RESEARCH DESIGNS & STANDARDS ORGANISATION

(Traction Installation Directorate)

REASONED DOCUMENT FOR REVISION OF SPECIFICATION
NO.TI/SPC/OHE/INSCOM/1070 for 25 KV SILICONE RUBBER
COMPOSITE INSULATORS

Sub:-Revision of Specification No.TI/SPC/OHE/INSCOM/1070(01/07).

Ref:-Comments received from manufacturers & meeting held with
them on 09.01.2013 on the subject.

1. RDSO have amended the existing Specification No.

TI/SPC/OHE/INSCOM/1070(01/07) and draft specification had been
uploaded on RDSO website for one month on 28.09.2012.

2. RDSO (TI) has received comments/suggestions from manufacturers and

meeting held with them on 09.01.2013. Based on the
comment/suggestion a draft specification has been prepared and draft
copy of specification and remarks given by this directorate is being
uploaded on website for fifteen days.

S.No. Contents/Clause Comments/Suggestions of firms RDSO decision

no. of RDSO
Specification
2 Clause 1.2 (iii) M/s SGEL- IEC no & Title may be Corrected in line with new
‘IEC TS 60815- corrected. IEC standard.
2008’
3 Clause 1.2 (xii) M/s Lamco- Check once again type DIE “C” for tear strength
‘ASTM D620 Type ‘B’ or ‘C’. test finally accepted.
C’ Meeting- DIE ‘C’ finalised.
4 Clause 2.2 (Note) M/s SGEL- As per latest IEC five As per IEC five level & as
level of pollution defines. per IS four level therefore
latest ‘IEC has been
accepted.
5 Clause 3.1.2, SGEL-To be specified as 30% Silicone polymer content
“Silicone content minimum (like PGCIL) to achieve by weight specified 30%
between 40-50 % specific gravity 1.52-1.58, electrical minimum finally accepted.
by weight”. parameter and tracking properties.
M/s Deccan-To be specified as 40%
minimum.
M/s Stork- Not mandatory for
vendor procuring standard
compound from reputed
manufacturers. Also, test
methodology is not known.
M/s ABI- To be specified as 30%
min. as the concept of higher %
silicone has better performance not
fact. As main aim to achieve all

1
 parameter i.e. tensile, tear,
hardness density etc required to
achieve for better performance. Also
stated to constitute a committee
consisting CPRI and other expert to
discuss and frame the specification.
Meeting-Maximum firms suggested
that silicone polymer content by
weight should be specified as 30%
minimum.
6 Clause No. 3.1.3 M/s SGEL- Same comment as No need to change as the
mentioned against clause 3.1.2. said clause 3.1.3 stated
M/s Stork- Clause not relevant to the general quality of
manufacturing process. silicone rubber.
7 Clause No. 3.2 M/s Lamco- Minimum FRP dia. to be FRP rod has specified as
specified in line with strength 32mm minimum for Stay
required by Railways as shed edge arm, Bracket, 9-Tonne &
specified in clause 3.1.3. Operating rod Insulator.
M/s Asiatic- Diameter of FRP rod In case of Post &
must be specified because there are Sectioning Insulator the
many firms who can cut corners by FRP diameter has been
reducing its diameter without specified as 55mm
realizing that it is heart of insulator minimum to minimise
& provide requisite mech. Strength. bend/sag/deflection
Meeting- The minimum diameter for during application.
Stay arm, Bracket & 9-Tonne
insulator to be specified as 32mm
minimum as one RDSO approved
vendor (M/s YPIL) has FRP rod dia.
32 mm.
8 Clause 3.3.1 M/s Stork- Why is make of fitting To maintain the quality
“Approval of the relevant. If fitting manufacturer and as decided in the
type test of the shuts shop, why insulator vender meeting no change is
insulator implies suffer with re-testing cost. required from draft
employment of M/s Deccan- No standard specified specification except new
metal fitting of make of material, only specified clause have been
the particular properties of material. mentioned for mechanical
make, material & M/s Lamco- RDSO may specify the test.
design used name of vendors for metal cap &
during type test Silicone rubber.
and the same Meeting- Firms suggested that
shall be RDSO should specify the` vendor.
approved” After deliberation it was finalised
that in case metal fitting vendor
changed than Mechanical load tests
as per specification shall be
repeated.
9 Clause 3.4.1 M/s Stork-Why injection moulding The injection moulding
“Injection only. Why not by compress, process is best process for
moulding transferring moulding. manufacturing of
process” composite insulators.

2
10 Clause 3.4.1 M/s Deccan- should be replaced Corrected as “any other
“Rheological Oscillating rheometry in place of suitable method”.
methods, such as capillary reheometry.
capillary M/s Stork- Why not other method to
rheometer” be used. This need not be specified
by exceptional.
M/s Prithvi- Not required as the
material using by standard supplier
which have provide details.
11 Clause 3.4.2 M/s PRITHVI-Manufacturing of FRP Few insulators vendors
rod is not in the scope of the manufacturing the FRP
specification. The material rod in-house therefore
specification is the scope. manufacturing of FRP rod
process is essentially
required.
12 Clause 3.4.3 M/s GIL- All firms does not have To minimise the on line
“coloured coloured bonding agent. puncture (flash-under)
bonding agent failure of insulator
shall be used for M/s SGEL-this to be discussed & coloured bonding agent
manufacturing studies alongwith the supplier for shall be used for
the insulator” feasibility without affecting the manufacturing of
bonding characteristic. insulators.
M/s Stork-Why do we need to use
coloured bonding agent? World
leading bonding agent is colourless.
Most colourless bonding agent can
seen under UV light.
Meeting- No other method to
identify the poor bonding between
FRP & polymer housing have been
suggested by firms. Finally, it is
decided to use colour bonding
agent.
13 Clause 3.4.4 M/s Deccan-Not feasible to remove Suggestion accepted and
“Galvanization up to the portion on which sheath corrected suitably.
shall have to be extended. There is no problem of
removed on the bonding over galvanization hence
metal fitting, up may be deleted.
to the portion on M/s Stork-the removal of
which sheath is galvanization could eventually lead
extended”. to rust on the fitting which will lead
to bond failure.
M/s Prithvi- Not possible to remove
up to the portion on which sheath
extended. Bonding should be
ensuring on overlap portion.
Meeting- Firms suggested that it is
not possible to remove up to the
portion on which sheath extended.

3
14 Clause 3.4.5 M/s Deccan- Point may be deleted It is essential requirement
“manufacturer as detailed work instructions are for quality control
shall furnish to confidential and proprietary therefore all work
RDSO, the information hence cannot be shared instructions except
detailed work with others. moulding shall be
instructions of all submitted to RDSO. The
the processes Meeting- Firms suggested that point clause is corrected
like crimping, may be deleted as work instructions suitably.
bonding, are confidential and proprietary
moulding, information. Finally, it was decided
cleaning, that all work instructions except
finishing, testing moulding to be submitted. For
and packing & moulding instruction the instruction
storage related number & its revision No. shall be
to manufacturing mentioned in QAP.
of composite
insulators along
with the QAP at
the time of
design approval
15 Clause 4.1 “Type M/s Stork-The tests mentioned The both type of tests has
tests” under clause are not type tests been listed in one table
these are Design tests. There is namely as type tests.
large fundamental difference
between two.
15 Clause 4.1.2 M/s Deccan-Point may be deleted as As per quality point of view
“manufacturer details are confidential and this may not be deleted.
shall furnish all proprietary information. The raw material prototype
the data sheet of tests shall be carried out
Rubber material” on the particular grade &
material offered by firm.
16 Clause 4.1.3 M/s Deccan- Make of rubber Rubber is very important
compound may be deleted as firms part of composite insulator
may use multiple grade, type & and maximum tests
composition and it is not possible to mentioned in specification
carried out multiple type tests. is related to rubber
Further, no international standard therefore as decided a
specify the same. code No. name shall be
Meeting- It was decided that there mentioned in approval
are no need of change if any change letter.
required code no. shall be
mentioned in approval letter for
particular manufacturers & grade.
17 Clause 4.1.4 M/s Lamco-Approval may be It is an ISO policy of
accorded for 5 years. RDSO, as per latest policy
of RDSO already
mentioned.
18 Clause 4.1.5 M/s Lamco-Sample size may be 01 Not accepted as minimum
(3.2) “03 Nos.” in place of 03. 03 sample is required.

4
19 Clause 4.1.5 M/s Lamco-To be deleted as in 3.3, Not accepted as this is
(4.0) 4.0 & 5.1 already tensile test is different tests.
conducted.
20 Clause 4.1.5 M/s GIL- This may be common for Partially accepted, in case
(7.0) Stay arm & Bracket insulators as of initial approval (1st
load & profile is same i.e 7000 kgf. approval) or change in
design the test shall be
conducted on every item
however status (pt-I/Pt-II)
shall be remains same. In
case of renewal of
approval without change of
design, the test shall be
conducted /repeated on 9-
tonne insulator if profile is
same of other items and
based on 9-Tonne
insulators results approval
of other (Stay arm &
Bracket) item shall be
accorded.
21 Clause 4.1.5 M/s SGEL-This test may be specified - Limiting Oxygen Index
(8.1.9) “Limiting as flammability test. limit is already specified, in
Oxygen Index This test conducted at outside Lab place of flammability test.
test” hence necessary time slot is to be -Time slot is no problem
provided for test mentioned in at sn. from RDSO side.
8.1.9, 8.1.10 & 8.2.5.
22 Clause 4.1.5 M/s Lamco- This may be conducted Accepted, if there is no
(8.1.8) “Brittle on 9-Tonne only. change in diameter of
Fracture other item.
resistance test”
23 Clause 4.1.5 M/s Lamco- Maximum flashover test Not accepted, however if
(11.0 & 12.0) may be deleted. there are no change in
design these tests may be
repeated with a time gap
of every 5/6 years.
24 Clause 4.1.5 M/s Deccan- This test is usually Traction insulators is
(13) “Power arc carried out on 400kV and above usually subjected to power
Test” class insulators hence may be arc during its application
deleted. therefore essentially to be
M/s Asiatic-no standard vide which carried out. Tests
this test is to be carried out is procedure and acceptance
mentioned. We check whether CPRI criteria has been given in
perform this test or not. clause No. A-12 of
M/s Lamco- To be deleted as it may specification and test may
not prove any evaluation of RDSO be carried out in
specification. CPRI/ERDA. Test shall be
M/s ABI-Firm completed this test conducted only on traction
for 220 & 400kV insulator as IEC- insulators sealed during
61467-1997 with arc current type tests and no other
10KAfor .3 sec. please accept our tests report shall be
test report. accepted.

5
 M/s YPIL- Test mentioned at S.
No.13, 14 & 15 of specification, such
conducting costly not for small
organization not be feasible. The
company using standard compound
should not be required. The firm
who are using in-house compound
should conduct this test.
Meeting-Few firms said that they
had conducted this test for other
utility and same report may be
accepted. Also, there is only one lab
(CPRI) for conducting Power arc
test. It was finalized that this test
shall be carried out on traction
insulators offered for type tests and
name of other lab shall be added.
25 Clause 4.1.5 M/s GIL- This test should be done in Test shall be conducted
(14) sheet not on insulators of particular only on the sample sealed
“Accelerated design. We have done this test for during type tests by RDSO
weathering test” PGCL, kindly accept the same. and no other tests report
shall be accepted.
26 Clause 4.1.5 M/s GIL- This test is carried out for 5000 hours Tracking &
(15) “Tracking & rubber material not for insulators of erosion test (as per
erosion test” particular design. We have done this Annexure-B of IEC62217)
test for PGCL, kindly accept the have been deleted. As per
same. latest IEC 62217 2012-09
M/s ABI- This is material test and we edition ‘2’ the 1,000 hours
have conducted for other party, salt fog tracking & erosion
kindly accept our report and wave test is given, as screening
for us. this is expensive test of Rs.25 test intended to reject
Lac material or designs.
M/s SGEL- May elaborated as multi
stress test as per IEC The tracking & erosion
M/s Prithvi- To be removed as test- 1,000 hours salt fog
facility not available in India. test shall be conducted as
Accelerated weathering test is in per clause no. 9.3.3 of IEC
place the material weathering 62217.
properties can be evaluated.
M/s Asiatic- 5000hr. test has over
specified 1000hr. test as per IEC is
more than adequate for kind of
environment. This test 5000hr. is
applicable for very heavy pollution
and time required for tests is going
to be almost one year.
M/s CPRI-This test(i.e. multi stress
test) is being withdrawn from
standards.
Meeting- Latest IEC 62217-2012 for
tracking & erosion test shall be
followed.

6
27 Clause 4.1.5 M/s Deccan-As overall design is In case of same design,
[Note (ii)] “3 same hence nos. of sample may be only one type of insulators
samples”. changed to one sample. has specified but minimum
Meeting- As discussed, these test 3 samples is required.
may be repeated with a time gap of However, if there is no
every 5/6 years. change in design these
tests may be repeated
with a time gap of every
5/6 years.
28 Clause 4.1.5 M/s Deccan- Time gap may be Already allowed to 5/6
[Note (iv)]. changed to 10 years. years instead of 2/3 years.
M/s SGEL- for 1050mm & 1600mm The clause corrected
CD, this test to be conducted on any suitably. In case of 1050
one type out of both. This is to be mm & 1600 mm test shall
clarified. In addition power arc is not be conducted on both type
mandatory test as per page 6 para 3 of insulators.
of IEC 61109.
29 Clause 4.2.1 M/s Deccan- This may be changed Firm may check quality at
“case any as “in case any sample fails in type their end before offering
insulators / test test, 3 times the test should be the product for type tests.
specimen sample successfully carried out.
fails in the type
test, fresh batch
of insulators
shall be offered
for all type
tests”.
30 Clause 4.2.2 “At M/s Deccan- This may be changed It is an essential
the time of type as “RDSO shall verify. requirement for quality
tests, the firm Meeting- As discussed, it is essential control and based on the
shall have to requirement for quality control. same approval shall be
furnish test accorded by RDSO.
certificates (as
received from
the OEM’s) for all
raw materials”.

31 Clause 4.2.5 M/s Deccan- This may be changed to Not accepted as it’s an ISO
“renewal of 5 years. policy of RDSO.
prototype
approval shall be M/s YPIL-This may be changed as 5
accorded for a years.
period of three
years only or as
per RDSO
policy”.

32 Clause 4.2.10 M/s Deccan- This may be changed It is an essential

as “document shall be verified by requirement for quality
RDSO at the time of control.
type/acceptance tests”.

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33 Clause 4.4.1 M/s Stork-Acceptance tests shall be
performed by manufacturer/Third
party prior to dispatch.
33 Clause 4.4.3, M/s YPIL-There should be
(Table-3, sample provision of clubbing 2 or 3 orders
size) during one inspection of acceptance
testes.
34 Table-3, list of M/s Lamco-Bending & Mechanical
acceptance performance tests may be deleted
tests) from the list of acceptance tests as
already tested in type test.
M/s Stork- Bending & Mechanical
performance tests are destructive
tests must not form a part of
acceptance tests.
35 Table-3, list of M/s Asiatic-The new test (tear
acceptance tests strength, % of silicone,
penetration, % of glass, hardness &
specific gravity) are not practical in
view of long time required. Fore e.g.
% of silicone can carry out only in
external Lab. How inspector can wait
to see the test results.
M/s Deccan- Qty may be changed to
50,000 nos. or 6 months whichever
is earlier as testing for every 1000
nos. very expensive and time
consuming.
M/s SGEL-Till the results are
received the lot could not be held
without being dispatched. Hence,
deleted or modified suitably without
affecting dispatch.
M/s YPIL- To be conducted in type
tests only.
M/s Prithvi- 9.3, 9.4, 10.3 & 10.4
not possible in acceptance.
Stork- tests mentioned at S. No.
9.1, 9.2, 9.3, 10.1, 10.2, 10.3 &
10.4 can not be performed as per
the standard specified as each
standard has certain specimen
requirement.
8
Not accepted as the
acceptance test shall be
conducted in the presence
of Authorised inspector.
a The orders of PO quantity
up to 200 nos. may be
clubbed.
Not accepted as these
tests is essential to check
the mechanical
performance of supplied
lot of insulators.
As discussed during the
Die meeting the following have
been corrected.
i) Tear strength &
Hardness test has been
removed for conducted
the test on housing
material.
ii) The elongation & tensile
strength test on test
slab has also been
added.
iii) Percentage of
silicone polymer content
by weight test modified
suitable as “the IC may
be issued by Inspecting
authority based on other
satisfactory test results
and manufacturers shall
submit the test results
to inspector within one
month. In case sample
fail the lot shall be
rejected and every
insulator of the lot shall
be destroyed in
presence of inspector at
consignee place.
36 Clause 4.4.5 (a) M/s Deccan-Limit Changed as ±5. Limit removed as the said
ABI- These tests done as per test can not be conducted
standard specimen only. The on insulator sample.
preparation of sample from insulator However, the test results
is not possible. Hence test to be should meet the
conducted on test specimens in type requirement as specified in
test only. the specification.
M/s SGEL-Test sample from
insulator not possible hence limited
to specific gravity for compare. The
tolerance given is to narrow.
M/s Stork-We have checked and
results do not fall within the
tolerances specified.
37 Clause 4.4.5 (b) M/s GIL-Shape of specimen from Limit removed but test
insulator is not possible. results should meet the
M/s Deccan- changed as minimum requirement as specified in
11. the specification.
M/s Prithvi- Not possible on insulator
shed.
M/s ABI- Test done as per standard
specimen only. The preparation of
sample from insulator is not
possible. Hence test to be conducted
on test specimens in type test only.
M/s SGEL-Test sample from
insulator not possible hence limited
to specific gravity for compare. The
tolerance given is too narrow.
M/s Stork-We have checked and
results do not fall within the
tolerances specified.
38 Clause 4.4.5 (c) M/s Deccan-Changed as ±0.04. Limit changed as ±0.04.
M/s ABI- These tests done as per
standard specimen only. The
preparation of sample from insulator
is not possible. Hence test to be
conducted on test specimens in type
test only.
M/s SGEL-Test sample from
insulator is not possible hence
limited to specific gravity for
compare. The tolerance given is to
narrow.
M/s Stork-We have checked and
results do not fall within the
tolerances specified.

9
39 Clause 4.4.6 (d) M/s Deccan-TGA may be changed as
EDXRF as it is more accurate and
reliable.
Meeting- EDXRF test is for % of
silicon instead of Silicone.
40 Clause 4.4.8 M/s Prithvi- Marking by paint not
adherent.
41 Clause 6.1 M/s Asiatic- The drawings attached
with specification are not legible.
M/s Prithvi- Essential dimensions
should not be the shed dia or profile
parameters.
42 Clause 7.0 M/s Asiatic-RDSO increase the
marking font size 10 mm. earlier the
size 5 mm is more than adequate.
Any increase in font size may
increase the chances of water
droplets getting collected and
performance may be affected.
M/s Deccan- Marking on end fitting
may be included in this point.
-The option of Pad printing/laser
marking must not be ruled out.
43 Clause 8.1 M/s Deccan-cardboard box thickness
75 mm may be changed to 50 mm.
44 Clause 8.2 M/s Deccan- local language may be
deleted as it is impractical to provide
instructions in multiple languages.
M/s Stork-Local language may be
difficult. Hindi & English should be
enough.
10
Not accepted as EDXRF
test determine the % of
silicon instead of Silicone.
Marking shall be in
moulding itself which is
adherent.
In addition, marking of
batch no. by punching on
metal fitting has been
specified.
Legible drawings attached
and profile parameters
have not been specified as
essential dimensions.
At present also on shed 10
mm and 4/5 mm on
sheath any one.
In addition, marking of
batch no. by punching on
metal fitting to be done.
To avoid the damage of
insulator no need of
change.
Accepted.
45 Clause 11.0, M/s Lamco- Condition of clause may Not accepted as it is
“After sales be limited to some minimum period essentially required for
service” and financial implementation may be satisfactory performance in
decided for considering the cost of service.
product.
M/s Stork- After sales point is more
relevant to contract than
specification.
46 Clause A-7.1 M/s GIL- “If length is less than 800 Corrected.
mm the test should be performed on
the full insulator” to be added.
M/s Prithvi- 800 mm may corrected
as insulator in not more than 600
mm.
47 Clause A-8.1 (b) M/s SGEL- Standard left blank. Standard mentioned.

48 Clause A-8.1 (e) M/s Deccan-Tear strength to be Accepted as 12 KN/m min

specified as 11KN/m in place of 13 by DIE-C.
KN/m.
Meeting-decided as 12 KN/m min by
DIE-C.
49 Clause A-8.1 (g) M/s SGEL-In clause No. A-13 IEC Not accepted as both are
has specified in place of ASTM. different test. The clause
No. A-13 is for
accelerating weathering
test.
50 Clause A-8.1 (i) M/s Deccan- Currently supplier are Not accepted for
supplying the material of specific consistency purpose.
gravity 1.9 to 2.3 hence to be
changed.

51 Clause A-12 M/s Deccan- Power arc test to be Traction insulators is

deleted. usually subjected to power
The comment of other firms arc during its application
mentioned under SN-24 above. therefore essentially to be
carried out. Tests may be
carried out in CPRI/ERDA.
Test shall be conducted
only on traction insulators
sealed/signed during type
tests and no other tests
report shall be accepted.
52 Clause A-13 M/s GIL- Accelerated weathering The test shall be
test should be done in sheet not on conducted as per IEC
insulators of particular design. We 62217 on the sample
have done this test for PGCL, kindly sealed & signed by RDSO
accept the same. representative during
M/s Stork- Accelerated weathering prototype only the report
test is dropping from the upcoming of other insulators sample
IEC therefore this should not be shall not be accepted.
added.

11
53 Clause A-14 M/s GIL-The firm conducted 5000
hour salt fog pollution test in 2008
for RDSO. As per IEC 62217 tests
can be performed by three method.
GIL conducted 5000 test 1st in 2006
at CESI & 2nd in 2011 at KEMA and
accepted by PGCL & GETCO. Kindly
waiver multi stress 5000 test till
2016.
M/s Prithvi- Clause to be deleted.
The comment of other firms on the
same test have been mentioned at
SN-26 above,
M/s Stork- 5000 hr. test is dropping
from the upcoming IEC therefore
this should not be added.
Meeting- Latest IEC shall be
followed.
54 Clause A-16 M/s SGEL- CPRI have not TGA
“determination of facility IRMRA have these facility
% of silicone hence before finalisation of
content” specification NABL approved Govt.
Lab. to be corrected.
M/s Asiatic- The method for % of
silicone has specified as TGA
method. We feel that external lab
should be given liberty in following
any scientific method to determine
as per prevalent practice.
M/s Deccan- determination method
may be changed to EDXRF.
M/s ABI- The value of silicone
polymer content may be specified as
30 % minimum.
12
5000 hours Tracking &
erosion test (as per
Annexure-B of IEC 62217)
have been deleted. As per
latest IEC 62217, 2012-09
edition ‘2’ the 1,000 hours
salt fog tracking & erosion
test is specified to
considered as screening
test intended to reject
material or designs.
The tracking & erosion
test- 1,000 hours salt fog
test shall be conducted as
per clause no. 9.3.3 of IEC
62217 or latest.
Other government Lab has
this test facility i.e. CIPET
etc.
TGA or any other suitable
method already specified
by RDSO for determination
of % of Silicone polymer
content by weight.
EDXRF is determining % of
silicon instead of Silicone.