SUPPLY CHAIN MANAGEMENT

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SPECIFICATION

ACSR RABBIT & RACCOON CONDUCTORS

APPLICABLE TO KSEBL Rev#0 DOC. NO.: SCM-SPEC/XH/ACSR Rabbit & Raccoon Conductors

EFF. DATE: 15/12/2021

Number of Pages: 19

Technical Specification and Evaluation Committee for Distribution Material

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Doc. #: SCM-SPEC/XH/ACSR Rabbit & Raccoon
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(i) Document Approval & Control Status `

Compiled by Verified by Approved by

Name Smt.Sheeba Karim Smt.Bindu.T.Wilson Smt.Presannakumari.S

Assistant Executive Engineer Executive Engineer Chief Engineer

Position
(Supply Chain Management) (Supply Chain Management) (Supply Chain Management)

Date 07/09/21 13/12/2021 15/12/2021

Signature Sd/- Sd/- Sd/-

(ii) Amendments and History

Sec. # Rev. # Date History of Change

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1. PURPOSE:

Purpose of this document is to document updates & history, upkeep and publish the

specifications related to ACSR Rabbit & Raccoon Conductors in a professional manner

2. SCOPE:

The Scope of this document is to inform and alert all relevant stakeholders including

KSEBL. Public, KSERC etc regarding the current specifications and historical changes adopted in

specifications of ACSR Rabbit & Raccoon Conductors used in field by KSEBL

3. RESPONSIBILITY:

The Executive Engineer (H), Office of Chief Engineer, Supply Chain Management shall

compile and take necessary steps to publish the specification in KSEBL website and shall inform

relevant stakeholders regarding updates and revisions

4. PROCEDURE FOR REVISION:

Modifications if any, in the technical specification will be incorporated as Revisions. Any

changes in values, minor corrections in pages, incorporation of small details etc. will be

considered as Minor Modification. The Revisions due to minor modifications will be assigned

as Rev. No.0.1, 0.2 etc.

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A complete updation of the technical specification will be considered as Major

modification. The Revisions due to major modifications will be assigned as Rev. No.1.0, 2.0

etc.

All the details of regarding the revisions (both minor and major) will be incorporated in

“(ii)-Amendments and history” above.

The concerned officers, in consultation with the Technical Committee will review and

suggest changes required and the revision suggestion will be approved by Chief Engineer (SCM).

Those who notice any discrepancy or have any suggestion regarding revision, may bring the

matter to the attention of Chief Engineer (SCM) in writing or through e-mail id:[email protected]

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CONTENTS

1) Scope: ..........................................................................................................................................7

2) Standards .....................................................................................................................................7

3) Materials ....................................................................................................................................7

4) Sizes ............................................................................................................................................8

5) Tolerances ..................................................................................................................................8

6) Mechanical Properties ..................................................................................................................8

7) Technical Specification for ACSR Raccoon, Rabbit Conductors .......................................................8

8) Surface Conditions .......................................................................................................................8

9) Stranding......................................................................................................................................9

10) Conductor Drums ........................................................................................................................9

11) Lengths and Variation in Lengths ...............................................................................................12

12) Rejection ...................................................................................................................................13

13) Tests and Test Certificate ...........................................................................................................13

14) Wrapping Test ..........................................................................................................................14

15) Galvanizing Test .......................................................................................................................14

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16) Torsion Test ......................................................................................................................................................................................... 14

17) Resistance Test ..........................................................................................................................15

18) Specific Resistivity ......................................................................................................................15

19) Guaranteed Technical Particulars ..............................................................................................16

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Technical Specification of ACSR Rabbit & Raccoon conductors

1) Scope:- This specification provides for the manufacture, testing before despatch, supply and
delivery including unloading of ACSR Rabbit & Raccoon conductors at site as per the technical
specification & GTP attached. The steel cored Aluminium conductor and galvanised steel wire
shall have Mechanical and Electrical properties specified in IS.398 Part-II and latest
Amendments.
2) Standards:-
2.1) The conductor shall comply in all respects with the Indian Standards specification (ISS) 398-
1996/British Standard 215/IEC Publication No.209 with latest amendments or any other
authoritative standard. The specification and working shall be marked in the flat sides of the
drum.
3) Materials:-
3.1) The materials offered shall be of best quality and workmanship. The steel cored aluminium
conductor strands will consist of hard-drawn aluminium wire manufactured from 99.6% pure
electrolytic aluminium rods of E.C.Grade, conform to IS:5484. The steel wire shall be made
from materials produced either by the acid or base open hearth process or by electric process.
No steel wire drawn from Bessmar process steel shall be used. The steel wire shall not exceed
the limits of sulphur or phosphorus as stipulated in the IS:398 (Part-2).The raw material
Aluminium rods shall be purchased from M/s.National Aluminium Company Limited,
M/s.Hindalco Industries Limited and M/s.Vedanta Aluminium Company Limited.
3.2) The steel wire shall be evenly and uniformly treated with zinc complying with Indian Standard
209-1992 specification with latest amendments for zinc (Revised) or BS or any other
authoritative standard. The uniformity of zinc coating and the weight of coating shall be in
accordance with technical specifications and shall be tested and determined according to Indian
Standard IS:4826 or any other authoritative standard.The zinc used for galvanising shall be
electrolytic high grade zinc not less than 99.95% purity.The raw material steel wire rods shall be
purchased from M/s.Tata SSL Limited, Mumbai, M/s.Ramsarup Industrial Corporation,Kolkata
or other reputed companies.
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4) Sizes:- The size of steel cored aluminium conductors shall be as given in technical specifications
& GTP attached. The resistance and weights shall be in accordance with the values given in
the same.
5) Tolerances:- No negative tolerance shall be permitted on the nominal diameter of aluminium &
steel wires used in the manufacture of ACSR. However positive tolerance in this respect shall be
as provided in IS.398 (Part- II)
6) Mechanical Properties:- The value of the final modulus of elasticity for steel cored Aluminium
conductor is the average of values obtained from actual stress strain tests. The co-efficient of
linear expansion for steel cored Aluminium Conductors has been calculated on the basis of co-
efficient of linear expansion of 23x10-6 per degree centigrade for Aluminium at 0 0C and 11.5 x
10-6 per degree centigrade for steel and represent only the average values. These values shall,
however, be given by the tenderer under the guaranteed technical particulars.
7) Technical Specification for ACSR Raccoon, Rabbit Conductors.

Sl No Name of conductor Raccoon Rabbit

1) Nominal Aluminium Area in mm2 80 50
2) Stranding and Wire diameter
a) Aluminium 6/4.09 6/3.35
b) Steel 1/4.09 1/3.35
3) Sectional Area of Al. in mm2 78.83 52.88
4) Total Sectional Area in mm2 91.97 61.70
5) Approximate Mass Kg/km 319 214
6) Approximate Over All diameter in mm 12.27 10.05
7) Calculated Resistance at 200 C in Ω /km 0.3712 0.5524
8) Approx. Calculated breaking load in KN 26.91 18.25
8) Surface Conditions:- The wires shall be smooth and free from inequalities, spills and splits. The
surface conductor shall be free from points, sharp edges, abrasions or other departures from
smoothness or uniformity of surface contour, that would increase radio interference and corona

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losses. When subjected to tension upto 50% of the ultimate strength of the conductor, the
surface shall not depart from its cylindrical form, not any part of the component parts or
strands, move relative to each other in such a way as to get out of place and disturb the
longitudinal smoothness of the conductor.
9) Stranding:-
9.1) The wires used in construction of a stranded conductor shall before stranding, satisfy all
requirements of IS.398/BS.215/IEC-209. For steel cored aluminium conductor the lay ratio of
the different layers shall be within the limits given in the relevant IS.
9.2) For all construction, each alternate layer shall be stranded in opposite directions. The wires in
each layer shall be evenly and closely stranded round the underlying layer of wires. The final
layer of wires shall have a right hand lay.
9.3) The steel core inner Aluminium layer shall be protected by a suitable compound before
application of the aluminium strands. The type of coating used shall be lithium soap grease
corresponding to Grade II of IS.7623/1993.
10) Conductor Drums:- The conductor to be supplied shall be packed in the drums.
The drums used shall conform to IS specification No.1778/1981 amended upto date
applicable for reels and drums for bare wire and the dimensions of the conductor drums
(wooden reel) shall be such that after accommodating suitable number of lengths of the
conductor, the total weight of the drum with conductor on it should not exceed the values
given below.

ACSR Raccoon 1,400 Kg

ACSR Rabbit 1,400 Kg
The supplies effected with the gross weight of drum exceeding the above values shall
not be accepted.
The conductor drum shall bear the following marking and shall conform to the
specifications IS – 1778-1981.

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10.1) Specification of Drum:-

1) Materials and construction : Soft wood or seasoned wood.
2) Flange diameter : 1220mm.
3) Barrel diameter : 600 mm.
4) Traverse : 710mm.
5) Flange thickness : 2X32mm.
6) Bore diameter : 80mm.
7) Nail Circle : 5mm.
8) Nail length : 75mm.
9) Nail size minimum : 3.25mm.
10) Thickness of Barrel and supports : 38mm.
11) Thickness of Barrel end lagging : 38mm.
12) No. of strechers : 4 Nos.
13) Strecher size : 100 X 38 mm.
14) No. of bolts : 4 Nos.
15) Diameter of Bolts (minimum) : 12mm.
16) Size of square washer : 50mm X 6mm
17) Size of spindle plate : 150 X 150 X 6mm.
18) Diameter of spindle plate holes : 90mm.
19) No. of spindle plate bolt : 4 nos
20) Spindle plate bolt diameter : 12mm.
21) Thickness of external logging : 38mm.
22) No. of Binders over the external lagging : 2 nos.
23) Materials used for lining the barrel of : Water proof materials.
the drum
24) Material used for lining over the last : Water proof material.
layer of conductor
25) Material used for painting the barrel : Bitumen based paints
surface and inner surface of flanges

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10.2)Details to be marked on the Drum:-

1) Drum No. : To be marked.

2) Roll this way making : An arrow shall be marked on
the sides of the drums with
the word “Roll this way”.
3) Manufacturer's name or trade marks :
4) Size & Type of conductor :
5) Net weight of conductor : In kg.
6) Bare weight of conductor : In kg.
7) Gross weight of conductor and drum : In kg.
8) No. of pieces and length of each piece : In m.
9) Total length on the drum : In m.
10) Name and address of the consignee :
11) Year of manufacture :
12) ISI certification mark :
13) Position of top conductor finishing end : Should be marked.
14) Tests to be conducted on the drum :
15) Barrel batten strength :Should be twice the winding
tension.
The supplier shall forward along with the Test Certificates particulars of the drum as
required in ISI 1778—1981.Painting shall be carried out and all protection as per IS 398 Part-II
and latest amendments provided.
After reeling the conductor, the exposed surface of the outer layer of the conductor
shall be wrapped with water proof thick bituminised bamboo paper to preserve the conductor
from dirt, grit and damages during transport and handling. Either soft wood or seasoned wood
should be used for the manufacture of drums, spindle plate and its accessories should be fixed.
The minimum space of 50mm shall be provided between the inner surface of the external
protective lagging and outer layer of the conductor.
The conductor ends shall be properly sealed and secured with the help of nails or bolts
on the side of one of the flanges to avoid loosening of the conductor layers during transit and
handling. The supplies effected without complying the above packing conditions shall not be
accepted.

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11) Lengths and Variation in lengths:-

11.1) The standard length of ACSR Conductor shall be 1000 Metre and lengths bigger than the
standard lengths also allowed. Short length shall not be less than 80% (Eighty percent) of the
standard length specified as above and the total acceptable quantity of such short lengths shall
be within 5% (Five percent) of the allotted quantity to each consignee of the respective size of
the conductor.
11.2) Verification of length of conductor:-
i) KSEB Limited shall ascertain the length of ACSR Conductor at supplier’s works and at the
receiving store centers by measuring the actual length by length measuring machine used
for the purpose. Marking should be made for each 1km length of the conductor. The
supplier should ensure that length measuring machine is available for measurement of the
length by our inspecting officer.
ii) The supplier shall produce before the inspecting officer documents showing that good
quality raw materials have been procured for the manufacturing of conductors.
iii) Both ends of the ACSR Conductor shall be sealed by supplier and the seals shall be
contained in the drum and not exposed out of drum.
iv) The declared length will be measured between manufacturer’s seals at both ends of ACSR
Conductor.
v) Weight of the ACSR Conductor will also be checked for ensuring correct lay and length of
the ACSR Conductor. The supplier should have the facility to take weights from 50mg. upto
500gms. He should also have facility for rewinding so that the weight of the drum and
conductor can be taken separately. The supplier should have the facility to conduct tests as
per IS on the strand, conductor and drum.
vi) Verification of length will be carried out on 10% of total lot at works and two drums at any
store out of the lot.
vii) If the length is found correct or more the lot will be accepted. If the length is found to be
less than the declared, the percentage of such short length will be applied for reduction for
the entire quantity supplied in the lot at various stores for payment.

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viii) In case of dispute, joint inspection along with the representative of the supplier shall be
carried out after giving 10days notice to the supplier to remain present at store for the
purpose. If the representative fails to attend on stipulated date for joint inspection, the
decision of consignee shall be final and binding.
12) Rejection:- While measuring the length the sample piece from each length shall be taken for
carrying out the test as per IS-398 Part – II. All the values of each sample should not exceed the
values of the relevant BIS read with specification. In case of deviation, whole lot will be rejected
at works.
13) Tests and Test Certificate:-
13.1) Individual wire and finished steel cored Aluminium conductor shall be subjected before dispatch
from the works to the tests as specified in the Indian Standard Specification 398-1996 or any
other authoritative standard.
13.2) Samples of individual wires for test shall be taken before stranding from not less than 10% of
the spools in the case of aluminium wire and ten percent of the wire coils in the case of steel
wires. If samples are taken after stranding they shall be obtained by cutting 1.2 metre from the
outer end of the finished conductor, from not more than 10% of the finished reels.
13.3) The mechanical tests shall be carried out on single wires only.
13.4) The tensile test shall apply to wires of all diameters forming part of steel cored aluminium
conductors. If it is not possible to test the component wires before stranding, the test may be
made on wires taken from stranded conductors. In such cases the tensile strength of any of the
wires shall not be less than 95 percent of the minimum values given in technical specifications
attached.
13.5) Tensile testing machine shall be used, the accuracy of which can easily be checked and the
machine adjusted if necessary. The test samples, before being placed in the machine, shall be
straightened, if necessary, in such a way as to cause the minimum alteration in its physical
properties. When an automatic tensile testing machine is issued, the load shall be applied
gradually and rate of separation of the jaws of the testing machine shall not be less than
25mm/min. greater than 100mm/min. When a hand operated lever testing machine is used, 90
% percent of the breaking load shall be applied quickly and the load shall then be increased
steadily until the specimen breaks. The time taken to apply the last ten percent of the load shall

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be approximately 15 seconds and the total time from the application of the load to the break
shall be approximately 20 seconds.
13.6) The breaking load of steel cored aluminium conductor in terms of the sum of the strength of the
individual components wires may be taken to be as follows.
a) 98 percent of the sum of the strength of the aluminium wires plus 89 percent of the sum of
the strengths of the steel wires when taken from the stranded conductor and tested or
b) 98 percent of the sum of the strength of the aluminium wires plus 85 percent of the sum of
the strengths of the steel wires, based on the strengths of the component wires before
stranding, that is, in the coil
The value of approximate calculated breaking load of conductor has been given in the
technical specification attached.
14) Wrapping Test:-
14.1) Samples of aluminium wires shall be wrapped round a wire of its own diameter to form a close
helix of eight turns. Six turns shall then be unwrapped and again closely wrapped in the same
directions as before. The wire shall not break.
14.2) Samples of galvanized steel wires shall be wrapped around a mandrel of diameter six times
round a mandrel of diameter equal to four times the wire diameter to form a close helix of 8
turns. Six turns shall then be wrapped and again closely wrapped in the same direction as
before. The wire shall not break.
15) Galvanizing Test:-
15.1) The uniformity of galvanizing and the weight of coating shall be in accordance with
IS:4826/1979 and shall be determined according to Indian Standard Specification. Indian
Standard No.2633-1072 and 6745-1972 respectively or any other authoritative standard.
15.2) This test shall be made whenever practicable on wires before stranding and before the
specimen has been bent, straightened or tested in any other way.
16) Torsion Test:- The sample of steel wire shall be gripped in two vices exactly 15cm apart. One of
the vices shall be made to revolve at a speed not exceeding one revolution per second and the
other shall be capable of moving longitudinally to allow for contraction or expansion during
testing. The test shall be continued until fracture occurs and the fracture shall show a smooth
surface at right angles to the axis of the wire. After fracture, the specimen shall be free from

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helical splits. The samples shall withstand a number of twists equivalent not less than 16 on a
length equal to 100 diameters.
17) Resistance Test:- The measurement of resistance shall be made on solid Aluminium conductors,
and shall be carried out to an accuracy of at least one part in a thousand. The length of the
sample wire selected for this test shall be sufficient to give the accuracy required and shall be
suitable for the method of testing, employed. Certificates as to the accuracy of the apparatus
shall be provided and either party shall have the right to satisfy himself that the apparatus and
methods of testing are correct.
18) Specific resistivity of Aluminium used should not exceed 0.028264 ohm sq.mm/m at 20 degree
centigrade as prescribed in IS.398. If the results are at variance, the whole lot shall be rejected.
19) Guaranteed Technical Particulars:- The tenderer shall fill in the guaranteed technical
particulars in the proforma in Annexure-II and submit the same with his tender.
20) Routine test Certificate shall be furnished while offering inspection.

Sd/-
Chief Engineer (SCM)

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GUARANTEED TECHNICAL PARTICULARS

Sl. No Description KSEBL’s Requirement

Rabbit Raccoon
1) Code word Rabbit Raccoon
2) Makers Name & Address
a) Aluminium rods. M/s.National Aluminium Company Limited,
M/s.Hndalco Industries, Limited,
M/s.Vedanta Aluminium Company Limited.
b) Steel wire rods M/s.Tata SSL Limited, Mumbai,
M/s.Ramsarup Industrial Corporation, Kolkatta
or other reputed companies.
c) Complete conductor
3) Stranding and wire diameter
a) Aluminium 6/3.35 6/4.09
b) Steel 1/3.35 1/4.09
4) Calculated equivalent aluminium area in 52.21 77.83
sq.mm
5) Actual aluminum area in sq.mm 52.88 78.83
6) Standard area of cross section in sq. mm
a) Aluminium strand 8.814 13.14
b) Steel strand 8.814 13.14
c) Conductor 61.70 91.97
7) Diameter of complete conductor in mm 10.05 12.27
8) Minimum Ultimate tensile stress of strand in
Kg/ sq.mm
a) Aluminium strand 16.52 16.17
b) Steel strand 134 134
9) Guaranteed ultimate tensile strength of 1860 2746
conductor in kg.
10) Minimum breaking load in KN for
a) Aluminum strand

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Before stranding 1.43 2.08

After stranding 1.36 1.98
b) Steel strand
Before stranding 11.58 17.27
After stranding 11.00 16.4
11) Purity of aluminum rods 99.60%
12) Zinc coating of steel strand
a) Uniformity of coating and duration of dips 1 min – 3 dip, 1 min – 3 dip,
(No.1 Min. x …. No) 1/2 min-1 dip 1/2 min-1 dip
b) (Preece test) with strand (No.2 Min. x … No)
c) Minimum weight of coating (gm/sq.mm) 250gm/m2 275gm/m2
13) Maximum working tension 50% of ultimate tensile strength
930 1373
14) Weight in Kg. per Km
a) Aluminium. 23.82*6 35.51*6
b) Steel. 68.75 102.48
c) Conductor 214 319

15) Resistance in ohms per Km at 20 oC 3.265 2.19

16) a) Continuous maximum current rating of As per IS:398 – Part-2
conductor in still air at 32 oC ambient
temperature. Amps. 157 200
b) Temperature rise for the above current oC As per IS:398 – Part-2 -30
17) Modulus of elasticity of conductor 79 GN/m2
18) Coefficient of linear expansion per degree
centigrade of
a) Aluminium strand. 23 x 10-6
b) Steel strand. 11.5x 10-6
c) Conductor 19.1x 10-6

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19) Percentage of carbon in steel wire rods. 0.5 to 0.85%

20) Standard length of each piece in Km. 1000 mts and above
21) Tolerance, if any, on standard length. 800-1000 mtrs short length to a maximum of 5%
22) No. of standard lengths in one reel. 2 or 3
23) Dimensions of the reel in cms. 122 *60*71cm
24) Weight of the conductor in one reel in Kg. 1100+/- 10%
25) Weight of the reel in Kg. 200kg Approximate
26) Gross weight of the reel including weight of Approx.1400 kg
the conductor.
27) Standard according to which the conductor IS:398 (Part-2):1996
will be manufactured and tested.
28) Lay ratio. Min10 and Max.14
Mini.
Max.
29) Diameter of strands in mm
Aluminium
a) Nominal 3.35 4.09
b) Minimum 3.32 4.05
c) Maximum 3.38 4.13
Steel
a) Nominal 3.35 4.09
b) Minimum 3.28 4.01
c)Maximum 3.42 4.17
30) Calculated maximum D.C resistance at 20O C 3.265 2.194
for Aluminium wires.
31) Approximate calculated breaking load of 18.25 26.91
conductor KN.
32) Number of twists, which the steel wire can Before – 18 – After -16

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withstand in the torsion test.

33) Minimum stress in the steel wire As per IS:398 (Part-2):1996
corresponding to10% elongation in Kg/
sq.mm
34) Drum.
Constructional details:
a) Type of wood used. Seasoned/ Soft Wood
b) Number and thickness of plies forming the 2*32 mm
flange
c) No. and diameter of barrel bolts. 4 * 12mm
d) Thickness of barrel battens in mm 38mm
e) Thickness of external logging in mm 38mm
f) Spindle hole diameter in mm. 90mm
g) Details of protective wrapping. Painting will be carried out and all protection as
per IS:398 (Part02):1996
h) Weight of the empty drum with protective Approx. 250kg
wrapping and external loggings.
i) Standard to which the conductor drums IS:1778:1980 and latest amendment
conforms
j) Licence No. and date for using ISI
Certification (or mark if any)
35) Other particulars, if any Nil

Sd/-

Chief Engineer (SCM)

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