List of raw materials as well as bought out accessories, and the name of
suppliers of raw materials as well as bought out accessories.

ii) Type test certificates of the raw material and bought out accessories.
iii) Quality assurance plan (QAP) with hold points for purchaser's
inspection.

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 20.3 The Bidders shall submit the routine test certificates of all the bought
out items, accessories etc.

21.0 DOCUMENTATION
21.1 Two sets of type test reports, duly approved by the Purchaser shall
be submitted by the Bidder, before commencement of supply. A
copy of acceptance and routine test certificates, duly approved by
the purchaser shall accompany the dispatch consignment.
21.2 The bidder shall submit the drawings in triplicate for the offered
insulators well within the commencement period for approval. The
manufacturing of the insulator shall be strictly in accordance with
the approved drawings and no deviation shall be permitted without
the written approval of the Purchaser. All manufacturing and
fabrication work in connection with the insulator prior to the
approval of the drawing shall be at supplier’s risk.
21.3 Approval of drawings etc. by the purchaser shall not relieve the
Bidder of his responsibility and liability for ensuring correctness
and correct interpretation of the latest revision of applicable
standards, rules and codes of practices. The insulator shall conform
in all respects to high standards of engineering, design,
workmanship and latest revisions of relevant standards in vogue on
the day of opening of the Technical Bid and purchaser shall have
the power to reject any work or material which in his judgment is
not in full accordance therewith.
21.4 In case the bidders offers Silicon rubber composite insulators
tested and supplied to other utilities , and are in service, the

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 following additional information shall be furnished along with
the bid.
1. The certificates of Type test as specified conducted within 5
years from the date of enquiry.
2. Performance report from the utilities for satisfactory
performance of the Composite insulator for at least
‘Three’ years.
3. List of similar past orders executed for insulator for the last 5
years period.
4. Quality assurance plan in prescribed proforma.
22.0 DRAWINGS
All the bidders have to submit the drawings for Composite long rod
(Silicon Rubber) insulator along with the crates to be utilised for
packing of the insulator, for the numbers specified in this Tender
Specification along with the offer. In the event of an order the
successful bidder shall submit the drawings stated above in triplicate
for approval during the commencement period to CEE (P&C), KPTCL,
Kaveri Bhavan, Bangalore.
The set of approved drawings shall be submitted in soft copy in Auto
CAD format.
23.0 DEVIATIONS
23.1 Any deviation to this tender Specification will be out rightly
rejected. All the Bidders have to submit this specification duly
authenticated without any alterations, additions etc. on each page
along with the Technical Bid. Any offer without this will be out
rightly rejected.
24.0 MAINTENANCE:

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 The insulator shall be capable of high pressure washing at a maximum
nozzle pressure of 550psi. The insulators offered shall be suitable for
employing Hot Line Maintenance Techniques with required speed, ease
and safety.

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 ANNEXURE-A

1. Tests on Complete Strings with Hardware Fittings.

1.1 Mechanical Strength Test
The complete insulator string alongwith its hardware fitting excluding arcing
horn, corona control ring grading ring and suspension assembly/dead end
assembly shall be subjected to a load equal to 50% of the specified minimum
ultimate tensile strength (UTS) which shall be increased at a steady rate to
67% 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 load is reached and
the value recorded.
1.2 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 suspension string a load equal to 600 kg shall be applied along the axis of
the suspension string by means of turn buckle. The insulator string along
with hardware fittings and two sub-conductors (each tensioned at 43 KN
shall be secured with clamps. The system shall be suitable to maintain
constant tension on each 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 insulators string (more than 10 Hz) by means of

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 vibration inducing equipment. The peak to peak displacement in mm of
vibration at the antinodes point, nearest to the string, shall be measured and
the same shall not be less than 1000/fwhere is the frequency of vibration in
cycles/sec. The insulator string shall be vibrated for not less than 10 million
cycles without any failure. After the test the insulators shall be examined for
looseness if pins and cap or any crack in the cement. The hardware shall be
examined for looseness, fatigue failure and mechanical strength test. There
shall be no deterioration of properties of hardware components and
insulators after the vibration test. The insulators shall be subjected to the
following tests as per relevant standards :

a) Temperature cycle test followed by mechanical performance test.

1.3 Salt -fog pollution withstand test
This test shall be carried out in accordance with IEC-60507. The salinity
level for composite long rod insulators shall be 80 Kg / m3 NACL.

2.0 Composite Long rod Insulator Units

2.1 Brittle Fracture Resistance Test.
Assembled core load time test with container that contains in-HNO3
concentric acid this is applied at the naked rod. The rod should be held at
80% of SML for the duration of the test. The rod should not fail within the 96
hour test duration.
2.2 Recovery of Hydrophobicity Test
(1) The surface of selected samples shall be cleaned with isopropyl alcohol.
Allow the surface to dry and spray with water. Record the HC
classification. Dry the sample surface.
(2) Treat the surface with corona discharges to destroy the hydrophobicity.
This can be done utilizing a high frequency corona tester. Holding the
electrode approximately 3 mm from the sample surface slowly move the

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 electrode over an area approximately 1’’ x 1’’. Continue treating this area
for 2-3 minutes, operating the tester at maximum output.
(3) Immediately after the corona treatment, spray the surface with water and
record the HC classification. The surface should be hydrophilic with an
HC value of 6 to 7. If not, dry the surface and repeat the corona treatment
for a longer time until an HC of 6 or 7 is obtained. Dry the sample
surface.
(4) Allow the sample to recover and repeat the hydrophobicity measurement
at several time intervals. Silicone rubber should recover to HC 1 – HC 2
within 24 to 48 hours, depending on the material and the intensity of the
corona treatment.
3.0 Test on All components (As applicable).
3.1 Chemical Analysis of Zinc used for Galvanizing.
Samples taken from the zinc ingot shall be chemically analyzed as per IS
209-1979. The purity of zinc shall not be less than 99.95%.
3.2 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 Owner in Quality Assurance Programme.
3.3 Tests on Castings.
The chemical analysis, mechanical and metallographic tests and
magnetic, article 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 Owner in
Quality Assurance Programme.
4.0 Grading device test:

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 4.1 In addition to the electrical design tests, for 220 KV & above class
insulator design with applicable grading device test, similar to the
following
described test: Grading devices shall be tested using a mechanical
shaker with at least a one inch stroke at the grading device and a
frequency of no less than three cycles per second for duration of
2,000,000 cycles. Movement shall be along the long axis of the
insulator. The grading device shall be attached to the shaker in a
vertical position. The test shall be considered successful if no movement
is detected in the ring with respect to the insulator and there is no
physical damage to the grading device and the attachment assembly.
The manufacturer should provide with documentation that the insulator
design with applicable grading devices will minimize or eliminate corona
discharge activity under wet and dry conditions.

5.0 Power Arc Test:

5.1 Three insulators having any one design of end fittings shall be tested for
power arc endurance while tensioned horizontally at 3000lb. An arc
shall be initiated across the insulator by means of a Copper shorting
fuse wire. The arc shall burn 15 to 30 cycles and its current magnitude
is determined by ampere-time product(IxT) equal to a minimum of
150kA cycles. Each insulator is only acceptable if there is no exposure
of the core, no mechanical separation of the insulator, and no cracks in
the housing (As per IEC61467-1997)

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GUARANTEED TECHNICAL PARTICULARS FOR SILICON RUBBER HOUSED
COMPOSITE INSULATORS
(To be furnished by the bidder and submitted with the
offer. Entering Duplicate/overwritten data may
lead to rejection of offer.)
Sl GTP PARTICULARS SUSPENSION TYPE TENSION TYPE
No COMPOSITE COMPOSITE
INSULATOR INSULATOR
GENERAL 220KV 110KV 66KV 220KV 110KV 66KV
1 Manufacturer’s name,
address & country.
2 Bidder’s name, address
& country
3 Size & designation of
Ball & Socket(mm)
4 Standard to which Ball
& socket will conform
5 Section length of
insulator (mm)
6 No. of units per string
7 Number of weather
sheds per unit.(nos)
8 Material of housing
and weathershed
9 Creepage distance of
insulator in mm.
10 Dry arc distance (mm)
11 Specified Mechanical
Load (SML) of insulator
in KN
ELECTRICAL
12 Dry Power frequency
withstand Voltage (KV
rms)
13 Wet Power frequency
withstand Voltage (KV
rms)
14 Positive Lightning
Impulse withstand
Voltage under Dry

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 condition (KVp)
15 Negative Lightning
Impulse withstand
Voltage under Dry
condition (KVp)
16 Dry Power frequency
Flash over Voltage (KV
rms)
17 Wet Power frequency
Flash over Voltage (KV
rms)
18 Positive Lightning
Impulse Flash over
Voltage under Dry
condition (KVp)
19 Negative Lightning
Impulse Flash over
Voltage under Dry
condition (KVp)
20 Maximum RIV
including CC rings,
Arcing horns, Clamps
etc. at 1.1 times
maximum Corona
inception Voltage (KV
rms) line to ground
voltage ( micro volts)
21 Corona extension
Voltage (KV rms)
22 Whether details
regarding method of
fixing end fitting to
FRP rod, method of
detecting harmful
cracks on FRP rod
during crimping and
method of
manufacturing are
enclosed.

REFERENCE DRAWINGS OF 220KV,110KV AND 66KV INSULATOR

HARDWARE WITH DISC INSULATOR

537456407.doc Page 229

537456407.doc Page 230
 SECTION – VII
(VOLUME – II)

TECHNICAL SPECIFICATIONS
FOR

ACCESSORIES FOR ACSR DRAKE CONDUCTOR

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 VOLUME-II

SECTION-VII

TECHNICAL SPECIFICATIONS FOR ACCESSORIES FOR ACSR

CONDUCTORS

1.0 SCOPE

2.0 STANDARDS

3.0 MATERIALS

4.0 GENERAL REQUIREMENTS

5.0 TESTS

6.0 SUBMISSION OF DRAWINGS

7.0 INSPECTION

8.0 PACKING

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 VOLUME-II
SECTION-VII
TECHNICAL SPECIFICATION FOR ACCESSORIES FOR ACSR
CONDUCTORS

1.0 SCOPE:

This specification covers, design, manufacture, testing at

manufacturer’s works, supply and delivery of midspan compression
joints, preformed armour rods, vibration dampers, repair sleeves,
P.G.Clamps for the power conductor specified. The equipment required
shall be complete with all components which are necessary or useful for
their efficient performance and satisfactory maintenance.
2.0 STANDARDS:
The fittings and accessories shall comply in all respects with the latest
edition of relevant IS Specification or any other equivalent authoritative
standard. Except as modified by this specification, the conductor
accessories to be supplied shall conform to the latest addition with
amendments and revisions thereof the following Bureau of Indian
Standards (IS) and British Standards (BS) specifications.
Insulator fittings for overhead
IS 2486
power lines of 3.3 kV and above.
General Requirements and tests
IS 2486 (Part-I) 1977 (First Revision with Amendment
No.1)
Dimensional Requirements (First
IS 2486 (Part-II) 1974
Revision)
IS 2486 (Part-III) 1974 Locking devices
IS 2486 (Part-IV) 1981 Tests for locking devices
Conductors and Earthwire
IS 2121 Accessories for overhead power
lines
Armour rods, binding wires and
IS 2121 (Part-I) 1981 tapes for conductors

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 Mid span joints and repair sleeves
IS 2121 (Part-II) 1981
for conductors.
Hexagon head bolts (Second
IS 1363 (Part-I) 1984
Revision with Amendment No.1)
Hexagon head screws (Second
IS 1363 (Part-II) 1984
Revision with Amendment No.1)
Hexagon nuts (Second Revision
IS 1363 (Part-III) 1984
with Amendment No.1)
Hexagon head bolts, screws and
IS 1363
nuts
Technical supply conditions for
IS 1367
threaded steel fasteners
Introduction and general
IS 1367 (Part-I) 1980
information (Second Revision)
Product grades and tolerance
IS 1367 (Part-II) 1979
(Second Revision)
Mechanical properties and test
methods for bolts, screws and
IS 1367 (Part-III) 1979
studs with full leadability (Second
Revision)
Hexagon bolts for steel structures
IS 6639 – 1972
(Amendments –1 & 2
Methods of testing uniformity of
coating on zinc coated articles
IS 2633 – 1972
(First Revision)

Recommended practice for hot dip

IS 2629 – 1966
galvanizing of Iron and Steel
IS 209 – 1979 Zinc (Third revision)
Stockbridge vibration dampers for
IS 9708 – 1980
overhead power lines
Method of determination of mass
IS 1327 – 1966 of tin coating on tinplate (Second
revision)
Hot dipped galvanized coatings on
IS 4826 –1979 round steel wires (First Revision
with Amendment No.1)
Electroplated coatings of zinc on
IS 1573 – 1976
Iron & Steel (First revision)
IS 8263 – 1976 Method of radio interference tests
on high voltage insulators

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 Spacers and spacer dampers for
IS 10162 – 1982
twin horizontal bundle conductors
Carbon steel forging for general
IS 2004 – 1978 engineering purposes (Second
Revision)
General instructions and testing
procedures specific requirements
BS 970 (Part-I) 1983
for carbon and carbon Manganese
alloy and stainless steels

Conductor accessories and hardware’s conforming to any other national

or international standards are also acceptable. However, in such an
event, the salient points of comparison between the standards adopted
and deviations schedule in section BPS with an authentic English
version of such standards.

3.0 MATERIAL:

The materials offered shall be complete in all respects and of best

quality and workmanship. The materials in the manufacturer of
accessories viz. malleable iron and forged steel depending on the type of
application for which the accessories are used shall be corrosion
resistant and mechinable. The composition of aluminium alloys used
shall be made available to the owner if required for verification.

4.0 GENERAL REQUIREMENTS:

All parts of fittings shall be suitable for use in atmospheric condition

indicated elsewhere in the specification inherently resistant to
atmospheric corrosion or be suitably protected against corrosion both
during storage and in service.

All ferrous metal parts except those made of stainless steel shall be
protected by hot dip galvanizing. Spring washers shall be electro
galvanized.

All castings shall be free from blowholes and other casting defects such
as cracks etc. The surface shall be as smooth as possible.

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 The tension joints shall be so designed that strength of complete joints
shall not be less than 95% of the minimum breaking load of the
conductor under tension.

In case of rods, wire or tape no joints shall be permitted except those in

the base rod or wire before final drawings.

4.1 MID Span Compression Joints for Power Conductor:

i) This shall be suitable for jointing the two ends of the power
conductor. The joint shall have a conductivity of an equivalent
length of the conductor. The joint shall not permit slipping of,
damage to or failure of the complete conductor or any part thereof
at a load of not less than 95% of the ultimate tensile strength of
the conductor. The electrical resistance of the joint after
installation shall not exceed 75% of the measured resistance of the
equivalent length of the conductor.

ii) The components of the joint shall consist of steel and Aluminium
sleeves for joint compression of the steel core conductors and
aluminium conductors respectively. The steel sleeve shall not
crack or fail during compression. The steel sleeve shall be hot dip
galvanized. The Aluminium sleeve shall be manufactured and
extruded out of EC grade Aluminium with a purity of not less than
99.5%. Tapered Aluminium filler plugs shall be provided at the
line of demarcation between compression and non-compression
zone.

iii) The dimensions and dimensional tolerances of this mid span

compression joint shall be as per relevant ISS.

4.2 Repair Sleeves for Power Conductor:

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 i) Repair sleeves to be used shall be for repairing the conductor when
a few strands of the Aluminium conductor in the outermost layer
are damaged with scratches, kinks abrasions, nicks or cuts. They
shall be of the compression type. The sleeve shall be
manufactured and extruded out of EC grade Aluminium having a
purity of 99.5%. The sleeve shall be in two halves with a seat
provision for sliding of the keeper piece. The edges of the seat as
well as of the keeper piece shall be so rounded that the conductor
strands are not damaged during installation. The outer body of
the sleeve shall be smooth even and with rounded off edges.

ii) The compressed conductor with the repair sleeve shall not permit
damage or failure of the conductor at a load of not less than 95%
of the ultimate tensile strength of the conductor. The electrical
resistance of the repaired portion of the conductor shall not exceed
75% of the measured resistance of an equivalent length of the
conductor.

iii) The dimensions and dimensional tolerances of the repair sleeves

shall be as per relevant ISS.

4.3 Vibration Dampers for Power Conductor:

i) The vibration dampers shall be of the stock bridge 4R type for

being used at all suspension and tension points at each and every
span to damp out the vibrations of the conductors to the level
specified hereinafter. These shall conform to the relevant ISS.

ii) The clamp of the vibration damper shall be made of aluminium

alloy. It shall be capable of supporting the damper during
537456407.doc Page 237
 installation and prevent damage or chafing of the conductor
during erection or continued operation. The clamp shall have
sufficient grip to maintain the damper in position on the conductor
without damaging the strands or causing premature fatigue of the
conductor under the clamp. The groove of the clamp body and
clamp cap shall be smooth, free of projections grit or other
materials, which could cause damage to the conductor when the
clamp is installed. Clamping bolts shall be provided with self-
locking nuts and designed to prevent corrosion of the threads or
loosening during service.
iii) The messenger cable of the damper shall be made of high strength
steel with a minimum strength of 136 kg/mm. It shall be
preformed and post formed in order to prevent subsequent drop of
weights and to maintain consistent flexural stiffness cable while in
service. The messenger cable shall be suitably and effectively
sealed to prevent corrosion.
iv) The damper mass shall be made of hot dip galvanized mild
steel/cast iron or a permanent mould cast zinc alloy. All castings
shall be free from defects such as cracks, shrinkage, inclusions
and blowholes etc. The inside and outside surfaces of the damper
masses shall be smooth.
v) The damper assembly shall be electrically conductive to reduce
radio interference.
vi) The vibration damper shall be capable of being installed and
removed from energized line by means of hot line technique. In
addition, the clamp shall be capable of being removed and
reinstalled on the conductor at the design torque without shearing
or damaging of bolts, nuts or cap screws.

537456407.doc Page 238

 vii) The vibration analysis of the system with and without damper,
dynamic characteristic of the damper shall have to be submitted
by the Bidder along with the bid. The technical particulars for
vibration analysis and damping design of the 220-kV/110 kV/66
kV systems.
viii) The bidder recommend the number of vibration dampers of the
type offered by them and their points of fixation for spans of 250
M, 400 M and up to 600 Metres in steps of 50 Meters.
4.4 Preformed Armour Rods:

These shall conform to the relevant Drawings. Suitable aluminium alloy

shall be used for the manufacture of preformed armour rods. The
armour rods shall be marked in the centre with black paint. No joint
shall be permitted in the individual rods.
4.5 P.G. Clamps:
Forced wedge type clamps shall be used for giving jump connections at
anchor point. All the bolts, nuts and washers should be hot dip
galvanized.

5.0 TESTS:

All tests shall be conducted in accordance with latest edition of IS

2121/IS 9708. The following shall constitute the tests. Type test
certificates of recent origin (not older than 5 years) for having conducted
the tests should be furnished along with the quotation. In case the test
certificates are older than 5 years, then the contractor shall conduct the
same afresh at his own cost.

5.1 I. Type tests:

i) For Mid Span compression joints and repair sleeves.

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 a) Visual examination.
b) Dimensional verification.
c) Failing load test.
d) Electrical resistance test.
e) Heating cycle test.
f) Galvanizing test.

ii) For Preformed Armour Rods.

a) Visual examination.
b) Verification of dimensions.
c) Tensile strength test.
d) Electrical resistance test.
e) Slip strength test.
f) Bend test.
g) Resilient test.

iii) Vibration dampers:

a) Visual examination.
b) Verification of dimension.
c) Resonance frequency test.
d) Fatigue test.
e) Mass pull off test.
f) Dynamic characteristic test.
g) Damping efficiency test.
h) Clamp slip test.
i) Torque test.
j) Galvanising electroplating test.
k) Magnetic power loss test.
l) Radio interference voltage test.

iv) P.G. Clamps:

a) Failing load test.
b) Electrical resistance test.

5.2 II. Acceptance Tests:

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 Following Acceptance tests shall be conducted as per IS 2121 /IS 9708
and any other relevant standards in the presence of the Purchaser’s
representative.
i. Mid span compression joints and repair sleeves.

a) Visual examination.
b) Dimensional verification.
c) Failing load test.
d) Galvanising test.

ii. Armour rods.

a) Visual examination.
b) Verification of dimensions.
c) Tensile strength test.
d) Electrical resistance.
e) Slip strength test.

iii. Vibration dampers.

a) Visual examination.
b) Verification of dimensions.
c) Resonance frequency test.
d) Fatigue test.
e) Mass pull off test.
f) Galvanizing/electroplating test.

iv. P.G. Clamps: As per the relevant ISS.

5.3 III. Routine tests:

i) Mid span compression joints and repair sleeves, armour rods,

vibration dampers, spacers and dampers.

a) Visual examination.
b) Dimensional verification.

5.4 Galvanisation test:

Galvanised parts shall be tested in accordance with latest edition of

relevant IS.
6.0 SUBMISSION OF DRAWINGS:

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 Drawings equivalent to the number of consignees plus six extra for each
item have to be submitted for approval before commencement of supply.
Supplies shall not be commenced before approval of drawings. Non-
submission of drawing/receipt of approval shall not be linked with
delivery schedule. Delivery schedule should be adhered to.
The drawing shall be complete in all respects. Detailed dimensions shall
be furnished in each of the drawings. Full specification of the
equipment such as material weight, tensile strength, tolerance, chemical
composition etc shall be incorporated in each drawing.
Any defects noticed in the manufacture of the equipment during
inspection or after receipt at destination have to be promptly set right by
the contractor free of all cost to the owner.

7.0 INSPECTION:

The owner’s representative shall have access to the manufacturer’s

works for purposes of inspection during the manufacture of the
equipment.

8.0 PACKING:

All accessories shall be supplied in strong wooden case all packages

shall be marked on the sides as follows:

a) Name and designation of the consignee.

b) Ultimate destination as required by the Owner.

******

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 SECTION – VIII
(VOLUME – II)

TECHNICAL SPECIFICATIONS
FOR

ACCESSORIES AND HARDWARE FOR 7/3.15mm

GROUND WIRE

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 VOLUME-II
SECTION-VIII
TECHNICAL SPECIFICATION FOR GROUND WIRE ACCESSORIES

1.0 SCOPE

2.0 STANDARDS

3.0 MATERIALS

4.0 GENERAL REQUIREMENTS

5.0 MATERIAL DESIGN AND WORKMANSHIP

6.0 BID DRAWINGS

7.0 TESTS

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 VOLUME – II
SECTION – VIII

TECHNICAL SPECIFICATION FOR GROUND WIRE ACCESSORIES

1.0 SCOPE:

This specification covers design, manufacture, testing at manufacturer’s

works, supply and delivery of accessories for the ground conductor. The
details of the conductors for which these accessories are required have
been given under the specifications for Ground wire elsewhere in the
specifications. The equipment required shall be complete with all
components which are necessary or usual for their efficient performance
and satisfactory maintenance and shall be as per the enclosed drawings.
The accessories/Hardware suitable for 7/3.15 GSS ground wire shall
comprise of the following:
i) Mid span compression joint.
ii) Flexible copper earth bonds.
iii) Vibration dampers.
iv) Suspension clamp.
v) Tension clamp.
vi) P.G. Clamps.
vii) Repair sleeves.

2.0 STANDARDS:

The fittings and accessories shall comply in all respects with relevant
Indian Standard Specification, IS 2121-1962 and IS 2486 with latest
amendments. The Indian Standards wherever mentioned in this
specification shall mean only the latest edition of the relevant standards
including latest amendments.
3.0 MATERIALS:

The materials offered shall be of best quality and workmanship. The

materials employed in the manufacture of accessories viz-malleable iron
and forged steel etc. On the type of application for which the
accessories are used shall be corrosion resistant and mechinable.

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4.0 GENERAL REQUIREMENTS:

4.1 All parts of fittings shall be suitable for use in atmospheric conditions given in Part-
I (General) of Technical Specifications and shall be inherently resistant to
atmospheric corrosion or be suitably protected against corrosion both during storage
and in service.
All ferrous metal parts except those made of stainless steel shall be protected by hot
dip galvanizing. Spring washers shall be electro galvanized.

The threads in nuts and in tapped holes shall be cut after galvanizing and shall be
well lubricated or greased. All other threads shall be cut before galvanizing. The
bolt threads shall be under cut to take care of the increase in diameter due to
galvanising and if required should be return after galvanizing.

All castings shall be free from blowholes and other casting defects such as cracks.

The tension joints shall be so designed that when installed they withstand at least
95% of the minimum-breaking load of the ground wire.

Fittings intended to connect conductors of two dissimilar metal shall be designed to

avoid harmful bimetallic corrosion when erected in accordance with conductor
accessories manufacturer’s recommendations.

All fittings shall be so designed that the effects of vibration both on the
conductor and the fitting itself are minimized.

4.2 Mid span compression joint for ground wire conductor:

i) The mid-span compression joint for Ground wire conductor is to

be used for jointing of two lengths of galvanized steel stranded
(GSS) earthwire of size 7/3.15 mm and of 110 Kgs/ sq.mm tensile
strength.

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 ii) The joint sleeve shall be made of high strength mild steel tubes
with aluminium sleeves and shall be easily compressible with a
100 tonne capacity hydraulic compressor. The mild steel shall
conform to IS:226 grade, 58A grade or equivalent thereof. The
clamp shall not permit slipping of damage to or failure of the
complete earth wire or any part thereof at a load of not less than
95% of the ultimate tensile strength of the earthwire. The joint
shall have conductivity more than the conductivity of an
equivalent length of earthwire. The dimensions of the joint shall
be as per drawing enclosed.

4.3 Flexible Copper Earth Bond:

The flexible copper-earthing bond shall be made of tinned flexible copper

cable of size 37/7/0.417 with 9.81 mm dia and copper area equivalent
to 34 Sq.mm. The tinning shall be as per relevant Indian Standard. The
length of copper cable shall not be less than 500 mm. Two tinned
copper connecting lugs shall be press jointed to the either ends of the
flexible copper cable. The complete assembly shall also include one 16
mm dia 40 mm. 10hs HRH M.S. bolt hot dip galvanized with nut and
lock washer.

4.4 Vibration Damper for Ground Wire Conductor:

i) Vibration dampers of stock bridge 4R type be used at all

suspension and tension points on each overhead ground wire in
each span to damp out the vibrations of the ground wire to the
specified level as stated hereinafter.

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 ii) The clamp of the vibration damper shall be made of aluminium
alloy. It shall be capable of supporting the damper during
installation and prevent damage or chafing of the earthwire during
erection or continued operation. The clamp shall have sufficient
grip to maintain the damper in position on the earthwire without
damaging the strands or causing premature fatigue of the
earthwire under the clamp. The groove of the clamp body and
clamp cap shall be smooth, free of projections, grit or other
materials, which could cause damage to the earthwire when the
clamp is installed.

iii) The messenger cable of the vibration damper shall be made of high
strength steel with a minimum strength of 136 Kg/mm and
performed in order to prevent subsequent drop of weights in
service. The number of strands in the messenger cable shall be
19. Clamping bolts shall be provided with self-locking nuts
designed to prevent corrosion of the threads or loosening during
service. The messenger cable shall be suitably and effectively
sealed to prevent corrosion.

iv) The damper mass shall be made of hot dip galvanized mild
steel/cast iron or a permanent mould cast zinc alloy. All castings
shall be free from defects such as cracks shrinkage, inclusions and
blowholes etc. The inside and outside surfaces of the damper
masses shall be smooth.

v) The vibration damper shall be capable of being installed and

removed from an energized line by means of hot line techniques.
In addition, the clamp shall be capable of being removed and

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 reinstalled on the earthwire at the design torque without shearing
or damaging of bolt and nuts or cap screws.

vi) The vibration analysis of the system with and without damper,
dynamic characteristic of the damper shall have to be submitted
by Bidder along with the bid. The vibration analysis and damping
design shall be suitable to the 220-kV/110-kV/66 kV system now
offered for construction.

vii) The Bidder shall recommend the number of vibration dampers of

the type offered by them and their point of fixation for spans of
250 Metres to 600 Metres at an interval of 50 Metres.

4.5 Suspension Hardware for Ground Wire Conductor:

i) These are to be used for suspending the ground wire conductor at

all tangent/suspension towers and shall be suitable for supporting
the G.S.S. earthwire of size 7/3.15 mm.

ii) The suspension clamps shall conform to IS 2486-1971 and shall

have adequate area of support for the earthwire. The groove of the
clamp shall be smooth, finished in an uniform circular or oval
shape and shall slope downwards in a smooth curve to avoid edge
support and hence to reduce the intensity of bending moment on
the earthwire.

iii) There shall be no sharp points in the clamps coming in contact

with earthwire. There shall not be any displacement in the
configuration of the earthwire strands nor shall these be unduly
stressed in final assembly.

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 iv) The clamping piece and the clamp body shall be clamped by at
least two ‘U’ bolts of size not less than 10 mm with 3-mm thick
lock washers on each of its limbs. Suspension clamp shall be
provided with inverted type of ‘U’ bolts. One limb of the ‘U’ bolt
shall be long enough to accommodate the lug of the flexible copper
bond.

v) The suspension clamp shall be of the ‘Trunion’ type or envelope

type.

vi) The complete assembly of the suspension clamp shall be

guaranteed for slip strength and Mechanical test as per clause
5.4.1 and 5.5.1 of ISS 2486 Part-I 1971.
4.6 Tension Hardwares for Ground Wire Conductor:

i) These tension hardwares are to be used at all tension towers for

anchoring the 7/3.15-mm galvanized steel earthwire (ground wire).
The hardware assembly shall comprise of Bolted type/compression
type of tension clamp and two ‘D’ shackles. The tension clamp is
to be attached to the horizontal strain plate of the tower body by
means of a ‘D’ shackle.

ii) These clamps shall give adequate area of support without any slip
to the ground wire under normal working tension and vibration
conditions.
iii) The complete tension hardware assembly shall be so designed as
to avoid undue bending in any part of the clamp and shall not
produce any hindrance to the movements of the clamp in
horizontal and vertical direction.

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 iv) The slip strength of tension clamp assembly shall not be less than
95% of the ultimate strength of the ground wire. The ultimate
strength of the clamp and individual components shall not be less
than that of ground wire.

5.0 MATERIAL, DESIGN AND WORKMANSHIP:

5.1 General:

i) All the equipments shall be of the latest design and shall conform
to the best modern engineering practice adopted in the field of
extra high voltage engineering. The bidder shall offer only such
equipment as are guaranteed for satisfactory and suitable
performance of 220 kV transmission lines.

ii) The design, manufacturing process and quality control of all the
materials shall be such as to give maximum factor of safety,
maximum possible working load, highest mobility, elimination of
sharp edges and corners to limit corona and radio interference
best resistance to corrosion and a good finish.

5.2 Galvanising:

i) All ferrous parts including steel components, bolts, nuts and

washers etc shall be hot dip galvanized after all machining has
been completed. Nuts may, however be tapped (threaded) after
galvanizing. Spring washers shall be electro-galvanized. The bolt
threads shall be undercut to take care of increase in diameter due
to galvanizing. Galvanizing shall be done in accordance with IS-
2629 and shall satisfy the tests mentioned in IS 2633. Bolts and

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 nuts and washers shall withstand four dips while spring washers
shall withstand three dips. Other galvanized materials shall be
guaranteed to withstand at least six dips each lasting one minute
under the standard preece test for galvanizing.

ii) The zinc coating shall be perfectly adherent, of uniform thickness,

smooth, reasonably bright, continuous and free from all
imperfections such as flux, ash, rust stains, bulky white deposits
and blisters. The zinc used for galvanizing shall be of grade Zn
99.95 as per IS 209.

5.3 Castings:

i) All ferrous and aluminium alloy castings, shall be free of all

internal defects, shrinkage’s, inclusions, blow holes, cracks etc.

ii) All castings shall be smoothly and evenly finished by machining,

buffing etc., so as to eliminate sharp ends, edges, abrasions and
projections. No surface area of the accessories and hardware in
contact with the conductors in any manner either during erection
or during continuous operation. The surface in contact with the
conductor shall not cause any abnormal electrical or mechanical
stresses during normal working and operating conditions.

5.4 Current Carrying Parts:

i) All current carrying parts shall be so designed and manufactured

that the contact resistance is reduced to a minimum.

ii) The design of metal parts and their mating surfaces in contact
with power conductors shall be such as to prevent corrosion of the
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 contact surface and to maintain good electrical contact under all
operating conditions.

5.5 Metal parts of ground wire hardware:

i) The suspension clamp shall be of malleable cast iron or forged

steel. The tension clamp shall be made of forged steel/malleable
cast iron with aluminium sleeves conforming to IS-2486 or of a
grade or equivalent thereof.

ii) ‘D’ shackles, clevis ‘U’ bolts, cotter pins and other components
shall be manufactured from drop forged steel conforming to IS
2004/1978 or equivalent thereof.
iii) Bolts, nuts and washers shall be as per IS 1367 and shall be of
reputed makes such as GKW, TATA brands etc.
iv) All split pins shall be of stainless steel.
5.6 Interchangeability:
All components like design shall be interchangeable.
5.7 Compression Markings:
i) Die compression areas shall be clearly marked on components,
which are to be pressure compressed such as Mid-span
compression joints and tension hardwares. The marking shall be
an etched inscription with the words “COMPRESS FIRST” on
components, which are meant for continuous die compression.
Where components are designed for in termiltent die
compressions, the compression and non-compression zones shall
bear etched inscription such as “COMPRESS ZONE” and “NON-
COMPRESSION ZONE” distinctly with etched arrow signs
indicating the direction of compression and knurled marks
showing the end of the zones.
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 ii) All inscriptions etched on metal shall be distinct, legible and shall
not wear out in the course of normal handling.
6.0 BID DRAWINGS:
i) The bidder shall furnish along with the bid the dimensional
drawings of all accessories and hardware’s.
ii) These drawings shall include the following information.
a) Dimensions.
b) Tolerances on dimensions.
c) Material designation used for different components with
reference to standards.
d) Fabrication details such as welds, finishes and coatings.
e) Catalogue or part numbers for each component and the total
assembly with bill of materials.
f) Identification marking.
g) Weight of individual components and total assembled weight.
iii) The assembly drawings shall include the following:
a) Brief installation instructions.
b) Design installation torque for the bolt or cap screw.
c) Withstand torque that can be applied to the bolt or cap screw
without failure of components or parts thereof.
d) Compression dies number with recommended compression
pressure.
e) Relevant technical details of significance.

7.0 TESTS:

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 All tests shall be conducted in accordance with IS 2121-1962 and IS-
2486. Tests are divided groups viz. type tests, sample tests and routine
tests. Details of tests have been given under the respective fittings.
7.1 Type Tests:
Type tests are normally made once and unless otherwise agreed test
certificates giving the results of the appropriate type tests made on not
less than three fittings identical in all essential details with those to be
supplied are regarded as evidence of compliance. All the type test
certificates of recent origin not older than 5 years as on Bid opening
date conducted in a reputed laboratory shall be furnished along with the
Bid. In case the type test reports are older than 5 years the contractor
shall conduct the type tests on his own cost before commencement of
mass production.
7.2 Sample Test:
Sample tests are not applicable when the order is for less than one
hundred identical fittings. The number of samples shall be the nearest
whole number to one half of one percent of the batch offered for
inspection. If these samples meet the test requirements, the batch is
deemed to comply with the standard. In the event of a sample not
meeting the requirement, twice the original no. of new samples shall be
tested. If all these new samples meet the test requirement, the batch is
deemed to comply with the standard but if any fails to do so, the batch
is deemed not to comply with the standard.
7.3 Routine Test:
Those shall be applied to every fitting unless mentioned otherwise.

7.4 Acceptance Test:

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 These are tests carried out on samples taken from a lot for the purpose
of acceptance of the lot.
7.5 The following shall constitute the type tests, routine tests and
acceptance tests as contemplated in the relevant ISS.
I. Mid span compression joint for Ground wire, Repair Sleeves and
vibration damper for ground wire:
The type tests, acceptance tests and routine tests shall be the
same as that for mid span compression joint for ACSR conductor
and vibration dampers ACSR conductor respectively. However,
following type tests are not applicable for earth wire accessories:
i) Mid Span compression joint for earth wire.
a) Heating Cycle test.
ii) Vibration dampers:
a) Magnetic power loss test.
7.6 The tests to be carried out on other hardware/accessories are as follows:
II. Flexible copper bond:
Type test: Slip strength test.
Acceptance test: i) Visual examination ii) Dimensional verification
and iii) Slip strength test.
The Routine tests shall be as per the relevant ISS.
III. Suspension hardware and tension hardware for ground wire:
i) Type tests:
a) Slip strength test.
b) Mechanical tests.
c) Verification of dimensions.
d) Galvanizing/electroplating test.
e) Visual examination test.
ii) Acceptance tests:

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 a) Verification of dimensions.
b) Galvanizing Test.
c) Mechanical Test.
iii) Routine Test;
a) Visual examination test.
b) Routine mechanical test.
All the above tests shall be carried out in accordance with
the latest edition of IS 2121, IS 2486, IS 2263, IS 8263.
iv) P.G. Clamps:
The type test and routine test shall be
a) Failing load test and any other test specified in the latest ISS.

******

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 SECTION – IX
(VOLUME – II)

TECHNICAL SPECIFICATIONS
FOR

HARDWARE FOR DISC INSULATORS

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 VOLUME-II
SECTION-IX
TECHNICAL SPECIFICATION FOR INSULATOR HARDWARE FOR
TRANSMISSION LINES

1.0 SCOPE
2.0 STANDARDS
3.0 PRINCIPAL PARAMETERS
4.0 GENERAL TECHNICAL REQUIREMENTS
5.0 TESTS
6.0 INSPECTION
7.0 QUALITY ASSURANCE PLAN
8.0 DOCUMENTATION
9.0 PACKING AND FORWARDING

DETAILS OF TESTS

1.0 VOLTAGE DISTRIBUTION TEST

2.0 CORONA EXTINCTION VOLTAGE TEST
3.0 RIV TEST
4.0 MECHANICAL STRENGTH TEST FOR COMPLETE STRING
5.0 VIBRATION TEST
6.0 GALVANIZING TEST
7.0 MECHANICAL STRENGTH TEST FOR WELDED JOINT
8.0 CLAMP SLIP STRENGTH V/S TORQUE TEST AND CLAMP SLIP FOR AGS
CLAMP/ENVELOPE TYPE SUSPENSION CLAMP
9.0 SHORE HARDNESS TEST OF ELASTOMER CUSHION FOR AGS ASSEMBLY
10.0 PROOF LOAD TEST
11.0 CHEMICAL ANALYSIS OF ZINC USED FOR GALVANIZING
12.0 TEST FOR FORGING CASTING AND FABRICATED HARDWARE

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 VOLUME – II
SECTION – IX

TECHNICAL SPECIFICATION FOR INSULATOR HARDWARE FOR

TRANSMISSION LINES

1.0 SCOPE:

1.1 This specification provides for design, manufacture, inspection and

testing before despath packing and delivery F.O.R. (destination) of
hardware fittings required for 220 kV Double Circuit transmission
line insulator strings as per the requirement furnished in Bid
proposal sheets.
1.2 The hardware shall conform in all respects to high standards engineering, design,
workmanship and latest revision 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 is full accordance therewith.
2.0 STANDARDS:
2.1 Except as modified in this, the hardware fittings shall conform to the
following Indian Standards, which shall mean latest revisions and
amendments thereof. Equivalent International and Internationally
recognized standards to which these standards generally correspond are
also listed below:
Sl. Indian International
Title
No. Standard Standard
Methods for Chemical Analysis
1 IS: 206
of Slab Zinc
2 IS: 209 Specification for zinc BS: 3436
Porcelain insulators for
BS: 137 (I&II)
overhead power lines with a
3 IS: 731 IEC: 274
nominal voltage greater than
IEC: 383
1000 V
4 IS: 1570 Schedules for wrought steels
for general engineering

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 purposes (amendment No.1&3)
Steel specified by tensile and/
(Part-I)
or yield properties
Electroplated coatings of zinc
5 IS: 1573
on iron and steel
Carbon Steel forging for
6 IS: 2004
general engineering purposes
Methods of High Voltage
7 IS: 2071
Testing
Specification of conductor and
8 IS: 2121 Earthwire Accessories for
overhead power lines
Specification for Insulator
fittings for overhead Power
9 IS:2486
lines with a nominal voltage
Greater than 1000 V
Part-I General Requirements & tests BS: 3288
Part-II Dimensional Requirements IEC:120
Part-III Locking Devices IEC:372
Recommended practice for Hot
10 IS: 2629 Dip Galvanisation for Iron and
Steel
Testing for Uniformity of
11 IS: 2633
coating of zinc coated articles
ISO/R 947 and
12 IS: 3138 Hexagonal Bolts and Nuts
ISO/R 272
13 IS: 3188 Dimensions for Disc Insulators IEC:305
Dimensions for heads of bolts
14 IS: 4172 and screws

Dimensions for nominal

lengths and thread length for
15 IS:4206
screws and studs (with
amendment No.I)
ISO/R-68-1969
R-26-1963,
16 IS:4218 Metric Screw Threads
R-262-1969 &
R-965-1969
17 IS: 6603 Stainless steel bars and flats
Hexagonal bolts for steel ISO/R-2/2-
18 IS: 6639
structures 1968

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 Determination of weight of zinc
19 IS: 6745 coating on zinc coated Iron
and Steel articles
Phosphor Bronze sheet, strip
20 IS: 7814 BS: 2870
and foil
Methods of RIV Test of HV IEC: 437 NEMA
21 IS: 8263
Insulators Publication
Method for switching impulse CISPR
22 IS: 8269
test on HV Insulators IEC: 506
23 ASTM-D-1171 & ASTM-D-573

2.2 The Standards mentioned above are available from:

Reference
Name and Address
Abbreviation
British Standards, British Standards Institution, 101,
BS
Pentonvile Road, N-19-NO UK.
International Electro technical Commission Bureau
Central de la commission Electro Technique
IEC/CISPR
International, 1, Rue de Verembe Geneva,
SWITZERLAND
IS Bureau of Indian Standards, Manak Bhavan, 9, Bahadur
Shah Zafar Marg, New Delhi-110 001, INDIA
ISO International Organization for Standardization, Danish
Board of Standardization Aurehoegvej-12 DK-2900
Helleprup DENMARK
NEMA National Electric Manufacturers Association 155, East
44th Street New York, NY USA, 10017

2.3 Hardware fittings conforming to any other or International Standards

are also acceptable provided always that such standards are
equivalent to or better than the corresponding standards specified in
2.1 above. However in such an event the salient points of
comparison between the standards adopted and the standards
quoted herein shall be detailed in the appropriate schedule two
copies at authentic English version of such standards shall be
submitted the offer.

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3.0 PRINCIPAL PARAMETERS:
3.1 Details of hardware fittings:
3.1.1 The hardware fittings shall be as per the specification drawings for
hardware fittings attached herewith. Hardware fittings shall be
suitable for single/double suspension insulator strings and
single/double tension insulator strings for 220/110/66 kV
transmission lines.
3.1.2 Each hardware fitting shall be supplied complete in all respect and
shall include all components indicated in the specification drawings.
3.2 Insulator String Characteristics:
Single/Double Single/Double Strain
Sl. tension tension Clamps
Characteristics
No. 220 110 66 220 110 66 33 11
kV kV kV kV kV kV kV kV
1x13 1x7 1x4 1x15 1x8 1x5 1x3 1x1
1 No. of standard discs
2x13 2x7 2x4 2x15 2x8 2x5 2x3 --
Size of each disc (Dia x
2 -----------------------255 x 145----------------------
height)
Power frequency with-
3 stand voltage (wet) kV 460 230 140 460 230 140 75 35
rms
Lightning impulse with
4 stand voltage (dry) 1050 550 325 1050 550 325 170 75
(kVp)
Power frequency with
5 510 265 165 510 265 165 95 55
stand voltage (dry) kVp
Mechanical failing load 120/ 90/ 90/ 120/ 90/ 90/
6 90 90
(KN) 240 180 180 240 180 180
7 Pollution ------------------Refer Part-III----------------------
Note: The details of 110 kV/ 66kV may be ignored as they are not in the scope of this Bid.
3.3 Specification Drawings:
DELETED
4.0 GENERAL TECHNICAL REQUIREMENTS:
4.1 Dimensions of insulator string along with hardware fitting:
4.1.1 Fabrication drawings shall be prepared by the supplier.

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4.1.2 The dimensions shall be suitably selected by the supplier while
preparing the fabrication drawings.
4.1.3 The fabrication drawings shall be submitted to the purchaser for
scrutiny and approval.
4.1.4 Dimensional tolerances as per relevant ISS only shall be allowed.
4.2 Corona and RI performance:
Sharp edges, scratches on all the hardware fittings shall be avoided. All
surfaces must be clean, smooth, without cuts and abrasions or
projections. The Bidder must give suitable assurance about the
satisfactory corona and radio interference performance of the materials
offered by him.

4.3 Ball and socket fittings:

The dimensions of the ball and socket shall be of 16 mm & 20 mm
designation for suspension and tension string respectively in case of
220 kV line assembly in accordance with standard dimensions
stated in IS: 2486 (Part-II).
4.3.1 Ball Fittings:
Ball fittings shall be made of class IV steel as per IS: 2004 or steel of
equivalent grade forged in one piece. They shall be normalized to
achieve the minimum breaking strength specified on the respective
drawings. Before galvanization of ball fittings, all die flashing on the
shank and on the bearing surface of the ball shall be carefully removed
without reducing the dimensions below the requirements.
4.3.2 Socket Fittings:
Socket fittings shall be made of class-IV steel as per IS:2004 or steel of equivalent
grade and shall be forged in one piece. They shall be normalized to achieve the
minimum breaking strength specified on the respective drawings.

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4.3.3 Dimensions and Tolerances:
4.3.3.1 The dimensions and tolerances of pinballs and socket ends shall
conform to IS: 2486, Part-II and shall be checked by the gauge
therein after galvanizing.
4.3.3.2 The pinballs are checked with the applicable ‘GO’ gauges in at least
two directions, one of which shall be across the line of die flashing,
and the other 900C to this line. “NO GO” gauges shall not pass in
any direction.
4.3.3.3 The bearing surfaces of balls and machined sockets, before
galvanizing shall not have surface roughness more than 250
microns.
4.3.3.4 The bearing surface of socket ends shall be uniform about the entire
circumference without depressions or high spots. The internal
contour of the socket ends shall be concentric with the axis of
fittings. The axis of the bearing surface of socket ends shall be
coaxial with the axis of fittings with no appreciable tilting.
4.3.4 Security clips for socket fittings :
4.4.4.1 Socket fittings shall be provided with R-shaped security clip in
accordance with IS:2486 (Part-III) to provide positive locking against
unintentional disengagement of socket from the ball of the insulator.
The security clip shall be humped to maintain the clip in the locked
position and shall have both prongs spread to prevent complete
withdrawal from the socket. The clip end shall not project outside
the recess of socket when the clip is in locked position.
4.4.4.2 The hole for the security clip shall be on the side of the socket
opposite to the socket opening. The hole for the clip shall be counter
sunk. The clip eye shall be of such design that the same may be

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 engaged by a hotline clip puller to provide for disengagement under
energized conditions.
4.4.4.3 The force required to pull the clip to its unlocked position shall not
be less than 50 N or more than 500 N.
4.4.4.4 The security clip shall be made of stainless steel of type AISI 302 or
304 or phosphor bronze as per IS: 7814.
4.4 Yoke Plate/Link Plate:
4.4.1 The yoke plate/link plate shall be made of mild steel plate as per IS:
226 or equivalent standards. Shearing/cutting of the plates shall be
clean without drawn or ragged edges. If the plates are flame cut,
mechanical guides shall be used. It shall be ensured that the grain
flow of the yoke plate shall be in the direction of the tensile load.
4.4.2 Holes shall be cylindrical, clean cut and perpendicular to the plane
of the material. The periphery of the holes shall be free from burrs.
4.4.3 All the corners and edges should be rounded off with a radius of at
least 3 mm.
4.5 Arcing Horns:
4.5.1 Arcing horns shall be provided on the line side as well as tower side
of various locations. It may be essential to reduce the insulation
near the substation ends up to a length of 1.6 KM on either side in
order to arrive at a good coordinated design. The spark gap shall be
so spaced as to ensure effective operation under actual conditions.
The range settings and dry, wet and impulse flashover values shall
be as given in the tender. The arcing horns shall be provided with
two bolts instead of one bolt to fix it to the main laviwave in order to
prevent it from sliding or tilting.

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4.6 Sag Adjustment Device:
Not applicable.

4.7 Suspension Assembly:

4.7.1 The suspension assembly shall be suitable for single ACSR ‘DRAKE’
conductor in case of 220 kV lines,
4.7.2 The suspension assembly shall include one/two armour-grip
suspension clamps except for pilot insulator string for which
one/two suitable envelope type suspension clamps shall be used.
4.7.3 The suspension clamp along with standard preformed armour rods
set shall be designed to have maximum mobility in any direction and
minimum moment of inertia so as to have minimum stress on the
conductor in the case of oscillation of the same.
4.7.4 The suspension clamp along with standard preformed armour rods
set shall have slip strength between 20 to 29 KN.
4.7.5 The suspension assembly shall be smooth without any cuts, grooves,
abrasions, projections ridges or excrescence, which might damage
the conductor.
4.7.6 Armour Grip Suspension Clamp (AGS):
Clause not used as this is not proposed to be used.
4.7.7 AGS Preformed Armour Rods:
4.7.7.1 The AGS Preformed Armour rod set suitable for ACSR ‘DRKE’
conductor (as the case may be) shall be used to minimize the stress
developed in the conductor due to different static and dynamic loads
because of vibration due to wind, slipping of conductor from the
suspension clamp as a result of unbalanced conductor tension in
adjacent span and broken wire conditions. It shall also withstand

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 power arcs; chafing and abrasion from suspension clamp and
localized heating effect due to resistance losses of the conductor.
4.7.7.2 The performed armour rod set shall have right hand lay and the
inside diameter of the hole shall be less than the outside diameter of
the conductor to grip the same tightly. The surface of the armour rod
when fitted on the conductor shall be smooth and free from
projections, cuts and abrasions etc.
4.7.7.3 The pitch length of the rods shall be determined by the Bidder but
shall be less than that of the conductor layer of ACSR ‘DRAKE’
conductor and the same shall be accurately controlled to maintain
uniformity and consistently reproducible characteristic wholly
independent of the skill of linemen.
4.7.7.4 The length and diameter of each rod shall be as per the drawing
enclosed. The tolerance in length of the rods in completed set
should be within 13 mm between the longest and shorter rod. The
ends of armour rod shall be parrot billed.
4.7.7.5 The number of armour rods in each set shall be twelve. Each rod
shall be marked in the middle with paint for easy applications on the
line.
4.7.7.6 The armour rod shall not lose their resilience even after applications.
4.7.7.7 The conductivity of each rod of the set shall not be less than 40% of
the conductivity of the International Annealed copper Standard
(IACS).
4.7.8 Envelope type suspension clamp:
4.7.8.1 The seat of the envelope type suspension clamp shall be smoothly
rounded and suitably curved at the ends. The lip edges shall have
rounded head. There shall be at least two U-bolts for tightening of
clamp body and keeper pieces together. Hexagonal bolts and nuts

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 with split-pins shall be used for attachment of the clamp. The clamp
body and keeper piece shall be cast out of aluminium alloy of type
LM-6 or equivalent.
4.8 Dead End Assembly:
4.8.1 The dead end assembly shall be suitable for ACSR single ‘DRAKE’
single.
4.8.2 The dead end assembly shall be of compression type with provision
for compressing jumper terminal at one end for 220 kV lines. The
Bidder may offer compression type as an alternative. The angle of
jumper terminal to be mounted should be 30 0 with respect to the
vertical line. The area of bearing surface on all the connections shall
be sufficient to ensure positive electrical and mechanical contact and
avoid local heating due to I2R losses. The resistance of the clamp
when compressed on the conductor shall not be more than 75% of
the resistance of equivalent length of conductor.
4.8.3 Die compression length shall be clearly marked on each dead end
assembly designed for continuous die compressions and shall bear
the words ‘COMPRESS FIRST’ suitably inscribed near the point on
each assembly where the compression begins. It shall bear
identification marks ‘COMPRESSION ZONE’ and ‘NON-
COMPRESSION ZONE’ distinctly with arrow marks showing the
direction of compressions and knurling marks, showing the end of
the zones. Tapered aluminium filler plugs shall also be provided at
the line of demarcation between compression and non-compression
zone. The letters, number and other markings on the finished clamp
shall be distinct and legible. The dimensions and dimensional
tolerances of the cross section of aluminium and steel dead ends
shall be as per the specification drawings.

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4.8.4 The assembly shall not permit slipping of, damage to or failure of the
complete conductor or any part thereof at a load less than 95% of
the minimum UTS of the conductor i.e. 153 KN.
4.8.5 The outer sleeve shall be made out of EC grade aluminium. The
steel sleeve shall be made of mild steel rod.
4.9 Balancing Weights:
4.9.1 The balancing weights shall be made of cast iron/machined mild
steel and consist of four weights weighing 50 Kg each. The
balancing weights shall be connected to the yoke plate of pilot
suspension string by means of eye bolt and shackle arrangement.
The bottom weight shall be provided with recess to shield the ends of
eyebolts.
4.10 Fasteners:
4.10.1 All fasteners shall conform to IS: 6639. All fasteners except spring
washer shall be hot dip galvanized. All bolts and nuts shall have
hexagonal heads, the heads being forged out of solid truly
concentric, and square shank, which must be perfectly straight.
4.10.2 Fully threaded bolt shall not be used. The length of the bolt shall be
such that the threaded portion shall not extend into the place of
contact of the component parts.
4.10.3 All bolts shall be threaded to take the full depth of the nuts and
threaded enough to permit the firm gripping of the component parts
but not further. It shall be ensured that the threaded portion of the
bolt protrudes not less than 5 mm and not more than 10 mm when
fully tightened.
4.10.4 Flat washers and spring washers shall be provided wherever
necessary and shall be of positive lock type. Thickness of washers

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 shall conform to IS: 2016. Spring washers shall be of rectangular
cross section.
4.10.5 To obviate bending stress in bolt, it shall not connect aggregate
thickness more than three times its diameter.
4.10.6 Bolts may have either rolled or cut threads. Nuts may be threaded
after galvanizing to ensure clean threads but bolts shall not be
threaded or re-threaded after galvanizing. Nut threads shall be
tapped oversize to closely fit those of the galvanized bolt, with no
unnecessary looseness but free enough to permit the nut to be
turned freely with fingers over the entire threaded length.
4.11 Forged Components:
Forged components other than those covered in the clauses mentioned herein above
shall be made out of class-IV steel as per IS:2004 or equivalent.
The items shall be normalized to achieve the required tensile properties. The forged
components shall not have sharp corners and edges so as to affect corona and RIV
performance.
4.12 Materials:
The materials of the various components shall be as specified in clauses mentioned
herein above. However, components made of alternative materials giving
equivalent or better performance shall also be considered. The Bidder shall indicate
the material proposed to be used for each and every component of hardware fittings
stating clearly the class, grade or alloy designation of the material and the reference
standards. However, the critical dimensions of components shall not be changed in
relation to selection of different material.

4.13 Galvanising:
4.13.1 Galvanizing shall satisfy the tests mentioned in IS: 2633. No
material shall be galvanised until all shop operations have been

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 completed except that the nuts may be threaded and oiled after
galvanizing. Minimum weight of zinc coating shall be 300 g/sq.m for
fasteners and 600 g/sq.m for all other hot dip galvanized articles.
4.13.2 Fasteners shall withstand four dips while spring washers shall
withstand three dips each of one-minute duration in the standard
preece test. Other galvanised material shall withstand minimum six
dips each of one-minute duration in the standard preece test.
4.13.3 The zinc coating shall be perfectly adherent, of uniform thickness,
smooth reasonably bright, continuous and free from imperfections
such as flux, ash, rust stains, bulky white deposits and blisters.
4.13.4 The zinc used for galvanising shall be grade 99.95% as per IS: 209.
4.14 Workmanship:
4.14.1 All the hardware fitting shall conform to the best modern practices
adopted in the extra high voltage field.
4.14.2 The manufacturing process and quality control of all the materials
shall be such as to give maximum possible working load, highest
mobility, elimination of sharp edges and corners to limit corona and
radio-interference, best resistance to corrosion and a good finish.
4.14.3 Castings shall be uniform without sharp edges or corners, free from
all defects like shrinkage, inclusion, blowholes, cracks etc. Pressure
die-casting shall not be used for casting of components with
thickness more than 5 mm.
4.14.4 Forgings shall be uniform in quality and condition, without sharp
edges or corners, free from cracks, flakes or seams, laps, slag,
silvers, scabs, rolled-in scale and fissures.
4.14.5 All current carrying parts shall be so designed and manufactured
that contact resistance is reduced to minimum.

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4.14.6 No item shall have sharp ends or edges, abrasions or projections and
cause any damage to the conductor in any way during erection or
during continuous operation, which would produce high electrical
and mechanical stresses in normal working. The design of adjacent
metal parts and mating surfaces shall be such as to prevent damage
of the contact surface and to maintain good electrical contact under
service conditions.
4.14.7 All fasteners shall have suitable corona free locking arrangement and
shall not loosen under vibration conditions.
4.14.8 Welds shall be clean, sound, smooth uniforms without overlaps,
properly fused and completely sealed. There shall be no cracks,
voids, incomplete penetration, incomplete fusions; undercutting or
inclusions. Porosity shall be minimized so that mechanical
properties of the aluminium alloys are not affected. All welds shall
be properly finished as per good engineering practices.
4.15 Markings:
Each component of hardware shall be marked with the trademark of the supplier.
Marks shall be forged or stamped with a steel die before galvanising. The marks
shall be distinct, durable, and conspicuous.
4.16 Bid Drawings:
4.16.1 The Bidder shall furnish insulator string drawings along with
component drawings in accordance with specifications.
4.16.2 The Bidder shall furnish fabrication drawings with all additional
dimensions along with the critical dimensions specified in the
specifications/ISS.
4.16.3 Material specifications, details of applicable standards and heat
treatment details shall also be furnished.

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4.16.4 The details of manufacturing process also shall be furnished along
with the component drawings.
4.16.5 The details of trademark to be provided on the components shall also
be furnished.
5.0 TESTS:
The following tests shall be carried out on the hardware fittings.
5.1 Type Tests:
These are those tests, which are to be carried out to prove the design,
process of manufacture and general conformity of the material in
accordance with the specifications. The Contractor shall furnish type
test certificates not older than 5 years. In case the same is older than 5
years then these tests shall be carried out on samples prior to
commencement of commercial production against this specification at
his own cost. The bidder shall indicate his schedule for carrying out
these tests.
5.2 Acceptance Tests:
These are those tests, which are to be carried out during inspection prior to despatch
for the purpose of acceptance of that lot.
5.3 Routine Tests:
These are those tests, which are to be carried out on each hardware fitting to check
the requirements, which are likely to vary during production.
5.4 Test During Manufacture:
Tests during manufacture shall mean those tests, which are to be carried out during
the process of manufacture by the Bidder to ensure quality control such that the end
product is of the designed quality conforming to the intent of this specification.
5.5 Testing Values:
For all type and acceptance tests, the acceptance values shall be those value
guaranteed by the bidder in the Guaranteed Technical Particulars or the acceptance

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 values specified in the relevant standard whichever is more stringent for that
particular test. The norms and procedures of sampling for these tests will be as per
the Quality Assurance Programme to be mutually agreed to by the supplier and the
purchaser.
The standards and norms to which these tests will be carried out are
listed against them. Where a particular test is a specific requirement
of this specification, the norms and procedures of these shall be as
specified in Annexure-III of this volume or as mutually agreed to
between the supplier and the purchaser in the Quality Assurance
Programme.
5.6 Type Tests:
The following type tests shall be conducted on a suitable number of individual
components, materials or complete strings.
5.6.1 On the complete insulator string with hardware fittings (Please also refer Clause
5.10.3)
a) Power frequency voltage withstands test with BS:137
arcing horns. (Part-I)
b) Switching surge voltage withstands test under
IEC:383
wet condition
c) Impulse voltage withstands test under dry
IEC:383
condition
d) Impulse voltage flashover test under dry
IS-731/1971
condition
e) Voltage distribution test
f) Mechanical strength test for complete string
g) Vibration test

NOTE: For electrical tests, the insulator string shall be mounted on a simulated
tower.

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5.6.2 On Suspension Hardware Fittings only.
a) Mechanical test IS-2486 (Part-I)
b) Clamp slip strength for AGS clamp As per this
Specification
c) Clamp slip strength Vs torque test for
suspension clamp
5.6.3 On Tension Hardware Fittings Only:
a) Electrical resistance test for dead end assembly
b) Heating Cycle test for dead end assembly IS:2486
c) Slip strength test for dead end assembly (Part-I)
d) Mechanical tests

5.6.4 All the type tests given under clause No.5.6.1 above shall be conducted separately
on Single/Double Suspension and Single/Double tension insulator string along with
hardware fittings.
5.6.5 The tests specified under clause No.5.6.1 (e) and (f), that is, the voltage distribution
test and corona/RIV (Dry) test shall also be conducted on single suspension pilot
insulator string along with hardware fittings.
5.7 Acceptance Tests/Sample Tests:
5.7.1 On both suspension and tension hardware fittings:
IS: 2486
a) Visual examination
(Part-I)
IS: 2486
b) Verification of dimensions
(Part-I)
c) Galvanizing test/Electroplating
As per
d) Mechanical strength test of welded
Specification
Joint
e) Mechanical strength test for corona control BS: 3288 (Part-
rings/grading rings I)
f) Test on locking devices for ball and socket
IEC: 372(2)
coupling

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5.7.2 On Suspension Hardware Fittings only:
a) Clamp slip strength Vs. Torque test for
suspension clamp As per
b) Shore hardness test of elastomer cushion for specification
AG suspension clamp
c) Band test for armour rod set
IS:2121
d) Resilience test for armour rods set
(Part-I
e) Conductivity test for armour rods set

5.7.3 On Tension Hardware Fittings only:

a) Slip strength test for dead end assembly on
Neoprene IS: 2486
b) Ozone test (Part-I)
c) Heat Resistance test

5.8 Routine Tests:

IS: 2486 (PART-
a) Visual Inspection
I)
As per the
b) Proof Load test
specification

5.9 Test During Manufacture:

On all components as applicable:
a) Chemical analysis of Zinc used for galvanizing
b) Chemical analysis, hardness tests, grain size,
inclusion rating and magnetic particle As per the
inspection for forgings/castings specification
c) Chemical analysis, and proof load test
fabricated hardware

5.10 Test Charges and Test Schedule:

5.10. 1 Type Tests:
The Hardware offered shall be fully type tested as per the relevant
standards. The bids offering equipment not type tested will be rejected.
These tests must not have been conducted earlier than five years from

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 the date of bid opening. In case the equipment of the type and design
offered has already been type tested, the bidder shall furnish four sets of
the type test reports along with the offer. In case these type tests are
conducted earlier than five years all the type tests as per the relevant
standards shall be carried out by the successful bidder in the presence
of purchaser’s representative at free of cost. The purchaser reserves the
right to demand repetition of some or all the type tests in the presence of
his representatives and these shall be conducted at no extra cost to
owner. For any change in the design/type already type tested and the
design/type offered against this specification, the purchaser reserves the
right to demand repetition of tests without any extra cost.

5.10.2 Acceptance and Routine Tests:

All acceptance and routine tests as stipulated in the relevant standards
shall be carried out by the supplier in presence of purchaser’s
representative.
5.10.3 For type test, which involve the tests on the complete insulator string
along with hardware fittings, the primary responsibility of
conducting test lies with the disc insulator supplier. However, the
hardware supplier shall make all the necessary hardware fittings for
testing available to the insulator supplier at the place of testing and
do all the associated co-ordination work in this regard. In respect of
electrical tests on the complete insulator string consisting of
insulators and hardware’s for RIV, Corona and voltage distribution
test and with insulator manufacturer for all other tests.
5.10.4 In case of any failure during testing, the cause of failure shall be
thoroughly investigated by the supplier in association with

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 purchaser’s engineers. In case it is established that the cause of
failure is due to some defects in manufacturing process or in the
material itself, then the re-testing shall be carried out by the supplier
without any extra cost to purchaser. However, if it is established
that the failure is due to deficiency in design itself, then the design
will be suitably modified by the supplier. After incorporating the
modification suggested, re-testing is to be carried out. In the latter
case, the re-resting charges will be paid as per the rates quoted in
the appropriate schedule of Bid Proposal Sheet for that particular
test. In case of any dispute, the assessment of the purchaser as to
what is the cause of failure shall be final and binding.
5.10.5 Supplier shall indicate the laboratories in which it is proposed to
conduct the type tests. Supplier shall also ensure that the tests can
be completed in these laboratories, within the time schedule
guaranteed, by him in the appropriate schedule of Bid Proposal
Sheet.
5.10.6 The entire cost of testing for acceptance and routine tests and tests
during manufacture specified herein shall be treated as included in
the quoted unit price of hardware fittings, except for the expenses of
the Inspector/Purchaser’s representative.
5.10.7 Immediately after finalization of the programme of
type/acceptance/routine testing, the supplier shall give sufficient
advance intimation to the purchaser, to enable to depute his
representative for witnessing the tests.
5.11 Sample Batch for Type Testing:
5.11.1 The supplier shall offer at least three times the quantity of materials
required for conducting all the type tests for sample selection.

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5.11.2 Before sample selection, the supplier shall be required to conduct all
the acceptance tests successfully in presence of purchaser’s
representative.
5.12 Additional Tests:
5.12.1 The purchaser reserves the right of having at his own expenses and
other test (s) of reasonable nature carried out at supplier’s premises,
at site, or in any other place in addition to the aforesaid type,
acceptance and routine tests to satisfy that material comply with the
specifications.
5.12.2 The Purchaser also reserves the right to conduct all the tests
mentioned in this specification at his own expense on the samples
drawn from the site at supplier’s premises or at any other test
centre. In case of any failure, it shall be binding on the part of
supplier to replace that particular lot completely, without any extra
cost to the purchaser.
6.0 INSPECTION:
i) The Purchaser shall have access at all times to the works and all
other places of manufacture, where the hardware fittings and its
components are being manufactured and the supplier shall
provide all facilities for unrestricted inspection of the supplier’s
works, raw materials, manufacture of all the accessories and for
conducting necessary tests as detailed herein.
ii) The supplier shall keep the purchaser informed in advance of the
time of starting and of the progress of manufacture of accessories
in its various stages so that arrangements could be made for
inspection.
iii) No material shall be despatched from its point of manufacture
unless the material has been satisfactorily inspected and tested.

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 iv) The acceptance of any quantity of accessories 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 hardware fittings later found to be defective.
7.0 QUALITY ASSURANCE PLAN:
7.1 The bidder shall invariably furnish the following information along with
his offer, failing which the offer shall be liable for rejection.
i) Statement giving list of important raw materials, names of sub-
suppliers for the raw materials, list of standards according to
which the raw materials are tested, list of tests normally carried
out on raw material in presence of Bidder’s representative, copies
of test certificates.
ii) Information and copies of test certificates as in (i) above in respect
of bought out materials.
iii) List of manufacturing facilities available.
iv) Level of automation achieved and list of areas where manual
processing exists.
v) List of areas in manufacturing process, where stage inspections
are normally carried out for quality control and details of such
tests and inspections.
vii) List of testing equipment 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.
7.2 The supplier shall within 30 days of placement of order, submit the
following information to the purchaser:

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 i) List of raw material as well as bought out accessories and the
names of sub-suppliers selected from there furnished along with
the offer.
ii) Type test certificates of the raw material and bought out
accessories.
iii) Quality Assurance Plan (QAP) with hold points for purchaser’s
inspection. The QAP and hold points shall be discussed between
the Purchaser and the Supplier before the QAP is finalized.
7.3 The supplier shall submit the routine test certificates of bought out
items and raw materials at the time of routine testing of the fully
assembled hardware fittings.
8.0 DOCUMENTATION:
8.1 i) The bidder shall furnish along with the bid the dimensional
drawings of all types of hardware fittings:
ii) These drawings shall include the following information:
a) Dimensions.
b) Tolerance on dimensions.
c) Material designation used for different components with
reference to standards.
d) Fabrication details such as welds, finishes and coatings.
e) Catalogue or part numbers for each component and the total
assembly with bill of materials.
e) Identification marking.
f) Weight of individual components and total assembled weight.
iii) The assembly drawings shall include the following:
a) Brief installation instructions.
b) Design installation torque for the bolt or cap screw.
c) Withstand torque that can be applied to the bolt or cap

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 Screw without failure of components or parts thereof.
d) Compression dies number with recommended compression
pressure.
c) Relevant technical details of significance.
8.2 Test Reports:
i) Four copies of type test reports shall be furnished to the purchaser
within one month of conducting the tests. One copy will be
returned duly certified by purchaser to the supplier within three
weeks there afterwards and on receipt of the same supplier shall
commence with the commercial production of the concerned
material.
ii) Four copies of acceptance test reports shall be furnished to the
purchaser. One copy will be returned duly certified by the
purchaser and only there after shall the materials be despatched.
iii) All records of routine test reports shall be maintained by the
supplier at his works for periodic inspection by the purchaser.
iv) All test reports of tests conducted during manufacture shall be
maintained by the supplier. These shall be produced for
verification as and when requested for by the purchaser.
9.0 PACKING AND FORWARDING:
i) All hardware fittings shall be packed in suitably sized strong and
weather resistant wooden cases/crates. The gross weight of the
packing shall not normally exceed 200 Kg to avoid handling
problems. Suitable lifting lugs shall be provided on the crates in
order to facilitate handling by cranes.
ii) Suitable cushioning, protective padding or spacer shall be
provided to prevent damage to or deformation of the hardware’s
during transit and handling.

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 iii) All identical items shall be despatched to destination duly
assembled and packed. Bolts, nuts, washers, cotter pins, security
clips and split pins etc. shall be packed duly installed and
assembled with the respective parts and suitable measures shall
be taken to prevent their transit loss.
iv) Each component part shall be legibly and indelibly marked with
the trademark of the supplier and year of manufacture.
v) All packing cases shall be marked legibly and correctly so as to
ensure their safe arrival at their destination and to avoid the
possibility of goods being lost or wrongly despatched on account of
faulty or eligible markings. Each wooden case/crate shall have all
the markings stenciled on it in indelible ink.

DETAILS OF TESTS

1.0 VOLTAGE DISTRIBUTION TEST:

The voltage across each insulator unit shall be measured by sphere gap
method. The result obtained shall be converted in to percentage and
proportionate correction applied so as to give a total of 100%
distribution. The voltage distribution across any disc shall not exceed
the values specified in clause 3.2.
2.0 CORONA EXTINCTION VOLTAGE TEST:
The sample assembly when subjected to 50 Hz Power frequency voltage
shall have a corona extinction voltage of not less than the value specified

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 in clause 3.2 under dry condition. These shall be no evidence of corona
on any part of the sample when all possible sources of corona are
photographed in a darkened room.
3.0 RIV TEST:
Under the conditions as specified under (2) above, the insulator string
along with the complete hardware fittings shall have a radio interference
voltage level below 500 micro-volts at one MHz when subjected to 50 Hz
AC voltage of 1.1 times the maximum line to ground under dry
condition. The test procedure shall be in accordance with IS: 8263.
4.0 MECHANICAL STRENGTH TEST FOR COMPLETE STRING:
The complete insulator string along with its hardware fittings excluding
arcing horn, corona control rings/grading ring and suspension
assembly/dead end assembly shall be subjected to a load equal to 50%
of the specified minimum ultimate tensile strength (UTS) which shall be
increased at a steady rate to 67% of the minimum UTS specified. This
load shall be held for five minutes and then removed. After removal of
the load, the string component 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 the reassembled and loaded to 50% of UTS and the load shall
be further increased at a steady rate till the specified minimum UTS is
reached and held for one minute. No fracture should occur during this
period. The applied load shall then be increased until the failing load is
reached and the value recorded.
5.0 VIBRATION TEST:
The suspension string shall be tested in suspension mode and tension
string in tension mode itself in a laboratory span of minimum 30
meters. In the case of suspension string a load equal to 6 KN shall be

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 applied along the axis of the suspension string by means of a
turnbuckle. The insulator strings along with hardware fittings and two
sub-conductors tensioned at 45 KN shall be suitably secured. The
system shall be suitable to maintain constant tension on each sub-
conductor throughout the duration of the test. Vibration dampers shall
not be used on the test span.
Both the sub-conductor shall be vertically vibrated simultaneously at
one of the resonance frequencies of the insulator string above 10 Hz by
means of vibration inducing equipment. The amplitude of vibration at
the anti-node nearest to the insulator string shall be measured and the
same shall not be less than +120/f, being the frequency of vibration.
The insulator string shall be vibrated for 5 million cycles then rotated by
900 and again vibrated for 5 million cycles without any failure. After the
test, the disc insulators shall be examined for fatigue and mechanical
strength. There shall be no deterioration of properties of hardware
components after the vibration tests.
6.0 GALVANISING TEST:
The test shall be carried out as per clause No.5.9 of IS: 2496 (Part-I)
except that both uniformity of zinc coating and standard preece test
shall be carried out and the results obtained shall satisfy the
requirements of this specification.
7.0 MECHANICAL STRENGTH TEST FOR WELDED JOINT:
The welded portion of the component shall be subjected to a load of
2000 Kgs for one minute. Thereafter, it shall be subjected to die-
penetration/ultrasonic test. There shall not be any crack at the welded
portion.

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8.0 CLAMP SLIP STRENGTH VS TORQUE TEST AND CLAMP SLIP FOR
AGSC LAMP/ENVELOPE TYPE SUSPENSION CLAMP:
The suspension clamp shall be vertically suspended by means of a
flexible attachment. A suitable length of ACSR conductor shall be fixed
in the clamp. The clamp slip strength at various tightening torque shall
be obtained by gradually applying the load at one end of the conductor.
The clamp slip strength vs torque curve shall be drawn. The above
procedure is applicable only for free centre type suspension clamp. For
AG suspension clamp only clamp slip strength after assembly shall be
found out. The clamp slip strength at the recommended tightening
torque shall be more than 20 KN but less than 29 KN.
9.0 SHORE HARDNESS TEST OF ELASTOMER CUSHION FOR AGS
ASSEMBLY:
The shore hardness at various points on the surface of the elastomer
cushion shall be measured by a shore hardness meter and the shore
hardness number shall lie between 65 to 80.
10.0 PROOF LOAD TEST:
Each component shall be subjected to a load equal to 50% of the
specified minimum tensile strength. The load shall be held for one
minute and then removed. After removal of the load the component
shall not show any failure or permanent deformation.
11.0 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%.
12.0 TEST FOR FORGING CASTING AND FABRICATED HARDWARE:
The chemical analysis, hardness test, grain size, inclusion rating and
magnetic particle inspection for forging, casting, radio-graphical
inspection for items made of aluminium alloys, chemical analysis and

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 proof load test for fabricated hardware and ductility test on tensile test
specimen shall 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 and acceptance criteria will
be as per the Quality Assurance Programme agreed upon.

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 SECTION – X (A)
(VOLUME – II)

TECHNICAL SPECIFICATIONS
FOR

STUB SETTING AND CASTING OF FOUNDATIONS

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 VOLUME-II

SECTION-X(A)

TECHNICAL SPECIFICATIO FOR STUB SETTING AND CASTING OF

FOUNDATIONS

1.0 TESTING OF SOIL

2.0 EXCAVATION
3.0 SETTING OF STUBS
4.0 MIXING, PLACING, COMPACTING OF CONCRETE AND REINFORCEMENT
5.0 BACK-FILLING AND REMOVAL OF STUB TEMPLATE
6.0 CURING
7.0 BENCHING
8.0 PROTECTION OF TOWER FOOTING
9.0 MEASURING OF BACK FILLING
10.0 EARTHING

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 VOLUME–II

SECTION-X (A)

TECHNICAL SPECIFICATION FOR STUB SETTING AND CASTING OF

FOUNDATIONS

1.0 Testing of soil:

The Contractor shall be required to undertake soil tests at approved

tower locations in the manner specified in and submit report and
recommendations thereof as specified under the said clauses for the
design of foundations. The Contractor shall also furnish soil resistivity
values to the Owner along the line alignment. The Contractor shall
furnish final foundation design for approval to the Engineer based on
the soil investigations carried out and on approval thereto such
foundations shall be cast.

2.0 Excavation:
2.1 Except as specifically otherwise provided, all excavation for footings
shall be made to the lines and grades of foundation. The excavation
walls shall be vertical and pit dimensions shall be such as to allow a
clearance of not more than 150 mm on all sides from the foundation
pad. All excavation shall be protected so as to maintain timbering,
shoring or casing, if necessary. Any sand, mud, silt or other
undesirable materials, which may have accumulated in the excavation,
shall be removed by the contractor before placing concrete.

2.2 The soil to be excavated for tower foundations shall be classified as

under:

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 a) Normal soil – soil removable by means of ordinary pick axes and
shovels.
PS
b) Wet: Where sub-soil water in encountered within
FS the range of foundation depth pumping or
WBC bailing out of water is required. Presence of surface water
will be treated as wet soil.
c) Soft/fissured rock: Lime stone, laterite, hard englomerate or other
soft or fissured rock to be quarried or split with crowbars, wedges or
pickaxes. If required, light short blasting may be resorted to, for
loosening the material, but this will not in way entitle the material to be
classified as hard rock.
d) Hard rock: Any rock excavation other than specified under soft/fissured rock above
for which blasting, drilling, chiseling are required. The unit rate quoted for hard
rock excavation shall include all costs of blasting, drilling chiseling and services
thereof.
2.3 Where soil at a tower foundation is of composite nature, classification
will be according to the type of soil, which is predominant in the footing
and the rate for the same will apply for the predominant soil foundation.
However, for excavation, the payment shall be made for different soils as
per soil encountered at the time of excavation but limited to the lowest
of the following:
i) Payment calculated based on the volume of different
types of soils encountered at the time of excavation at their
respective rates and excavated volumes as per actuals (i.e.
strata wise).
ii) Payment calculated based on the type of soil for which
foundation is classified considering the applicable ceiling

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 volume for that particular soil indicated in the Purchase
Order as quoted by the Bidder and its applicable rate.
iii) Payment calculated based on the type of soil for which
foundation is classified considering the design volume of
excavation for that particular soil and its applicable rate.
The decision of the Engineer shall be final and binding with reference to
the classification of soils.
2.4 No extra charge shall be admissible for the removal of the fallen earth in
the pit, when once excavated, shoring and timbering as approved by
authorized representative of the Board shall be admissible when the soil
condition is so bad that there is likelihood of accident due to the falling
of earth.
2.5 Where rock is encountered, the holes for tower footings shall preferably
be drilled, but where blasting is to be resorted to as an economy
measure, it shall be done with utmost care to minimize the use of
concrete for filling up the blasted area. All necessary precautions for
handling and use of blasting materials shall be taken. In cases where
unnecessarily large quantities are excavated/blasted, resulting in
placement of large volumes of concrete no extra payment is allowed. In
case where drilling is done, the stubs may be shortened suitably with
the approval of the Engineer.
2.6 The contractor shall supply requisite blasting material and be
responsible for the purpose of storage and use of this material. The unit
rates quoted shall include all cost of blasting drilling chiseling and
services thereof.
2.7 The foundation design for different soils shall be as given by the owner.
2.8 The excavation volumes for each type of tower footing shall be estimated
assuming the facing of surrounding earth as vertical keeping a distance

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 of 150 mm clearance from the extreme edge of the base slab of the
footing for all types of foundations except hard rock and fissured rock
where the undercut type of foundation is provided.
3.0 Setting of stubs:
3.1 The stubs shall be set correctly in accordance with the approved method at the
exact location aligned precisely to correct levels with the help of stub setting
template and leveling instruments. Stubs shall be set in the presence of owner’s
representative only and contractor shall sufficiently intimate in advance to the
Owner’s representative for such presence.
3.2 Setting of stubs shall be approved by the Owner’s representative.
3.3 The following tolerances shall be applicable in case of
position of foundation as a whole with reference to the
tower position as spotted on the survey chart:
Out of From centre From transn.
Type of Tower
alignment line of route Centre line
Suspension or
0.50 + 25 mm + 25 mm
Intermediate
Section or
Tension (Set at
0.50 + 25 mm + 25 mm
bi-section of
deviation angle

3.4 The Owner may get certain foundations such as well type or pile type
constructed through other agencies. However, the contractor shall be
required to set the stubs for the same and coordinate his work with the
other agencies accordingly.

4.0 Mixing, Placing, Compacting of Concrete and Reinforcement:

i) The concrete shall be mixed in a mechanical mixer. However, in

case of difficult terrain hand mixing may be permitted at the

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 discretion of the Engineer. The water for mixing concrete shall be
fresh, clean and free from oil, acids and alkalis. Saltish or
brackish water shall not be used.
ii) Mixing shall be continued until there is uniform distribution of
material and the mix is uniform in colour and consistency, but in
no case the mixing shall be done for less than two minutes.
Normally, mixing shall be done close to the foundation, but where
this is not possible mixing may be resorted to at the nearest
convenient place. The concrete shall be transported from the place
of mixing to the place of final laying/placing as rapidly as
practicable by methods, which shall prevent the segregation or
loss of any ingredient. The concrete shall be placed and
compacted before setting commences.
iii) The concrete shall be laid in 150 mm layers and consolidated well
so that the cement cream works up to the top and no honey-
combing is left in the concrete. However, in case of difficulty
terrain, manual compaction may be permitted at the discretion of
site Engineer. After concreting the chimney portion to the required
height, the top surface should be finished smooth with a slight
slope towards the outer edge, to drain off any rain water falling on
the coping, and making ingress in to the stub angle.
iv) In wet locations, the site must be kept completely de-watered, both
during the placement of concrete and for 24 hours thereafter.
There should be no disturbance on concrete by water during this
period.
v) The formwork shall be removed 24 hours later after concreting or
after the concrete has fully set. If the concrete surface is found to
be defective on removal of the formwork, the damage shall be

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 required with rich cement and sand mortar to the satisfaction of
the Engineer’s representative before the foundation pits are back
filled.
vi) The concrete volume and dimensions of the foundation shall be as
per approved drawings. Measurement of concrete volume shall be
in cubic metres and shall be worked out to the second decimal
place.
vii) Steel required for reinforcement of foundations shall be provided
for by the contractor. No payment will be made for wire required
for binding the reinforcement, chairs, bolsters and spacers, as the
cost of these is deemed to be included in the unit rate quoted for
reinforcement.
viii) The payment for foundations shall be restricted to the ceiling
volumes or design volumes whichever is lower.
5.0 Back-filling and removal of stub template:
i) Following the opening of the form work and removal of showing
and timbering, if any, back-filling shall be started, after repairs, if
any, to the foundation concrete, Back-filling shall normally be
done with the excavated soil, unless it consists of large
boulders/stones, in which case the boulders shall be broken to a
maximum size of 80 mm. At such locations where borrowed earth
is required for back filling, this shall be done by the Contractor at
his own cost, irrespective of lead.
ii) The back-filling materials should be clean and free from organic or
other foreign materials. The earth shall be deposited in maximum
200 mm layer, leveled, wetted and tamped properly before another
layer is deposited. Care shall be taken that the back filling is
started from the foundation ends of the pits, towards the outer

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 ends. After the pits have been back-filled to full depth, the stub
template may be removed.
iii) The back filling and grading shall be carried to an elevation of
about 75 mm above the finished ground level to drain out water.
After back-filling a 50 mm high earthen embankment (Bund) shall
be made along the sides of the excavated pits and sufficient water
will be poured in the back-filled earth for at least 24 Hours.
6.0 Curing:
The concrete after setting for 24 hours shall be cured by keeping the
concrete wet continuously for a period of 10 days after laying. The pit
may be back filled with selected earth sprinkles with necessary amount
of water for a period of 24 hours and thereafter both the back filled
earth and exposed chimney top shall be kept wet for the remainder of
the prescribed time of 10 days. The uncovered concrete chimney above
the back-filled earth shall be kept wet by providing empty cement bags
dipped in water fully wrapped around the concrete chimney for curing
and ensuring that the bags are kept wet by the frequent pouring of
water on them.
7.0 Benching:
When the line passes through hilly/undulated terrain, for a few tower
locations it may be required to level the ground for casting of tower
footings on same elevations. All the activities related to make the
required area of ground in same elevation for casting of foundation,
shall be termed as benching work. Benching work shall include cutting
of excess earth and removing the same to a suitable point of disposal as
required by the Owner. Benching shall be resorted to only after getting
specific approval from the Owner. Volume of the earth to be cut shall be
measured before cutting and got approved from the Owner. This volume

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 of earth shall be considered for the purposes of payment against the
head of benching work. The Bidders are requested to quote unit rates
for this work in the price schedules.
8.0 Protection of tower footing:
i) Special measures are required for protection of tower footings
located close to or in nallahs, river streambeds, etc. and subject to
approval by the Engineer. The work includes all necessary stone
revetment, concreting, earth filling above ground level, providing
suitable revetment or galvanized wire netting and meshing packed
with boulders. The contractor shall furnish recommendations for
providing protection at such locations. The Bidders are required to
furnish unit rates for such protective works in the price schedules.
The unit rates shall be applicable with actual quantities of
revetment and extra excavation work done if any.
ii) On ordinary flat ground, the stubs shall be set with their tops
above ground level as per design and given a coping but not
marking up of plinths shall be required. Where the ground surface
is irregular, the foundation shall be finished off in a substantial
and permanent way forming a plinth by side cutting, building a
suitable stone revetment or in case of rock foundations by building
up with cement, as desired by the Engineer.
The quantity of excavated earth obtained from a particular location
shall generally be utilized in back-filling work in protection of
tower footing of same location, unless it is unsuitable for such
purpose. In the later case, the back filling shall be done with
borrowed earth of suitable quality irrespective of lead, as per the
rate provided in the letter of award. The consolidation of earth
shall however, be done after back filling free of cost.

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 The provisional quantities for protections work to foundations are
furnished in respective schedule of Bid Proposal Sheets. The unit
rates shall also be applicable for adjusting with the actual
quantities for protection works done.
No separate rates shall be allowed for borrowed earth and the
Contractor shall make his own arrangements for procurement of
borrowed without any extra cost.
9.0 Measurement of back filling:
The volume of back filling shall be considered equal to that of the
excavation. This also applies to any earthwork embankments to be
provided over the foundation to the design drawings.
10.0 Earthings:
Each tower shall be earthed after the foundation has been cast. For this
purpose, earth strips shall be fixed to the stub during concreting of the
chimney and taken out horizontally below the ground level. The earth
strip shall be provided on the leg with step bolts.
The footing resistance of all towers to earth shall not exceed the values
specified in IS-3043-1966 after earthing and tower erection but before
stringing of the overhead ground wire. In case the resistance exceeds
the specified value, multiple pipe earthing or counterpoise earthing shall
be adopted in accordance with the following procedure, but without
interfering with the foundation concrete even though the earth
strip/counterpoise lead remains exposed at the tower end. The
connection in such case shall be made with the existing lattice member
holes on the leg just above the chimney top.
Pipe earth: The installation of the pipe earthing shall be in accordance
with IS 5613.

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 Counterpoise earth: Counterpoise earth consists of four lengths of
galvanized steel stranded wires, each fitted with a lug for connection to
the tower leg at one end. The wires are connected to arch of the legs
and taken radially away from the tower and embedded horizontally 450
Mtr. below ground level. The length of earth wire is normally limited to
15 mtr. but may be increased if the resistance requirements are not
met. The size of the galvanized steel stranded wire may be taken equal
to sizes of the earth conductor. The counterpoise type earthing of tower
shall be in accordance with IS 5613.

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 SECTION – X (B)
(VOLUME – II)

TECHNICAL SPECIFICATIONS
FOR

ERECTION OF TOWERS, STRINGING OF CONDUCTORS, INSTALLATIONS

OF LINE MATERIALS AND COMMISSIONING

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 VOLUME-II
SECTION-X(B)
TECHNICAL SPECIFICATION FOR ERECTION OF TOWER SUPER
STRUCTURE, STRINGING AND INSTALLATION OF LINE MATERIALS AND
COMMISSIONING

1.0 GENERAL

2.0 ERECTION OF SUPER STRUCTURE

3.0 TREATMENT OF JOINTS

4.0 ASSEMBLY

5.0 INSULATOR HOISTING

6.0 INSTALLATION OF POWER CONDUCTOR AND EARTHWIRE

7.0 FIXING OF CONDUCTOR AND EARTHWIRE ACCESSORIES

8.0 SAFETY PRECAUTIONS

9.0 FINAL CHECKING, TESTING AND COMMISSIONING

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 VOLUME-II

SECTION – X (B)

TECHNICAL SPECIFICATION FOR ERECTION OF TOWER SUPER

STRUCTURE, STRINGING AND INSTALLATION OF LINE MATERIALS AND
COMMISSIONING:

1.0 General:
The details of the scope of erection work shall include the cost of
labour, and tools and plants like tension stringing equipment and
all other incidental expenses in connection with erection and
stringing work.
The contractor shall be responsible for transportation of all
materials to the site, proper storage and preservation at their own
cost till such time the erected line is taken over the Owner.
Similarly the Contractor shall be responsible for transportation,
proper storage, safe custody, loss or damage of all materials for
incorporation in the lines and shall maintain and render proper
account for all such materials lost or damaged during storage and
erection.
The Contractor shall set up required number of stores along the
line and the exact location of such stores shall be discussed and
agreed to between the contractor and the owner.
If any defects are found in case of hot-dip galvanized members, the
members if acceptable to Owner shall be repaired by applying zinc
rich protection paint.

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2.0 Erection of Super Structure:
The towers shall be erected on the foundations not less than 14
days after concreting or till such time that the concrete has
acquired full strength. The towers are erected as per the erection
drawings furnished by the manufacturers. To facilitate, erection,
each tower member shall be marked to correspond with a number
shown in the erection drawing. The steel is first delivered to the
tower location and is placed in such a manner as to be accessible
for erection. Any damage to the steel and injuring of galvanizing
shall be avoided. No member shall be subjected to any undo over
stress during erection.
The erection of tower may be carried out by any of the following
methods generally followed:
i) Built up method or piece meal method.
ii) Section method.
iii) Any other approved advanced method.
3.0 Treatment of Joints:
Before starting assembly, the surfaces shall be cleaned and
applied with a coat of zinc rich paint, if required.
4.0 Assembly:
4.1 Irrespective of the method followed for the erection of towers, the points
mentioned below shall be observed:
a) Straining of the members shall not be permitted for bringing them in to
position. It may, however, be necessary to match hole positions at joints and
to facilitate this, tommy bars not more than 450 mm long may be used.
b) Before starting erection of an upper section the lower section shall be
completely braced and all bolts fitted in accordance with approved drawings.

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 c) All plan diagonals relevant to a section of tower shall be placed in position
before assembly of upper section is taken up.
d) All bolts shall have their nuts facing outside of the tower for horizontal or
nearly horizontal bolt connections and downwards for vertical bolt
connection. The bolt positioning in assembled towers shall be as per IS-
5613, Part-II, Section-2, 1976.
e) The cross arms be assembled on ground and the top cross arm shall be lifted
first, followed by the middle and bottom cross-arms. The tips shall be fully
tightened before lifting them in to position, such bolts which are not
accessible for tightening by ordinary tommy spanners, may be tightened
with the help of box or ratchet ring spanner.
f) The towers shall be fitted with Number plates, danger plates, phase plates,
circuit plates and anti-climbing devices as described elsewhere in the
specifications.
g) All the blank holes, if any left after complete erection of the tower are to be
filled up by bolts and nuts of correct size.
4.2 Tightening & punching of Bolts & Nuts:
All nuts shall be tightened properly using correct size spanners. Before
tightening it shall be seen that filler washers and placed in relevant gaps between
members, bolts of proper size and length are inserted and one spring washer has
been inserted under each nut. In case of step bolts the spring washer shall be
placed under the outer nut. The tightening shall progressively be carried on from
the top downwards, care being taken that all bolts at every level are tightened
simultaneously. It may be better to employ four persons, each covering one leg
and the face to his left.
The threads of bolts projecting outside nuts shall be punched at three positions on
the diameter to ensure that the nuts are not loosened in course of time. If during
tightening a nut is found to be slipping or running over the bolt threads, the bolt
together with the nuts shall be changed out right. All the bolts and nuts in all

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 joints up to the level of bottom cross arm from the tower base shall be tack
welded after final tightening. After welding cold galvanized paint having at least
90% Zinc content shall be applied to the welded portion. AT least two coats of
the paint shall be applied. The cost of welding and paint including application of
paint shall be deemed to be included in the erection price.
In addition to tack welding of nuts with bolts, as described above, the Contractor
can also propose some alternative arrangements like use of epoxy adhesive which
can serve the purpose of locking the nut permanently with the bolt and thus
preventing pilferage of the tower members.
In case the Bidder offers some alternative to tack welding as stated above, the
Bidder shall have to furnish all the technical parameters of the same, to facilitate
the owner to technically evaluate its acceptability. However, the evaluation of the
tender shall be done based on the tack welding only.
5.0 Insulator Hoisting:
5.1 The string shall be fixed on the tower just prior to the stringing of
conductors, but only after the towers have been fully assembled,
bolt/nuts tightened as per the requirements of the technical
specification. Damaged insulators and fittings, if any, shall not be
employed in the assemblies. Before hoisting all insulators shall be
cleaned in a manner that may not spoil or injure or scratch the
glaze of the porcelain and in no case any oils shall be used for the
purpose. Security clips shall be in position for the insulators
before hoisting.
5.2 Arcing horns or grading rings, shall be placed along the line on
suspension, and facing upwards on tension insulator string
assemblies. The yoke arrangements shall be horizontal for
tension, and longitudinal for suspension strings. Torque wrench
shall be used for fixing various line materials and their

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 components like suspension clamps for conductor and earthwire,
etc. wherever recommended by the manufacturer of the same.
6.0 Installation of power conductor and earthwire:

6.1 General:
The erection of conductors shall be done in 4 stages as follows:
a) Delivery of conductors at site
b) Running out (also called paying out) and stringing
c) Tensioning and sagging, and
d) Clipping-in.

6.2 Delivery of conductors at site:

6.2.1 The standard length contained in all the drums supplied against the line
requirement shall be noted down and the drums shall be batched 3 drums in a
batch.
6.2.2 At every dumping site, two such batches shall be dumped.
6.2.3 While deciding the place of dumping, due consideration shall be
made of the particular standard length of the batch, extra length
consumed on account of sag, damaged ends of the conductor in
the drum, inclined spans, etc. The points noted under the Clause
‘Tensioning and Sagging of conductors’ in this section shall as well
be borne in mind so that the planning for dumping of the drums
would not be disturbed, once it is finalized.
6.2.4 All drums in dilapidated condition shall be discarded and the
conductor shall be rewound on new drums before use. In case of
the drums with only the lagging damaged, use may be made of
turntables holding the drums on vertical rotational axis, for
running out.
6.3 Running out:
6.3.1 Whatever the method employed for running out the conductors, care shall be
taken that the conductors do not touch or rub against ground or objects which
would cause scratches or damages to the strands. The conductors shall be run out

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 of the drums from the top (and not from the bottom) in order to avoid damage due
to checking. The conductors shall be pulled out evenly in preference to pulling
out a complete section of one wire. The conductor immediately after running out,
shall be raised at the supports to a level as that of the clamp and placed into the
running blocks or the aerial rollers.
6.3.2 The running blocks shall be of diameter not less than the internal barrel diameter
of the drum as given in the IS: 1778-1961. In case such blocks are not avail able,
the blocks shall be provided with two small pulleys, which shall enable the
conductor to form a curve of minimum equivalent diameter. The groove of the
pulley shall be of the design that the seat is semi-circular and larger than the
diameter of the conductor and it does not slip or rub against the sides. The
groove shall be lined with hard rubber or neoprene to avoid damage to conductor
and shall be mounted on well-oiled bearings.
6.3.3 The running blocks shall be suspended in manner to suit the design of cross arms.
All running blocks, especially those at the tensioning end, shall be fitted with
cross arms with sacking wrapped over the steel work and under the slings to
avoid damage to the slings as well as to the protective surface finish of the steel
work. In case suspension, light angle or section towers are used for termination
of stringing operations for longer periods they shall be suitably guyed. Normally,
suspension towers shall not be used even for temporary terminations, if this
becomes necessary, these shall well guyed and steps taken to avoid damage. The
drums shall be provided with suitable breaking device to avoid loose running out
and to prevent kinking of the conductors. The conductor shall continuously be
observed for loose, or broken strands or any other damage. When approaching
the end of a drum length, at least three coils shall be left when the stringing
operations are stopped. These coils shall be removed carefully and if another
length is required to be run out, a joint shall be made according to the
recommendation of the manufacturers. Normally, the joint shall be compression
joint done with hydraulic compressor.

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6.3.4 Repairs to conductors, if necessary, shall be carried out during the running out
operations, with repair sleeves. Repairing of conductor surface shall be done only
in case of minor damage, scuff marks etc keeping in view both electrical and
mechanical safe requirements. The final conductor surface shall be clean, smooth
and without any projections, sharp points, cuts, abrasions etc.
6.3.5 Conductor splices shall be so made that they do not crack or get damaged in the
stringing operation. The contractor shall use only such equipments/methods
during conductor stringing which ensures complete compliance in this regard.
6.3.6 Derricks shall be used where roads, rivers, canals, telephones or over head power
lines, railway premises, fences or walls have to be crossed during stringing
operations. It shall be ensured that normal services are not interrupted or damage
caused to property. Shutdown shall be obtained when working at crossing of
overhead power lines, and railways (electrified or otherwise).
6.3.7 The sequence of running out shall be from top downwards, that is the earth
conductor shall be run out first, followed by top, middle and bottom power
conductors in succession. Unbalances of loads on towers shall be avoided as for
as possible. The sequence of running out shall be from top to downwards i.e., the
earthwire shall be run out first, followed by the conductors in succession.
Unbalance of loads on towers shall be avoided as far as possible. Outer phases of
line conductor shall be strung before the stringing of the middle phase is taken up.
B & C type towers are not designed for one side stringing. Therefore, proper
guying arrangement shall be made for B & C type of towers during stringing on
one section while the other section is strung. The contractor shall forward
detailed proposals along with calculation for guying for approval by the engineer.
Proper tools and instruments shall be made available to the Engineer by the
contractor for checking the tension in the guy wires. All the expenditure on
account of the above work is deemed to be included in the bid price.
6.3.8 The proposed 220 kV Transmission line may run in parallel for certain distances
with existing 220 kV, 110 kV & 66 kV lines which may remain energized during

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 the of dangerous voltage build up due to electromagnetic and electrostatic
coupling in the pulling wire conductors and earth wires, which although
comparatively small during normal operations could be the contractors
responsibility to take adequate safety precautions to protect his personnel and
others from this potential danger.
6.4 Stringing of the conductor and earthing:
The bidder shall give complete details of the stringing methods,
which he proposes to adopt. Before the commencement of
stringing, the contractor shall submit stringing charts for the
conductors and earthwire showing the initial and final sags and
tensions for various temperatures and spans, along with
equivalent spans in the lines for approval by the Engineer.

6.5 Jointing:
i) All joints on the earthwire and conductor shall be of
compression type, in accordance with the recommendations
of the manufacturer for which all necessary tools and
equipment like compressors, dies, etc. shall have to be
arranged for by the contractor. Each part of the joint shall
be cleaned by wire brush to make it free of rust or dirt etc.
and properly greased before the final compression is done
with the compressors.
ii) All joints or splices shall be made at least 30 meters away
from the structures. No joints or splices shall be made in
spans crossing over main roads, railways, small rivers etc.
Not more than one joint per sub-conductor shall be allowed
in one span. The compression type fittings used shall be of
self-centering type. Care shall be taken to mark the

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 conductors to indicate when the fitting is centered properly.
During compression or splicing operation the conductor shall
be handled in such a manner so as to prevent lateral or
vertical bearing against the dies. After pressing the joints,
the aluminium sleeve shall have all corners rounded, burrs
and sharp edges removed and smoothened.
iii) To avoid damage to the joint during sagging operation, the
contractor shall use a suitable protector with mid-span
compression joints in case the joints have to be passed over
pulley blocks/aerial rollers. The size of the sleeve of the
pulley shall be such that the joint with protector can be
passed over it smoothly.
6.6 Sagging-in-operation:
i) The conductors shall be pulled up to the desired sags and
left in running blocks for at least one hour after which the
sag shall be rechecked and adjusted, if necessary, before
transferring the conductors from the running blocks to the
suspension clamps. The conductors shall be clamped within
36 hours of sagging in.
ii) The sag shall be checked in the first and the last span of the
section in case of sections up to eight spans and in one
intermediate span also for sections with more than eight
spans. The sag shall also be checked when the conductors
have been drawn up and transferred from running blocks to
the insulator clamps.
iii) The running blocks, when suspended from the transmission
structure for sagging shall be so adjusted that the

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 conductors on running blocks will be at the same height as
the suspension clamp to which it is to be secured.
iv) At sharp vertical angles, the sags and tensions shall be
checked on both sides of the angle, for equality of tension.
All suspension insulator assemblies shall normally assume a
vertical position when the conductor is clamped.
6.7 Tensioning and sagging of conductors:
The tension insulator sets, complete with clamped conductors,
shall be hoisted at the ends remote from the tensioning points.
The running blocks at the tensioning end shall be fitted on the
cross-arms with tension end with sacking wrapped under the
slings.
The mid-span tension joints shall be placed to ensure the
following:
a) No joints shall be placed within 15 mtr of the conductor
support.
b) There shall be no joints in important crossing spans, except
where the spans are longer than the standard conductor length
on the drums: and
c) There shall be not more than one joint per conductor in a span.
The tensioning and sagging shall be done in accordance with the
approved stringing charts prepared form the data and relevant
specifications of the line. Initial stringing chart for conductor and
‘final’ – string charts for earth wire shall be employed for the
purpose. Both sags and tension may checked if considered
necessary, but checking on sag only shall also be considered
sufficient. The sag shall preferably be checked in a span lying
approximately in the middle of the relevant section, such span

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 being as near the length of the ruling span for the section as
practicable. Dynamometers shall be employed for measuring
tension in the conductor and earth wire. The Dynamometers
employed shall be periodically calibrated with standard
dynamometer.
Tensioning and sagging operations shall be carried out in calm
weather when rapid changes in temperature are not likely to
occur.

6.8 Clipping-in:
Clamping the conductors in positioning, armouring at supports
placing of the dampers and spacers, etc. shall be done in
accordance with the recommendations of the manufacturer or field
personnel or both.

The jumper at the section and angle towers shall be formed to parabolic
shape to ensure minimum clearance requirements. Pilot suspension
insulator strings shall be used where necessary to restrict jumper swing.
Fasteners on all fittings and accessories shall be secured in position, the
security clip also properly opened and sprung in to position.

7.0 Fixing of conductor and earthwire accessories:

All conductor and earth wire accessories shall be installed by the

contractor as per the design requirements and respective
manufacturer instructions within 24 Hours of the
conductor/earthwire clamping. While installing the conductor and
earthwire accessories proper care shall be taken to ensure that the

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 surfaces are clean and smooth and no damage shall occur at any
part of the accessories.
8.0 Safety Precautions:
8.1 All conductors shall be temporarily earthed in an effective manner
at every section point. Such temporary earth shall be removed
after stringing of the entire line is over and before testing and
commissioning of the line.
8.2 The jumps provided for the conductors at the anchor towers shall
be of adequate length to satisfy the live metal clearances as
indicated in the drawings enclosed.
8.3 Final checking, testing and commissioning: After completion of
works, final checking of the line shall be done by the contractor to
ensure that all the foundation works, tower erection, and stringing
are done strictly in accordance with the intent of the
specifications. All the works shall be thoroughly inspected keeping
in view, the following main points:
a) Sufficient back-filled earth laying over each foundation pit is
adequately compacted.
b) Concrete chimneys and their coping are in good pointed
conditions.
c) All tower members are correctly used, strictly in accordance
with the approved drawing and are free of any defects or
damage whatsoever.
d) All bolts are properly tightened and punched.
e) The stringing of the conductors and earthwire has been done
as per the approved sag and tension charts and desired
clearances are clearly available.
f) All conductor and earth wire accessories are properly installed.

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 g) All other requirements to complete the work like fixing of
danger plates; phase plates, number plates, ant climbing
devices, aviation signals (wherever required) etc are properly
installed.
h) The line insulation is tested by the contractor by providing his
own equipment, personnel, etc to the satisfaction of the
Engineer.
i) The line is tested satisfactorily for commissioning purpose
following clearance given by the electrical inspectorate and
KPTCL in this behalf.
9.0 Final Checking, Testing and Commissioning:
After completion of works, final checking of the line shall be done
by the contractor to ensure that all the foundation works, tower
erection and stringing are done strictly in accordance with the
intent of the specifications. All the works shall be thoroughly
inspected keeping in view, the following main points:
a) Sufficient back-filled earth laying over each foundation pit is
adequately compacted.
b) Concrete chimneys and their coping are in good pointed
conditions.
c) All tower members are correctly used, strictly in accordance
with the approved drawing and are free of any defects or
damage whatsoever.
d) All bolts are properly tightened and punched.
e) The stringing of the conductors and earthwire has been done
as per the approved sag and tension charts and desired
clearances are clearly available.
f) All conductor and earthwire accessories are properly installed.

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 g) All other requirements to complete the work like fixing of
danger plates, phase plates, number plates, anti-climbing
devices, aviation signals (wherever required) etc., are properly
installed.
h) The line insulation is tested by the Contractor by providing his
own equipment, personnel, etc., to the satisfaction of the
Engineer.
i) The line is tested satisfactorily for the commissioning purpose
following clearance given by the electrical inspectorate and
KPTCL in this behalf.

*****

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