S14 - Insulators 01 07 2021 Draft Final

TANZANIA ELECTRIC SUPPLY COMPANY LIMITED
“We light up your life”
SPECIFICATION S14
INSULATORS
JUNE 2021
TANZANIA ELECTRIC SUPPLY COMPANY LIMITED

TANESCO Head Quarter Jamatin Road – Dodoma
P.O Box 453, Dodoma, Tanzania
Telephone: +255-26-2323456/7
Email Info: info@tanesco.co.tz

Website: http://www.tanesco.co.tz
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Specification S14 – Insulator
This specification has been reviewed by:
S/No. Name Section/Zone Signature

1 Eng. Mary D. Kabakuzi Operations – Chairperson
2 Eng. Selemani K. Mgwira North Zone – Member
3 Eng. Himson Exaud DCC – Member
4 Eng. Ebenezer Fue ETDCO – Member
5 Eng. Khadija Abdallahmed South Zone – Member
6 Mr. Maximilian Lyapembile Transport – Member
7 Eng. Emmanuel Mrema TCPM – Member
8 Eng. Obay R. Sigala Operations – Secretary
Checked by:
S/No. Name Title Signature

1 Eng. Gwamaka Eliah Manager Operations
Approved by:
S/No. Name Title Signature

1 Eng. Athanasius H. Nangali Senior Manager Distribution
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Table of Contents
1 SCOPE ...................................................................................................................................................1
2 APPLICABLE STANDARDS .................................................................................................................1
3 SERVICE CONDITIONS ........................................................................................................................3
4 SYSTEM CHARACTERISTICS .............................................................................................................3
5 TECHNICAL SPECIFICATIONS ...........................................................................................................3
5.1 PIN INSULATORS ..........................................................................................................................4
5.2 STRAIN INSULATORS ...................................................................................................................6
5.3 LINE POST INSULATORS - HORIZONTAL STYLE .......................................................................9
5.4 LINE POST INSULATORS - VERTICAL STYLE .......................................................................... 12
5.5 SHACKLE INSULATORS AND BOBBIN INSULATORS.............................................................. 15
5.6 STAY INSULATORS .................................................................................................................... 16
6 QUALITY ASSURANCE ..................................................................................................................... 19
7 INSPECTION AND TESTING ............................................................................................................. 19
7.1 INSPECTION ................................................................................................................................... 19
7.2 TESTING ........................................................................................................................................ 19
7.3 TEST CERTIFICATES ................................................................................................................. 24
8 MARKING ........................................................................................................................................... 25
9 SPARE PARTS ................................................................................................................................... 25
10 WARRANTY ....................................................................................................................................... 25
11 PACKING AND SHIPPING ................................................................................................................. 26
11.1 PACKING ..................................................................................................................................... 26
11.2 SHIPPING .................................................................................................................................... 27
11.3 HAZARDOUS SUBSTANCES .............................................................................................................. 27
12 SUBMITTALS ..................................................................................................................................... 28
12.1 SUBMITTALS REQUIRED WITH THE BID.............................................................................................. 28
12.2 SUBMITTALS REQUIRED AFTER CONTRACT AWARD AND DURING DELIVERY ...................................... 28
13 SCHEDULES ...................................................................................................................................... 30
13.1 TECHNICAL DATA SCHEDULE: 11KV PIN INSULATORS....................................................................... 30
13.2 TECHNICAL DATA SCHEDULE: 33KV PIN INSULATORS....................................................................... 31
13.3 TECHNICAL DATA SCHEDULE: PORCELAIN STRAIN INSULATORS ........................................................ 32
13.4 TECHNICAL DATA SCHEDULE: POLYMERIC STRAIN INSULATORS........................................................ 34
13.5 TECHNICAL DATA SCHEDULE: 11KV LINE POST INSULATORS HORIZONTAL STYLE ............................. 35
13.6 TECHNICAL DATA SCHEDULE: 33KV LINE POST INSULATORS HORIZONTAL STYLE ............................. 36
13.7 TECHNICAL DATA SCHEDULE: 11KV PILOT POST INSULATORS VERTICAL STYLE ................................ 37
13.8 TECHNICAL DATA SCHEDULE: 33KV PILOT POST INSULATORS VERTICAL STYLE ................................ 38
13.9 TECHNICAL DATA SCHEDULE: SHACKLE INSULATORS ....................................................................... 39
13.10 TECHNICAL DATA SCHEDULE: BOBBIN INSULATORS ...................................................................... 40
13.11 TECHNICAL DATA SCHEDULE: STAY INSULATORS ......................................................................... 41
13.12 NON COMPLIANCE SCHEDULE ..................................................................................................... 42
13.13 TEST CERTIFICATES SCHEDULE .................................................................................................. 43
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Specification S14 – Insulators
List of Figures
Figure 1: 11kV and 33kV Pin Porcelain Insulator.....................................................................................6

Figure 2: Polymeric Strain Insulator...........................................................................................................8
Figure 3: Porcelain Strain Insulators .........................................................................................................8
Figure 4: 11kV & 33kV Line Post Insulators – Horizontal Style ....................................................... 11
Figure 5: Horizontal Base Mounting Bracket for 11kV & 33kV Insulators ...................................... 11
Figure 6: The horizontal clamp-top cap................................................................................................ 11
Figure 7: The clamp-top clamps ............................................................................................................ 12
Figure 8: 11kV and 33 kV Line Post Insulator - Vertical Style .......................................................... 14
Figure 9: Shackle Insulator – Double Groove ..................................................................................... 16
Figure 10: Bobbin Insulator .................................................................................................................... 16
Figure 11: Stay Insulators ...................................................................................................................... 18
Figure 12: 11kV and 33kV Solid Core Insulator Stud ........................................................................ 44
List of Tables
Table 1: Pin insulator performance characteristics ...............................................................................4

Table 2: Polymeric Strain Insulator Performance Characteristics .........................................................6
Table 3: Porcelain & Glass Strain Insulator Performance Characteristics ............................................7
Table 4: Line post insulators - horizontal style characteristics ............................................................9
Table 5: Line post insulators - vertical style characteristics ................................................................. 12
Table 6: Shackle and Bobbin insulators performance characteristics ................................................ 15
Table 7: Dimensions of Shackle and Bobbin Insulators ....................................................................... 15
Table 8: Stay insulator performance characteristics .......................................................................... 17
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1 SCOPE
This specification covers the design, manufacture, testing, supply, delivery and
performance requirements of pin, disc, strain, line post, shackle, bobbin and stay
insulators use in the distribution networks of Tanzania Electric Supply Company
Limited. It lays down minimum requirements for purchasing MV and LV insulators to
be used by the Company.
It shall be the responsibility of the supplier to ensure adequate of the design, good
engineering practices, adherence to the specification and applicable standards and
regulations as well as good workmanship in the manufacture of the item. This
specification does not include all necessary provisions of the contract.
Any departure from the provisions of this specification shall be disclosed at the time
of tendering in the Non-compliance schedule.
2 APPLICABLE STANDARDS
The following standard was referred to in the preparation of this specification: -
S/N STANDARDS DESCRIPTION

1 BSI British Standards Institution:
 BS 137: Insulators of ceramic material or glass for overhead

lines with a nominal voltage greater than 1000V.
 BS 729: Specification for hot dip galvanized coatings on iron
and steel articles.
 BS 3288: Insulator and conductor fittings for overhead
power lines.
2 ESI Electricity Supply Industry
 ESI 43-91: Stay strands and stay fittings for overhead lines
3 ASTM American Society for Testing and Materials
 ASTM B857: Standard Specification for Shaped-wire

Compact Concentric-Lay-Stranded Aluminium Conductors
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4 EUC European Union Commission
 SI 77: European Communities (dangerous substances)

(classification, packaging, labeling and notification)
regulation, 1994
5 IEC International Electrotechnical Commission
 IEC 305: Characteristics of string insulator units of the cap

and pin type.
 IEC 60383: Insulators for overhead lines with a nominal
voltage above 1000V.
 IEC 437: Radio interference test on high voltage insulators.
 IEC 471: Dimensions of clevis and tongue couplings of
string insulator units.
 IEC 575: Thermal-mechanical performance test and
mechanical performance test on string insulator units.
 IEC 1109: Composite insulators for ac overhead lines with
a nominal voltage greater than 1000V - Definitions, test
methods and acceptance criteria.
 IEC 60060-1: High Voltage Techniques – Part 1: General
definition and test requirement
6 ISO International Organization for Standardization
 ISO 9000: Quality management and quality assurance

standards - Guidelines for selection and use.
 ISO 14001: Environmental management
 OHSAS 18001: Occupational Health and Safety
 ISO 1461: Hot dip galvanized coatings on fabricated iron and
steel
7 Normative  S01: General technical requirements of MV and LV Networks.
References  S 11: Wooden Poles and Blocks
 S12: Stay wire accessories
 S13: Crossarms and associated steelwork
 S15: Line fittings
 S16: Bare and PVC covered conductors
 S17: Aerial Bundled Conductors
 S71B: Concrete Poles
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3 SERVICE CONDITIONS
The service conditions shall be as follows:
i. Altitude (above sea level) 1,600m
ii. Maximum outdoor temperature 40°C
iii. Minimum outdoor temperature -1°C
iv. Maximum monthly mean temperature 35°C
v. Annual mean temperature 25°C
vi. Maximum relative humidity up to 96%
vii. Type of atmosphere coastal
viii. Pollution Design pollution level to be taken as
“Heavy” (pollution level III) according to
IEC 60815
4 SYSTEM CHARACTERISTICS
The Hydraulic Digger Derrick shall be suitable for use in MV and LV Distribution
networks with the following characteristics:
SNo Description 33kV 11kV LV
i. Nominal System Voltages: kV 33 11 0.4/0.23
ii. Maximum system voltages: kV 36 12 0.44/0.253
iii. System Fault level: kA 25 25 7.5
iv. Insulation Level 1.2/50ms lightning impulse 170 75 12
withstand voltage: kV
Insulation Level 1.2/50ms lightning impulse 250 110 45
withstand voltage for Steep Wave: kV
v. Power Frequency (one minute withstand, wet): kV 70 28 3
Power Frequency (one minute withstand, wet) for 70 28 10

Steep Wave: kV
vi. Creepage distance 30mm/kV of maximum
system voltage
vii. Neutral earthing arrangements Effectively earthed
5 TECHNICAL SPECIFICATIONS
This specification covers the design, manufacture, testing, supply, delivery and
performance requirements of the pin insulators, strain/disc insulators, line post
insulators, shackle insulators, bobbin insulators and stay insulators required by the
33kV, 11kV and LV lines in Tanzania Electric Supply Company Limited (TANESCO).
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The type of insulators described in this specification are intended to maintain the
general look of the existing networks and to take advantage of the familiarity of the
TANESCO's staff with these type of units.
Wherever polymeric insulators are offered, the bidder shall clearly state the housing
material and percentage composition of each material used.
5.1 PIN INSULATORS

5.1.1 Performance Characteristics
The following performance levels shall be met:
Table 1: Pin insulator performance characteristics
Minimum Performance Characteristics 11kV 33kV

Dry Impulse Withstand Voltage (1.2/50µs) 95kV 200kV
Wet 50Hz Withstand Voltage 47kV 70kV
50Hz Puncture Voltage 105kV 250kV
Dry Critical Impulse Flashover

(Positive and Negative Wave) 100kV
Dry 50Hz Critical Flashover Voltage (RMS) 74kV
Wet 50Hz Critical Flashover 53kV
Creepage Distance 360mm 1,080mm
Protected Leakage Distance 530mm
Mechanical Failing Load 10kN* 10kN*
Radio Interference: 50Hz applied voltage 7.5kV 22kV
Radio Interference Noise Limit 30dB 30dB

(above 1µV across 300 ohm at 1MHz)
5.1.2 Materials
The materials to manufacture insulators shall be polymers and silicone rubber.
However, porcelain brown glazed insulators may be used.
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5.1.3 Design and Construction

i) The insulator shall be pin type moulded in one single piece and supplied with
complete metal end fittings.
ii) Metal fittings shall be galvanized according to ISO 1461 to suit service
conditions. The insulator bottom metal ending fitting shall be suitable for
mounting on steel crossarm
iii) The design shall be such that stresses due to expansion and contraction in any
part of the insulator shall not lead to deterioration.
iv) Sheds shall be substantially symmetrical in shape without appreciable warping
v) Where porcelain is used, it shall be sound, free from defects, smoothly glazed
and brown colour.
5.1.4 Spindle Design

The insulator spindle shall comply with BS 3288 part 2, or with an equivalent
standard. The whole length of the stalk shall be threaded to facilitate using the pin
insulators both on channel and angle crossarms.
Ferrous parts, unless of stainless steel, shall be hot dip galvanized in accordance
with BS 729, with the exception of cotter pins which shall be galvanized using the
methods of BS 729, but with a coating mass of 500g/sq m. For polymeric insulators
the stud should be of stainless steel or hot dip galvanized.
5.1.5 Dimensions
The insulator shall conform to the dimensions and tolerances in accordance with the
figure 1(a) and 1(b) for 11kV and 33kV porcelain insulator respectively which shall
accompany the bid documents.
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Figure 1: 11kV and 33kV Pin Porcelain Insulator
5.2 STRAIN INSULATORS

i) The following performance levels shall be met for polymeric:
Table 2: Polymeric Strain Insulator Performance Characteristics
Performance Characteristics Minimum Level
11kV 33kV
Number of Sheds Specify Specify
Leakage distance (mm) Specify Specify
Dry arc distance (mm) 235 457
Power frequency withstand, 60Hz (Dry and Wet 150kV 250kV

respectively) 75kV 140kV
Critical flashover (Positive and Negative 140kV 320kV

respectively) 160kV 330kV
80kN 80kN
Specified Mechanical Load (SML)
44.5kN 44.5kN
Proof Test for 10 seconds
7.5kV 7.5kV
Radio interference: 50Hz applied voltage
Radio interference: noise limit 30dB 30dB

(above 1uV across 300ohm at 1MHz)
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ii) The following performance levels shall be met for porcelain & glass:
Table 3: Porcelain & Glass Strain Insulator Performance Characteristics

Performance Characteristics Minimum
Level
Dry impulse withstand voltage (1.2/50us) 85kV
Wet 50Hz withstand voltage 28kV
50Hz Puncture Voltage 80kV
Dry critical impulse flashover (positive and negative wave) 100kV
Creepage distance 360mm
Mechanical failing load (glass only) 44.49kN
Electromechanical failing load (porcelain only) 44.49kN
Mechanical routine load 22.24kN
Shattering impact load 35.59kN
Thermal mechanical performance Qs>K
Radio interference: 50Hz applied voltage 7.5kV
Radio interference: noise limit

(above 1uV across 300ohm at 1MHz) 30dB
5.2.2 Materials
The materials to manufacture insulators shall be polymers and silicone rubber.
However, porcelain brown glazed insulators may be used.

i) The design shall be such that stresses due to expansion and contraction in any
part of the insulator shall not lead to deterioration.
ii) The insulator shall be strain type moulded in one single piece and supplied with
complete metal end fittings for tensioning purpose.
iii) Metal fittings shall be galvanized according to ISO 1461 to suit service
conditions. The insulator metal ending fitting shall be suitable for intended
mounting accessories.
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iv) Sheds shall be substantially symmetrical in shape without appreciable warping

v) For polymeric strain insulators, the end fittings should be manufactured from hot
dip galvanized malleable iron. The 70kN end fittings to be ball and socket and to
meet specification of BS. 3288 (16-16B) at line end and ground end respectively.
vi) Where porcelain is used, it shall be sound, free from defects, smoothly glazed
and brown colour.
5.2.4 Corrosion Protection and Finishing

i) Ferrous parts, unless of stainless steel, shall be hot dip galvanized in accordance
with BS 729.
ii) The minimum weight of zinc deposited generally shall be 610g/sq m, which is
equivalent to a minimum average thickness of coating of 85microns (µm).
5.2.5 Dimensions
The strain insulator shall conform to the dimensions and tolerances in accordance
with Figure 2 which shall accompany the bid documents.
Figure 2: Polymeric Strain Insulator
Figure 3: Porcelain Strain Insulators
5.2.6 Associated Hardware

Hooks, conductor clamps and other associated hardware shall comply with
associated specification S15: Line fittings.
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5.3 LINE POST INSULATORS - HORIZONTAL STYLE

Table 4: Line post insulators - horizontal style characteristics

Dry Impulse Withstand Voltage (1.2/50us) 150kV 220kV
Wet 50Hz, 1minute Withstand Voltage 80kV 145kV
50Hz Puncture Voltage Puncture Puncture

proof proof
(Positive and Negative Wave) 180kV 275kV
Dry 50Hz Critical Flashover Voltage (RMS) 110kV 160kV
Wet 50Hz Critical Flashover 100kV 145kV
Protected Leakage Distance 293mm 530mm

(above 1uV across 300 ohm at 1MHz)
5.3.2 Materials
TANESCO is used to porcelain brown glazed insulators but has a strong preference
for polymeric insulators with a proven track record. However, among polymeric
insulators, Silicone rubber composite insulators are preferred compared to others.
The bidder who offers insulators manufactured from insulating materials other than
porcelain, such as polymeric materials, shall give full particulars of such materials,
including long term weathering and tensile tests, and evidence of experience under
practical conditions.
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Length of the line post insulator has to be a concern if a specific clearance must be
maintained from conductors to pole or to other conductor. Typical 11kV and 33 kV
horizontal style line post insulators are shown in figure 4(a) and figure 4(b)
respectively. The structural design of the Line post insulators - horizontal style shall
consists of three basic parts:
i) Rod:
The insulator fiberglass rod shall be produced from the highest quality materials.
Strands shall be aligned for the maximum tensile strength. The rod shall be filled
57 percent, by volume, with electrical grade glass fibers.
ii) End Fittings:
Ferrous end fittings shall be crimped directly to the fiberglass rod. The crimp shall
require no inter-movement of the parts to achieve high strength, nor shall it
introduce potting compounds or adhesives.
The Horizontal Base mounting bracket, the Horizontal Clamp-top Cap and Clamp-
top clamps shall be made of ductile steel galvanized, bronze metal or aluminium
and shall both be mounted directly on the horizontal line post insulator. A typical
horizontal base mounting bracket, the horizontal clamp-top cap and clamp-top
clamps are as shown in figures 5, 6 and 7 respectively with the associated
dimensions.
All the end fittings shall be capable of withstanding a horizontal force at the
conductor of, at least 10kN.
iii) Weather sheds

The insulators shall be manufactured with polymeric material most preferred, as
indicated above, Silicone rubber. The polymeric material shall offer a desirable
toughness and resistance to tracking, with the hydrophobic characteristics derived
from low molecular weight silicone oils. The insulator shall be suitable for washing
by all known methods in current use.
The manufacturer shall use several tests to evaluate the material such as tracking,
Ultraviolet, corona cutting, salt fog, oxidative stability and variations of differential
thermal analysis tests to assure the quality shed material.
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Figure 4: 11kV & 33kV Line Post Insulators – Horizontal Style
Figure 5: Horizontal Base Mounting Bracket for 11kV & 33kV Insulators
Figure 6: The horizontal clamp-top cap
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Figure 7: The clamp-top clamps
5.3.4 Dimensions
The Supplier/Manufacturer shall guarantee that the dimensions and tolerances of the
insulator offered are in accordance with the drawing, which shall accompany the bid
documents.
5.4 LINE POST INSULATORS - VERTICAL STYLE

Performance Characteristics
Table 5: Line post insulators - vertical style characteristics

Dry Impulse Withstand Voltage (1.2/50us) 150kV 220kV
Wet 50Hz Withstand Voltage 80kV 145kV
50Hz Puncture Voltage puncture puncture

proof proof
(Positive and Negative Wave) 180kV 275kV
Dry 50Hz Critical Flashover Voltage (RMS) 110kV 160kV
Wet 50Hz Critical Flashover 100kV 145kV
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Protected Leakage Distance 293mm 530mm

(above 1uV across 300 ohm at 1MHz)
5.4.1 Materials
TANESCO is used to porcelain brown glazed insulators but has a strong preference
for polymeric insulators with a proven track record. However, among polymeric
insulators, Silicone rubber composite insulators are preferred compared to others.
The bidder who offers insulators manufactured from insulating materials other than
porcelain, such as polymeric materials, shall give full particulars of such materials,
including long term weathering and tensile tests, and evidence of experience under
practical conditions.

Length of the line post insulator shall be a concern if specific clearances must be
maintained from conductors to crossarms or to other conductor or pole. A typical 11kV
and 33 kV Porcelain Line Post Insulators vertical style are shown in figure 8(a) and
figure 8(b) respectively. The structural design of the Line post insulators - vertical style
mainly consists of two basic parts:
i) Base Fitting:
The base fitting, stud shall be made of malleable cast iron in conformity with BS
6681 or equivalent and galvanized in conformity with BS 729. The base fittings
shall be manufactured according to BS 3288 part 1 and its performance shall be
in conformity to BS 3288 part 2. The base fittings, that is studs shall be mounted
directly on the pilot post insulator and thus supplied together. The studs shall be
139.7mm long, 22.2 mm in diameter and shall have a minimum mechanical failing
load of 10KN.
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ii) Insulator:
The insulators shall be manufactured with brown glazed porcelain or Silicone
rubber material. In case of Silicone rubber material, the bidder shall offer the
desirable toughness and resistance to tracking, with the hydrophobic
characteristics derived from low molecular weight silicone oils. Also the insulator
shall be suitable for washing by all known methods in current use.
The manufacturer shall also use several tests to evaluate the material such as
tracking, Ultraviolet, corona cutting, salt fog, oxidative stability and variations of
differential thermal analysis tests to assure the quality of insulator material.
Figure 8: 11kV and 33 kV Line Post Insulator - Vertical Style
5.4.3 Dimensions
The bidder shall guarantee that the dimensions and tolerances of the insulator offered
are in accordance with the drawing, which shall accompany the bid documents.
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5.5 SHACKLE INSULATORS AND BOBBIN INSULATORS

5.5.1 Performance characteristics
Table 6: Shackle and Bobbin insulators performance characteristics
Performance Characteristics Minimum Level
Shackle Bobbin
Insulators Insulators
Wet 50Hz Withstand Voltage 3 kV 3 kV
Safe Working Load 4.2 kN 2.8 kN
Minimum Breaking Load 13.2 kN 7.1 kN
Dry Flashover 25 kV 17 kV
Wet Flashover 12 kV 9 kV
5.5.2 Materials
Materials used for shackle and bobbin insulators shall be porcelain brown glazed. The
surface of the insulators shall be perfectly smooth and free from all defects and cracks.
5.5.3 Dimensions
The main overall required dimensions are:
Table 7: Dimensions of Shackle and Bobbin Insulators
Description Unit Shackle Bobbin

Insulators Insulators
Maximum height mm 76.0 67.0
Diameter mm 70.0 76.0
Axial hole diameter (flared at both ends) mm 21.0 21.0
The groove radius should be sufficient to accommodate wasp conductor, and the PVC
covered 100mm2 AAC conductor offered, against TANESCO specification S16: Bare
and PVC covered conductors. Figure 9 and 10 illustrates the typical Shackle and
Bobbin Insulators respectively.
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Figure 9: Shackle Insulator – Double Groove
Figure 10: Bobbin Insulator
5.6 STAY INSULATORS

The insulators shall be designed for insulation of stays to reduce risk of dangerous
potential gradients at ground level and, in case of stays on earthed structures, to
prevent electrolytic corrosion of stay rods.
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5.6.1 Materials for Stay Insulators

Materials used for manufacturing stay insulators shall be porcelain brown glazed.
The porcelain shall be free from defects and the exposed parts shall be smoothly
glazed.

Table 8: Stay insulator performance characteristics
Performance Characteristics 0.4kV 11kV 33kV

Wet 50Hz, 1 minute Withstand Voltage 8kV 20kV 48kV
Dry, 1 minute Impulse Withstand Voltage 18kV 60kV 100kV
Minimum Creepage Distance 13.2mm 360mm 1080mm
Minimum Failing Load 80kN 110kN 110kN
Figure 11 illustrates typical 0.4kV, 11kV and 33kV Stay Insulators (all dimensions
are in mm).
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Figure 11: Stay Insulators
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5.6.3 Dimensions
The bidder shall guarantee that the dimensions and tolerances of the insulators
offered are in accordance with the drawing, which shall accompany the bid
documents.
6 QUALITY ASSURANCE
The manufacturer shall possess ISO 9001 or latest Quality Assurance Certification
for the manufacture of Hydraulic Digger Derrick. Bidder shall furnish a copy of the
ISO certificate certified as true copy of the original by the manufacturer.
7 INSPECTION AND TESTING
7.1 Inspection
The manufacturer/supplier shall submit a detailed programme covering the design,
manufacture and testing of the insulator within one month of receipt of the contract
award. Reports shall subsequently be submitted at intervals, outlining progress and,
if necessary, explaining deviations from the programme.
TANESCO’s representatives shall have free entry at all times, while work on the
contract is being performed, to all parts of the manufacturer's works which concern
the processing of the equipment ordered. The manufacturer shall afford the
TANESCO’s representatives, without charge, all reasonable facilities to satisfy
themselves that the equipment being furnished is in accordance with this
specification.
7.2 Testing
The insulator shall successfully pass all the type, sample and routine tests listed in
the most recent edition of the standards given in clause 2 of this specification.
7.2.1 Type Tests

Type tests are intended to verify the main electrical characteristics of an insulator,
which depend chiefly on its shape and size. This test should be done at accredited
independent laboratory and the certificates shall be submitted along with the bid.
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The type tests required are:

i) Dry, lightning impulse withstand voltage test;
ii) Wet, switching impulse withstand voltage test (polymeric insulators only);
iii) Steep front impulse voltage test (polymeric insulators only);
iv) Critical impulse flashover test;
v) Dry, power frequency voltage test (polymeric insulators only);
vi) Wet, power frequency voltage test:
 For shackle insulators the wet (RMS) withstand test voltage shall be 3kV,
50Hz.
vii) Sudden load release test (polymeric insulators only);
viii) Thermal mechanical test (polymeric insulators only);
ix) Thermal mechanical performance:
The manufacture shall state the result of the thermal mechanical
performance test, carried out in accordance with the requirements of
IEC 575, on a representative sample of the insulators offered. The
value of Qs shall be not less than the value of the acceptance
constant K, as specified in appendix A6 of IEC 575;
x) Mechanical load test (polymeric insulators only);
xi) Mechanical load-time test (polymeric insulators only);
xii) Torsion strength test (polymeric insulators only);
xiii) Water immersion test (polymeric insulators only);
xiv) Water diffusion test (polymeric insulators only);
xv) Dye penetration test (polymeric insulators only);
xvi) Test of housing tracking and erosion (polymeric insulators only);
xvii) Ageing test (polymeric insulators only);
xviii) Slippage test (polymeric insulators only);
xix) Flammability test (polymeric insulators only);
xx) Radio interference:
The manufacturer shall state the result of the radio interference
voltage test carried out in accordance with IEC 437 at a voltage of
15kV, 50Hz for pin insulators and 7.5kV, 50Hz for strain insulators.
The maximum radio interference voltage measured at 1MHz will be
100µV and 50µV respectively; and
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xxi) Power arc test.

Where relevant, these tests shall be carried out in accordance with
IEC 383 and, where applicable, the following clauses shall apply:
xxii) Characteristics of artificial rain;
xxiii) Atmospheric conditions;
xxiv) Correction factors for atmospheric conditions;
xxv) Mounting arrangement representing service conditions:
For shackle insulators, this requires that the insulator shall be mounted
between and in contact with two metallic straps 38mm wide and of any
suitable thickness. A rod of approximately 15mm diameter shall pass
through the axial hole of the insulator and through one end of each of the
straps. The straps shall extend in one direction from the rod and remain
parallel to each other for a distance from the insulator not less than the
height of the insulator. The remote ends of the straps shall be grounded.
The live electrode shall consist of one turn of conductor placed around the
wire groove and bound or clamped back on itself.
The overall diameter of the conductor shall be 19mm.
This conductor shall be carried away from the insulator parallel to, and in
an opposite direction to, the supporting straps.
The wet 50 Hz. withstand test shall be carried out with the axis of the
insulator both in a vertical and in a horizontal position.
In the case of stay insulators, the insulator shall be installed in the
TANESCO's stay wire and preformed fittings. The unit shall be mounted
with its major axis at 450 to the vertical and sag in the set up shall be
eliminated by the application of mechanical tension. The lower section of
the stay wire shall be earthed.
The wet flashover test shall be carried out with each of the insulator grooves
in turn, that supporting the upper section of the stay wire and that supporting
the lower section of the stay wire, facing into the rain.
No objects other than parts of the test assembly shall be nearer the test
specimen or energized electrodes than 300mm.
The wet flashover voltage shall also be recorded, for information only;
xxvi) Time intervals between consecutive applications of voltage; and
xxvii) Wet power frequency test.
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7.2.2 Sample Tests

These tests are made for the purpose of verifying the characteristics of an insulator
and the quality of the materials used. They are carried out on insulators taken at
random from batches offered for acceptance.
The tests shall be conducted according to the sampling procedure of IEC 383,
clause 23. The minimum quantity for sample tests shall be 5 units. Failure of one
insulator shall warrant re-testing according to clause 33 of IEC 383. Failure of two
or more insulators on retest shall result in the rejection of the batch.
The following tests shall be conducted:

i) Verification of dimensions
ii) 50Hz puncture test
iii) Thermal shock (glass insulators only)
iv) Temperature cycle (glass insulators only)
v) Mechanical failing load (glass insulators only)
vi) Mechanical load shall be applied to the insulator in the plane of the
external wire groove.
Mechanical load shall be increased rapidly to 75% of rated mechanical
failing load and then steadily increased at such a rate as to cause failure in
between 15 seconds and 45 seconds.
For the shackle insulators, the minimum rated mechanical failing load shall
be 1,500 kg.
The insulator shall be deemed to have passed the test if the rated
mechanical failing load is reached without mechanical failure.
The load at which failure occurs shall be recorded for information only
vii) Electromechanical failing load (porcelain insulators only)

viii) In the case of stay insulators, mechanical load shall be applied under
conditions reproducing service conditions, as closely as possible (for instance,
mounting the stay insulator on the TANESCO's stay wire, as described already
in clause 14.2). The binding or clamping shall be such that each loop through
the insulator is closed at a distance not greater than 75mm from the
corresponding insulator end.
22
Mechanical load shall be increased rapidly to 75% of rated mechanical failing

load and then steadily increased at such a rate as to cause failure between 15
and 45 seconds
ix) Verification of the specified mechanical load (polymeric insulators only)
x) Shattering strength (glass insulators only):
A tensile load of half the specified mechanical failing load will be applied to
the insulator. The glass portion shall be broken by hammer blows and the
load increased at 20% of the scheduled shattering strength load per minute
until failure occurs.
Failure shall not occur at a load less than 80% of the minimum mechanical
failing load specified for unbroken insulators.
This test shall be applied to one half of the units chosen for the mechanical
failing load test as required by IEC 383:
 Porosity (porcelain insulators only)
 Pinhole gauge:
For pin insulators, the gauge shown in figure 2 of BS 137 part 2, shall
be screwed into the assembled insulator with a torque of 50Nm. The
gap between the end A of the gauge and the closed end of the
thimble (as measured by the plunger B) shall not be less than 5mm
and not greater than 15mm; and
xi) Galvanizing coating mass (610g/m2 minimum and 1,005g/m2 preferred).
7.2.3 Routine Tests

These tests are made for the purpose of eliminating insulators with manufacturing
defects. They shall be made on every insulator offered for acceptance. The following
tests shall be carried out:
i) Visual examination
ii) Mechanical test
The tensile load in the mechanical routine test shall be 50% of the specified
electromechanical or mechanical failing load, rather than 40% as required
by clause 36 of IEC 383:
 Electrical test; and
 Thermal shock (glass insulators only)
23
7.3 TEST CERTIFICATES

Test certificates showing details of tests applied shall be given to TANESCO at time
of delivery or commissioning. The certificates shall show:
 The test loads applied
 The outreach of boom when loads were applied
 The safe working load
 Name and position/qualification of tester
 Serial number
 Integrated chassis number
 Total ballast weight applied (where required)
 Minimum unladen weight of Hydraulic Digger Derrick required to achieve
stability and stability test (angle applied).
24
8 MARKING
All insulators shall be clearly marked with the following markings. These markings
shall be legible and indelible. The markings may be printed or impressed, provided
such impressions do not impair the performance of the insulator. Markings shall be
applied before firing.
i) Name or Trademark of the Manufacturer
ii) Year of Manufacture.
iii) TANESCO's Logo
iv) Mechanical Load in kN
9 SPARE PARTS
The bid shall include, if any, a comprehensive list of all consumable and non-
consumable spare parts and accessories, necessary for five years of normal
operation as specified by the manufacturer.
In addition, the bid shall include, if any, in price schedule of this bidding document,
a price list of recommended non consumable spare parts for all major items of
equipment.
The bidder shall give an assurance that spare parts, if any, will continue to be
available through the life of the equipment.
The spare parts, if any, shall be clearly identified and related to the specific
equipment item. Spare parts, should they be required, shall be delivered suitably
packed and treated for long periods in storage. Each pack shall be clearly and
indelibly marked with its contents, including a designation number corresponding to
the spare parts list in the operation and maintenance instructions. All spare parts, if
any, shall be stored in the TANESCO designated stores.
10 WARRANTY
Warranty period shall be twelve (12) months commencing on the date of acceptance
by the purchaser and shall include all parts and labour.
25
11 PACKING AND SHIPPING
11.1 PACKING
All equipment, including accessories, shall be packed and securely clamped against
movement in robust, wooden, non-returnable packing cases to ensure safe transit
from the manufacturer's works to the work sites.
The packing shall provide suitable protection against all climatic conditions prevailing
during transport and on site. Equipment or material liable to deterioration by sea water,
moisture, or ingress of foreign matter shall be totally sealed in strong polythene bags.
All accessories shall be carefully packed so that they are fully protected during
transport and handling operations and in storage.
Internal surfaces of loose accessories shall be sealed off by means of gaskets and
blanking off plates. Equipment and surfaces liable to deterioration due to condensation
shall be protected by packs of silica gel or other approved desiccant.
Each packing case shall be indelibly marked, in two adjacent sides and on the top,
with the following:
i) Individual serial number;
ii) Client's name, that is: Tanzania Electric Supply Company Limited;
iii) Contract number;
iv) Contractor’s name;
v) Name and address of contractor's agent in Tanzania;
vi) Manufacturer's name;
vii) Description of contents;
viii) Country of origin;
ix) Case measurements;
x) Gross and net weights in kilogrammes; and
xi) All necessary slinging and stacking instructions.
Each case shall contain a fully detailed packing list in a sealed waterproof envelope.
Five copies of each packing list shall be sent to TANESCO prior to dispatching the
equipment.
26
11.2 SHIPPING
The supplier shall be responsible for the shipping of all plant and equipment supplied
from abroad to the ports of entry and for the transport of all goods to TANESCO
designated Stores and for all the costs and expenses resulting from it in accordance
with INCOTERM specified.
All transport accessories, such as riding lugs, jacking pads, blanking off plates, etc.
shall become the property of TANESCO.
All items of equipment shall be securely clamped against movement to ensure safe
transit from the manufacturer's facilities to the work sites.
All accessories shall be carefully packed so that they are fully protected during
transport and handling operations and while in storage.
The supplier shall advise, if requested, the storage required for any plant and
equipment that may be delivered to the TANESCO stores. The supplier shall be
required to accept responsibility for the advice given, in so far as these
arrangements may have a bearing on the behaviour of the equipment in subsequent
service.
11.3 Hazardous substances

The manufacturer/supplier shall submit safety data sheets for all substances used
with the equipment. These substances shall be classified in accordance with the
European Union SI 77: European Communities (dangerous substances)
(classification, packaging, labelling and notification) regulation, 1994, or any
subsequent amendment.
The manufacturer/supplier shall give an assurance that there are no other

substances classified as hazardous in the equipment supplied. The
manufacturer/supplier shall accept responsibility for the disposal of such hazardous
substances, should any be found.
The manufacturer/supplier shall also be responsible for any injuries resulting from
hazardous substances.
27
12 SUBMITTALS
In addition to the tender documentation, some technical documentation is required
as set out in clauses 12.1 and 12.2 below.
12.1 Submittals required with the Bid

The following shall be required:
i) Completed technical data schedule;
ii) Descriptive literature giving full technical details of equipment offered;
iii) Outline dimension drawing for each major component and general
arrangement drawing showing component layout;
iv) Certified original type test certificates and sample routine test reports with an
address of the Independent laboratory that undertook the type test.
Uncertified reports shall be rejected henceforth the bid will be non-
responsive.
v) Safety data sheets for all substances used with the equipment;
vi) Detailed reference list of customers, for the past three years, already using
the equipment offered with particular emphasis on units of similar design and
rating;
vii) Details of manufacture’s quality assurance standards and programme; and
viii) Deviations from this specification. Only deviations approved in writing before
award of contract shall be accepted.
ix) Bidders should submit with their bids a sample of the insulators for which they
bid for evaluation purposes.
12.2 Submittals Required After Contract Award and During Delivery

The following shall be required:
i) Drawing and a sample of the insulator offered for approval before the whole
consignment is manufactured.
ii) Programme for production and testing;
iii) A training video illustrating installation, operation and maintenance of the
plant item; and
iv) Five bound folders with records of the technical particulars relating to the
equipment. Each folder shall contain the following information:
a) General description of the equipment and all components, including
original brochures;
28
b) Technical data schedule, with approved revisions if any;

c) Calculations to substantiate mechanical strength of insulators taking
account of loads acting on them as a result of wind pressure and conductor
tension for maximum windspan and worse design conditions, for all
insulator duties and for all permitted line deviations;
d) Detailed dimension drawing for all components and detailed arrangement
drawing showing installation of the insulators;
e) Inspection and test certificates & reports carried out in the manufacturer's
works;
f) Detailed installation and commissioning instructions; and
g) Operation and maintenance instructions, as well as trouble shooting charts.
29
13 SCHEDULES
13.1 Technical Data Schedule: 11kV Pin Insulators

Description Unit TANESCO Bid
Applicable Specifications Specify
Manufacturer Specify
Country of origin Specify
Catalogue number Specify
Dry Impulse Withstand Test kV 150
Wet, 50Hz, 1 minute, Withstand Test kV 80
Dry, Critical Impulse Flashover Voltage Test kV 160
Dry, 50Hz, Critical Flashover Voltage Test kV 95
Wet, 50Hz, Critical Flashover Voltage Test kV 85
50Hz Puncture Voltage Test kV Puncture proof
Safe Working Load kN 4
Mechanical Failing Load kN 10
Creepage Distance mm 360
Radio Interference: 50Hz applied voltage kV 7.5
Maximum 1MHz voltage uV 100
Type and Grade of Material:

Insulator Specify
Thimble Specify
Cement Specify
Type of Semiconducting Glaze Specify
Radius of Conductor Groove Specify

Identification Markings: ■ Manufacturer's name or Specify
trademark
■ Year of Manufacture Specify
■ TANESCO's Logo Specify
■ Voltage level Specify
■ Electromechanical failing load Specify
Colour of Insulator Brown

Weight of Insulator Specify
Number of Insulators per Crate EA Specify
Gross Weight of Loaded Crate Kg Specify
Number of Crates per Pallet EA Specify
Gross Weight of Loaded Pallet kg Specify
Guarantee period Months 12
30
13.2 Technical Data Schedule: 33kV Pin Insulators

Description Units TANESCO Bid
Puncture
50Hz Puncture Voltage Test kV
proof
Safe Working Load kN 4
Protected Leakage Distance mm 22
Radio Interference: 50Hz applied voltage kV 200
Maximum 1MHz voltage μV Specify
Portland
Type and Grade of Material: Insulator
Cement
Thimble Specify
Portland
Cement
Cement
Identification Markings: Specify
Manufacturer's name or trademark Specify
Year of Manufacture Specify
TANESCO's Logo Specify
Voltage level Specify
Electromechanical failing load Specify

Weight of Insulator kg Specify
Gross Weight of Loaded Crate kg Specify

Guarantee period months 12
31
13.3 Technical Data Schedule: Porcelain Strain Insulators


Dry, Critical Impulse Flashover Voltage Test kV Specify
Dry, 50Hz, Critical Flashover Voltage Test kV Specify
Wet, 50Hz, Critical Flashover Voltage Test kV Specify

Wet, 50Hz, Critical Flashover Voltage Test (String
kV Specify
of Two)
Electromechanical Failing Load kN 45
Mechanical Routine Test kN Specify
Mechanical Impact Strength Nm Specify
Shattered Strength (Glass) kN N/A
Cap 16B
Pin Metal
Coupling Pin Metal
Locking Key Metal
Cement Metal
Type and Grade of Material: Cap Metal
Pin Metal
Coupling Pin Metal
Locking Key Metal
Cement Specify
Grade of Material in Polymeric Insulators: N/A
Housing and Sheds N/A
Core N/A
Metal Fittings N/A
N/A
Locking Key
N/A
Coupling Pin
32
Coupling between Housing and Metal (Polymeric) N/A

Identification Markings: Manufacturer's name or Specify
trademark
33
13.4 Technical Data Schedule: Polymeric Strain Insulators

Type of Semiconducting Glaze Silicone Rubber
Operating voltage kV 11/33
Number of Sheds No. Specify
Leakage distance mm 580/885
Dry Arc distance mm Specify
Dry, Power frequency withstand, 50Hz kV 150/457
Wet, Power frequency withstand, 50Hz kV 75/250
Positive, Critical Flashover kV 140/320
Negative, Critical Flashover kV 160/330
Power Arc cycles Specify
Specified Mechanical Load (SML) kN 80/80
Routine Test Load (RTL) kN 60/60
Proof Test for 10 seconds kN 45/45
Radio Interference: 50Hz applied voltage μV 7.5/7.5
Radio Interference: noise limit (above 1uV across
dB 30/30
300 ohm at 1MHz)
Grade of Material in Polymeric Insulators: Silicone rubber
Housing and Sheds (Clearly Specify Percentages
Composition)
Core Fibtre Glass
Ground end fittings Metal
Line end fittings Metal
Coupling between Housing and Metal (Polymeric) Specify
Identification Markings:
Specified Mechanical Load Specify
Colour of Insulator Brown or Grey

Weight of Insulator Kg Specify
34
13.5 Technical Data Schedule: 11kV Line Post Insulators Horizontal Style

Safe Working Load kV 12
Type and Grade of Material: Specify
Insulator (Clearly Specify Percentages Silicone Rubber
Composition) 100%
Thimble HDG
Cement Portland
Identification Markings: Manufacturer's name Specify
or trademark
Specified mechanical load Specify
35
13.6 Technical Data Schedule: 33kV Line Post Insulators Horizontal Style

Maximum 1MHz voltage V 14
Type and Grade of Material Silicone rubber
Insulator (Clearly state percentage composition)
Thimble Specify
Cement Specify
Specified mechanical load Specify
Gross Weight of Loaded Pallet Kg Specify
36
13.7 Technical Data Schedule: 11kV Pilot Post Insulators Vertical Style

Insulator Porcelain
Thimble N/A
Cement Portland
Cement
Type of Semiconducting Glaze N/A
Radius of Conductor Groove As per
Drawing
Identification Markings: Specify
Manufacturer's name or trademark

Weight of Insulator Kg Specify
37
13.8 Technical Data Schedule: 33kV Pilot Post Insulators Vertical Style

Maximum 1MHz voltage

Type and Grade of Material: Insulator Porcelain
Thimble N/A
Portland
Cement
Cement
Type of Semiconducting Glaze N/A
Radius of Conductor Groove As per Drawing

38
13.9 Technical Data Schedule: Shackle Insulators

Wet, 50Hz, 1 minute, Withstand Test 23
Wet, 50Hz, Critical Flashover Voltage Test Specify
Safe Working Load Specify
Mechanical Failing Load Specify
Type and Grade of Material Specify
Dimensions: Height mm Specify
Half height mm Specify
Half neck length of axial hole mm Specify
Diameter of neck of axial hole mm Specify
Maximum diameter of axial hole flare mm Specify
Diameter of insulator waist mm Specify
Maximum diameter of sheds mm Specify
Gap between sheds mm Specify
Groove radius mm Specify
Colour Brown
Weight kg Specify
Gross Weight of Loaded Pallet Kg Specify
Guarantee months 12
39
13.10 Technical Data Schedule: Bobbin Insulators

Wet, 50Hz, Critical Flashover Voltage Test kV Specify
Safe Working Load kN Specify
Mechanical Failing Load kN Specify
Type and Grade of Material Specify
Dimensions: Height mm Specify
Half height mm Specify
Half neck length of axial hole mm Specify
Diameter of neck of axial hole mm Specify
Maximum diameter of axial hole flare mm Specify
Diameter of insulator waist mm Specify
Maximum diameter of sheds mm Specify
Gap between sheds mm Specify
Groove radius mm Specify
Colour Specify
Weight kg Specify
40
13.11 Technical Data Schedule: Stay Insulators

Voltage rating kV Specify
Wet 50Hz, 1 minute Withstand Voltage kV Specify
Dry, 1 minute Impulse Withstand Voltage kV Specify
Minimum Creepage Distance mm Specify
Minimum Failing Load kN Specify
Type of material Specify
Stay wire hole diameter mm Specify
Whether marking on the insulator are as per Y/N Indicate
specification
Colour of Insulator Specify
Guarantee period months Specify
Certified copy of latest ISO 9001 furnished with the Y/N Indicate
offer
Test Certificates furnished with the offer? Y/N Indicate
Certified copy of ISO 14001 furnished with the offer Y/N Indicate
Drawing submitted with offer? Y/N Indicate
NB: Please fill in Bidder’s Offer for each item
…………………………………..... …………………
Signature and seal of the Manufacturer Date
I/We certify that the above data are true and correct
…………………………………. ……………………
Signature and seal of the Bidder Date
41
13.12 Non Compliance Schedule

On this schedule the bidder shall provide a list of non-compliances with this
specification, documenting the effects that such non-compliance is likely to have
on the equipment's life and operating characteristics. Each non-compliance shall
be referred to the relevant specification clause.
Clause Non-Compliance
No.
…………………………………............... …………………
…………………………………… …………………
42
13.13 Test Certificates Schedule

On this schedule a list of the test certificates included with the bid shall be provided.
This list shall include type test certificates and sample routine test reports. Each
certificate listed shall be referred to the relevant specification clause.
Clause No. Type Test Certificate or Routine Test Report
…………………………………................ …………………
……………………………………. …………………
43
Figure 12: 11kV and 33kV Solid Core Insulator Stud
44

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TANZANIA ELECTRIC SUPPLY COMPANY LIMITED

“We light up your life”

TANZANIA ELECTRIC SUPPLY COMPANY LIMITED

Email Info: info@tanesco.co.tz

This specification has been reviewed by:

S/No. Name Section/Zone Signature

S/No. Name Title Signature

S/No. Name Title Signature

Figure 1: 11kV and 33kV Pin Porcelain Insulator.....................................................................................6

Table 1: Pin insulator performance characteristics ...............................................................................4

S/N STANDARDS DESCRIPTION

 BS 137: Insulators of ceramic material or glass for overhead

2 ESI Electricity Supply Industry

3 ASTM American Society for Testing and Materials

 ASTM B857: Standard Specification for Shaped-wire

4 EUC European Union Commission

 SI 77: European Communities (dangerous substances)

 IEC 305: Characteristics of string insulator units of the cap

6 ISO International Organization for Standardization

 ISO 9000: Quality management and quality assurance

Power Frequency (one minute withstand, wet) for 70 28 10

5.1 PIN INSULATORS

Table 1: Pin insulator performance characteristics

Minimum Performance Characteristics 11kV 33kV

Wet 50Hz Withstand Voltage 47kV 70kV

50Hz Puncture Voltage 105kV 250kV

Dry Critical Impulse Flashover

Dry 50Hz Critical Flashover Voltage (RMS) 74kV

Wet 50Hz Critical Flashover 53kV

Creepage Distance 360mm 1,080mm

Protected Leakage Distance 530mm

Mechanical Failing Load 10kN* 10kN*

Radio Interference: 50Hz applied voltage 7.5kV 22kV

Radio Interference Noise Limit 30dB 30dB

5.1.3 Design and Construction

5.1.4 Spindle Design

Figure 1: 11kV and 33kV Pin Porcelain Insulator

5.2 STRAIN INSULATORS

Leakage distance (mm) Specify Specify

Dry arc distance (mm) 235 457

Power frequency withstand, 60Hz (Dry and Wet 150kV 250kV

Critical flashover (Positive and Negative 140kV 320kV

Radio interference: noise limit 30dB 30dB

Table 3: Porcelain & Glass Strain Insulator Performance Characteristics

Wet 50Hz withstand voltage 28kV

50Hz Puncture Voltage 80kV

Dry critical impulse flashover (positive and negative wave) 100kV

Creepage distance 360mm

Mechanical failing load (glass only) 44.49kN

Electromechanical failing load (porcelain only) 44.49kN

Mechanical routine load 22.24kN

Shattering impact load 35.59kN

Thermal mechanical performance Qs>K

Radio interference: 50Hz applied voltage 7.5kV

Radio interference: noise limit

5.2.3 Design and Construction

iv) Sheds shall be substantially symmetrical in shape without appreciable warping

5.2.4 Corrosion Protection and Finishing