MADHYA PRADESH POWER TRANSMISSION CO. LTD.

SHAKTI BHAWAN RAMPUR: JABALPUR

VOLUME –V Part-V

TECHNICAL SPECIFICATION FOR OF

HTLS CONDUCTOR
, INSULATORS, HARDWARE AND ACCESSORIES.

O/o CHIEF ENGINEER (PROCUREMENT)

MPPTCL, JABALPUR.
 TABLE OF CONTENTS

Specifications & requirements for supply of Transmission Line

Materials

Section- 1 Common Technical Requirement

Section- 2 Technical Specifications for Conductor

Section- 3 Technical Specifications for Disc Insulators

Section- 4 Technical Specifications for Hardware fittings for

Conductor
Section- 5 Technical Specifications for Accessories for Conductor

Section- 6 Technical Specifications for erection of transmission

lines
 SECTION-1
COMMON TECHNICAL REQUIREMENT

1.01 SCOPE:

1.01.01 The provisions under this section are to supplement common

requirements for supply of Transmission Line Materials and Installation work.
Section-2 to Section-6 contains technical specification for all the Materials to
be used for Construction of Transmission Lines. The bidders shall furnish
catalogues, engineering data / technical information, drawing etc. in
conformity with the technical specification.

1.01.02 It is not the intent to specify completely herein all details of the design and
construction of Material. However, the Material shall conform in all respects to high
standards of engineering, design and workmanship and shall be capable of performing
the duties specified herein. The Material offered shall be complete with all components
necessary for its effective and trouble free operation. Such components shall be
deemed to be within the scope of Bidder‟s supply, irrespective of whether these are
specifically brought out in this specification or not.

1.02 CLIMATIC CONDITION

The equipments and materials shall be suitable for satisfactory continuous operation
under the following climatic conditions:

1 Location in the state of MADHYA PRADESH

0
2 Maximum ambient air temperature ( C) 50
0
3 Minimum temperature in shade ( C ) 1
4 Maximum relative humidity (%) 95(sometimes
approaches
saturation)
5 Average daily ambient air temperature (0C ) 32° Centigrade
6 ISOCERANIC Level (days/year) (Average
50
number of thunder storm days)
7 Average rainfall(mm) 1250
8 Wind Zone as per IS 802(Part-I)- 1995 4
9 Max. Altitudes above mean sea level (meters) 1000
10 Seismic level (Horizontal acceleration)(g) 0.3

NOTE: Moderately hot and humid tropical climate conducive to rust and fungus growth.
The climatic conditions are also prone to wide variations in ambient conditions.
Smoke is also present in the atmosphere. Heavy lightening also occurs during
June to October.

1.03 STANDARDS:

1.03.01 Bidders may please note that all offered materials shall be manufactured,
tested and supplied with all guaranteed technical particulars generally conforming to
meet the requirement of technical specification as brought out in various Sections and
latest revisions of relevant standards of international electro technical commission or
equivalent national standards of India with latest amendments of relevant standards
rules and codes. The lists of standards are specified in relevant Sections of bid
document.

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1.03.02 The works covered by the specification shall be designed, engineered,
manufactured, built, tested and commissioned in accordance with the Acts, Rules Laws
and Regulations of India.

1.03.03 The Contractor shall also note that list of standards presented in this
specification is not complete. Wherever necessary the list of standards shall be
considered in conjunction with specific IS/IEC.

1.03.04 When the specific requirements stipulated in the specifications exceed or

differ than those required by the applicable standards, the stipulation of the
specification shall take precedence.
1.04 ACCEPTANCE OF OTHER AUTHORITATIVE STANDARDS :

1.04.01 The lists of Indian standards are specified in individual sections for various
materials and Installation work of bid document. However, the Material and Installation
work meeting any other authoritative International Standard, which ensures equal or
better quality than the Standards mentioned in bid document, shall also be acceptable.
Material for which Indian Standards are not available, any equivalent
International Standards will be applicable. Please attach photocopy of all such
Standards according to which the material and Installation work have been
offered.

1.04.02 If the material offered by the Bidder conform to any other standards,
salient points of comparison between the standards adopted and the specific standards
shall be clearly brought out in relevant schedule of deviation. It will be sole
responsibility of Bidder to prove that the salient features of offered materials are
equivalent or better than Indian standards as indicated in Section-2 to Section- 9 of this
document.

1.04.03 The Material and Installation work conforming to standards other than
specified in individual sections for various Material and Installation work shall be subject
to Employer‟s approval.

1.05 TYPE TESTS:

1.05.01 Type tests shall mean those tests, which are to be carried out to prove the
process of manufacture and general conformity of the Material. The offered Material
(except Towers & Tower Accessories) should be fully type tested as per the relevant
standards. Type test of offered technology will be acceptable.If any test is not
conducted,the same will have to be conducted by contractor at no extra cost.
1.05.02 Bidder shall invariably furnish type test reports from the reputed and
approved national/international laboratory/Government approved test houses to prove
that specifications of Material to be supplied conform to the relevant standard. Test
certificates shall clearly indicate the type and other details etc., so that relevant details
of offered Material could be verified. While submitting the bid the details and type etc.,
shall be clearly indicated. Type test reports so furnished should not pertain to the period
earlier than Seven years from the date of opening of Bid. In case the type tests were
carried out earlier than Seven years, the manufacturer will have to conduct these tests
without any extra cost to the Employer. In both the above cases type test certificate
must be submitted with the offer. The Bidders have to submit one complete set of Test
reports for the offered Material. Further, for any change in the design/type already type
tested and the design/type offered against this specification, the Employer reserves the
right to demand repetition of tests without any extra cost.

1.06 DISCREPANCY IN TECHNICAL PARTICULARS:

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The bidders will have to furnish confirmation in regard to compliance of our entire
technical requirement. The bid should clearly describe various technical particulars of
the material as per this specification.

1.07 MANUFACTURER'S AUTHORISATION:

The bidders shall have to submit the documentation from the manufacturer of the
Material on the format specified in this volume that they are authorised to supply the
material indicated in their bids in the employer's country.

1.08 SCHEDULE OF QUANTITIES:

1.08.01 The requirements of various Materials and Installation work are indicated
in Price Schedules. In these schedules short description of material has been given. The
details of all such description are given in relevant sections of this document. The
bidder shall refer these detailed descriptions for clarity.

1.08.02 Although all the quantity of Material and Installation work have been
included in the bid as mentioned in Price Schedules. However there may be
requirement of some minor nature items required for successful erection /
commissioning of transmission line work covered under this Bid. Bidder should include
all such items in the bid proposal sheets which are not specifically mentioned but are
essential for the execution of the contract. The cost of supply of such item which
explicitly may not appear in various schedules and are required for successful
commissioning of transmission line shall deemed to be inclusive in the bid price and
shall be provided at no extra cost to Employer.

1.09 WORKMANSHIP:

All Material shall be of the best class and quality most suitable for the conditions of
operation under the climate conditions as per clause no. 1.02 above for supply of
Material. The workmanship shall be of the best grade and the entire construction in
accordance with the best modern practice.

1.10 DRAWINGS AND DOCUMENTS:

1.10.01 In addition to those stipulated in Vol. I of bidding document, the following

also shall apply in respect of Contractor drawings.

1.10.02 Within one month from the award of contract, the contractor shall submit
the drawing of all Material for approval. Each drawing submitted by the Contractor shall
be clearly marked with the name of the EMPLOYER, the specification title, the
specification number and the name of the Project. All titles, noting, markings and
writings on the drawing shall be in English. All the dimensions should be to the scale
and in S.I. units.

1.10.03 The comments/ approval to drawings submitted by the Contractor shall be

conveyed by the EMPLOYER as far as practicable within 15 days and shall be modified
by the Contractor if any modifications and/or corrections are required by the
EMPLOYER. The Contractor shall incorporate such modifications and/or corrections and
submit the final drawings for approval with 15 days from date of EMPLOYERs
comments. Any delays arising out of failure by the Contractor to rectify the drawings in
good time shall not alter the Contractual Time Schedule.

1.10.04 The drawings submitted for approval to the EMPLOYER shall be in

quadruplicate. One print of such drawings shall be returned to the Contractor by the

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EMPLOYER marked “approved/approved with corrections”. The contractor shall there
upon furnish the EMPLOYER additional prints as may be required along with one
reproducible in original of the drawings after incorporating all corrections.

1.10.05 The work shall be performed by the Contractor strictly in accordance with
these drawings and no deviation shall be permitted without the written approval of the
EMPLOYER, if so required.

1.10.06 All manufacturing, fabrication and Installation work under the scope of
Contractor, prior to the approval of the drawings shall be at the Contractor‟s risk. The
contractor may incorporate any changes in the design, which are necessary to confirm
to the provisions and intent of the contract and such changes will again be subject to
approval by the EMPLOYER.

1.10.07 The approval of the documents and drawings by the EMPLOYER shall mean
that the EMPLOYER is satisfied that:
a. The Contractor has completed the part of the Works covered by the subject
documents (i.e. confirmation of progress of work).
b. The Works appear to comply with requirements of Specifications.
In no case the approval by the EMPLOYER of any document does imply compliance with
all technical requirements or the absence of errors in such documents.
If errors are discovered any time during the validity of the contract, then the Contractor
shall be responsible for consequences.

1.10.08 All drawings shall be prepared using AutoCAD software. After final
approval all the drawings and documents (structural drawings, BOMs, shop sketches,
tower accessories drawings and drawings of other materials) shall be submitted to the
EMPLOYER in CDs.
A copy of each drawing reviewed will be returned to the Contractor as stipulated herein.

1.10.09 Copies of drawings returned to the Contractor will be in the form of a print
with the EMPLOYER‟s marking.

1.10.10 All rights of the design/drawing for all Material and Installation work
drawings shall be strictly reserved with the EMPLOYER only and any
designs/drawings/data sheets submitted by the contractor from time to time shall
become the property of the EMPLOYER. Under no circumstances, the contractor shall
be allowed to user/offer above designs/drawings/data sheets to any other authority
without prior written permission of the EMPLOYER. Any deviation to above is not
acceptable and may be a cause for rejection of the bid.

1.10.11 The manufacturing of the material shall be strictly in accordance with the
approved drawings and no deviation shall be permitted without the written approval of
the EMPLOYER. All manufacturing and fabrication work in connection with the material
prior to the approval of the drawing shall be at Contractor‟s risk.

1.10.12 Approval of drawing/works by EMPLOYER shall not relieve the Contractor of

his responsibility and liability for ensuring correctness and correct interpretation of the
latest revision of applicable standards, rules and codes of practices. The plant shall
conform in all respect to high standards of engineering, design, workmanship and latest
revisions of relevant standards. EMPLOYER shall have the power to reject any work or
material, which in his judgment is not in full accordance therewith.

1.11 QUALITY ASSURANCE PROGRAM:

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1.11.01 Quality Assurance Program : To ensure that the Material and Services
under the scope of this contract whether manufactured or performed within the
Contractor's works or at his Sub-Contractor's premises or at the EMPLOYER's site
or at any other place of work are in accordance with the Specifications, the
Contractor shall adopt suitable Quality Assurance Program (QAP) with hold points for
EMPLOYER‟s inspection to control such activities at all necessary points. Such
program shall be outlined by the Contractor and shall be finally accepted by the
EMPLOYER after discussions.

1.11.02 Immediately after award of contract, the contractor shall submit to the
EMPLOYER, the quality assurance plan for all major items of Material covering the
manufacture and Installation activities of the transmission line. The list of selected sub
vendors for supply of minor items like Bolts & Nuts, tower accessories etc. shall also be
submitted.

1.11.03 The contractor shall ensure that manufacturer must establish that they are
following the accepted quality assurance programme for manufacture of offered
equipments.

1.11.04 The contractor shall ensure that manufacturers of major items of Material
invariably furnish following information:-
(i) Statement giving list of important raw materials, names of sub supplier for
the raw material, list of standards according to which the raw material are
tested, list of tests normally carried out on raw material in presence of
manufacturers representative, copies of test certificates.
(ii) Information and copies of test certificates as in (i) above in respect of
bought out items.
(iii) List of manufacturing facilities available.
(iv) Levels of automation achieved and list of areas where manual processing
exists.
(v) List of areas in manufacturing process, where stage inspections are
normally carried out for quality control and details of such tests and
inspection.
(vi) Special features provided in the equipment to make it maintenance free.
(vii) List of testing equipment available with the manufacturer for final testing
of equipment specified and test plant limitations, if any vis-à-vis type,
special, acceptance and routine tests specified in the relevant Indian
Standards or equivalent international standard. These limitations shall be
very clearly brought out in schedule of deviations from specified test
equipments.

1.11.05 The Contractor shall follow the accepted Quality Assurance Plan in true
spirit. If desired by the EMPLOYER, he shall give access to all the Specifications,
equipments and records so as to satisfy the EMPLOYER that Quality Assurance Plan
(QAP) is being followed properly.

1.11.06 All Material shall be subjected to the routine and acceptance tests before
dispatch, as specified in this Specification.

1.12 INSPECTION AND TEST CERTIFICATES:

1.12.01 All Material to be supplied will be subject to inspection and approval by the
EMPLOYER's representative before despatch. Inspection before despatch will not

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however relieve the contractor of his responsibility to supply the Material strictly in
accordance with the specifications.
1.12.02 For Inspection / testing, the contractor shall intimate the EMPLOYER at
least 15 days in advance about readiness of Material as per the scheduled delivery so
that action may be taken for getting the Material inspected. While notifying the
readiness of the Material, the factory test certificate in respect of offered Material shall
invariably be sent. The EMPLOYER will depute authorized representative for inspection
of Material or alternatively may issue waiver of inspection.
1.12.03 The contractor will submit a test certificate to the EMPLOYER after
inspection of offered Material by EMPLOYER‟s authorized representative. These test
certificates should be in accordance with latest issue of the relevant Indian Standards or
as approved by the order placing authority.
1.12.04 The Material shall not be dispatched unless the test certificates approval
and despatch instructions have been issued by the EMPLOYER.
1.12.05 All Material shall conform to provisions of any statutory acts such as
the Indian Electricity Act, Indian Factory Act, the Indian Boiler Act, etc. and
corresponding rules and regulations as may be applicable.

1.12.06 The EMPLOYER's representatives shall be entitled at all reasonable time

during manufacture to inspect, examine and test at the contractor's premises the
material and workmanship of the plant to be supplied under this contract.
1.12.07 A copy of the accepted Quality Assurance Plan must be available at the
manufacturer‟s works of the Material for reviewing by inspecting officer of the
EMPLOYER.
1.12.08 The acceptance of any quantity of plant shall in no way relieve the
Contractor of any of his responsibilities for meeting all requirements of the specification,
and shall not prevent subsequent rejection if such plant is later found to be defective.
The Contractor will have to assume the responsibility for free replacement/rectification
of such defects.
1.12.09 Testing Expenses:
The entire cost of testing for the acceptance and routine tests and tests during
manufacture specified in the bid document shall be treated as included in the quoted
unit price of plant.

1.13 SPECIAL REQUIREMENTS:

1.13.01 EMPLOYER expects that participating bidder will take all necessary precautions
to supply best quality Material, which may provide trouble free performance and also it
is expected that the modern practices for erection and commissioning shall be adopted
to ensure timely and trouble free commissioning of installation and also to ensure
aesthetic overall view of finished transmission line installation.

Some of the conditions which will have to be essentially accepted and followed by the
Bidders for the purpose of participating against the Bid and also for undertaking
construction activities are enumerated below for specific confirmation by the Bidders.

1.14 STORE FOR SUPPLY OF MATERIAL:

The Contractor shall supply the Material at selected destination set up by him along the
route of the transmission line. The Contractor will set up above site store within one
month from the date of contract and inform the EMPLOYER. The Contractor will have
to supply above materials and receive them at these places only and the rates

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quoted by the Bidder should include charges for delivery of such materials at the
store set up by him, receipt and proper stacking/ stocking at the store.

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 SECTION-2
HTLS CONDUCTOR, HARDWARE FITTINGS & ACCESSORIES

2.01 Scope:

2.01.1 This specification covers design, engineering, manufacture, assembly, stage

testing, inspection and testing before supply and delivery at site F.O.R.
destination of HTLS Conductor restringing of 220 kV Line with existing
conductor (viz. ACSR Zebra) for Up-rating of current carrying capacity of
existing 220 kV lines and its associated Hardware Fittings & Accessories.

2.01.2 It is not the intent to specify completely herein all details of the design and
construction of conductor. However, the conductor shall conform in all respects
to high standards of engineering, design and workmanship and shall be
capable of performing in continuous commercial operation. The Purchaser, who
will interpret the meanings of drawings and specification, shall have the power
to reject any work or material which in his judgment is not in accordance
therewith. The material offered shall be complete with all components
necessary for its effective and trouble free operation. Such components shall
be deemed to be within the scope of Bidder's supply only, irrespective of
whether these are specifically mentioned in his specification and/or the
commercial order or not.

2.01.3 Submission of complete Technical details of the proposed HTLS conductor with
relevant calculation to adjudge the sufficiency of existing Towers for carrying
out the up-rating works. This shall be carried out in strict compliances/
adherence to all safety and standards requirements as per Indian Electricity
Rules/IS.

2.01.4 The scope also includes detailed survey of existing line & preparation of profile
with existing tower and proposed conductor indicating all types of crossings to
ascertain sufficient clearances available as per IS/IE rules. Design and
submission of detailed drawings of hardware and accessories. Preparation and
submission of stringing chart etc. are included in the scope of the Bidder.

2.01.5 The General Technical Requirement of Zebra equivalent HTLS Conductor is

detailed in the tender specification. The offered HTLS conductor should comply
these general requirement or should have improved parameters as compared
to the HTLS Conductor specified in the tender specification. For comparision
purpose Bidders are required to submit detailed/calculations in this regard
separetly alongwith their offer preferably in Hard copies.

2.01.6 Disclaimer:- The bidders may please note that the technical parameters
indicated in the tender specification are indicative only and the actual
parameters shall be as per the relevant Indian or Internationally accepted
specifications

In this regard the Bidder may note that the general requirement of ACSR Zebra
equivalent HTLS Conductor are indicated in the Technical specification. Further the
offered HTLS conductor should have parameters equivalent to HTLS Conductor
specified in Technical specification OR Improved parameters as compared to Conductor
parameters specified in the Technical specification.Further the Technical Particulars of
offered HTLS Conductor should confirm to their relevant Indian or Internationally
accepted specifications and also the Type tests conducted on conductors of offered
technology shall acceptable

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2.02 The HTLS Conductor shall meet the following minimum requirements:

(i) Overall diameter of complete conductor Overall diameter of the

conductor should be less
than or equal to 28.62
mm. Approx.
(ii) Mass of complete conductor (kg/Km) Less than or equal to 1621
kg/km
(iii) Direction of lay of outer layer Right Hand

(iv) UTS of offered conductor shall be equal to or higher than UTS of

ACSR Zebra conductor.

(v) Mid span clearances of top conductor with respect to earth wire
shall be maintained as per IS.

(vi) Overall conductor design should be such that it can carry minimum 1400
Amperes with allowable maximum conductor temperature. Bidder can
offer higher amperes.
(vii) During any stage, in case any changes are required in offered design of
HTLS conductor to comply the stipulated requirement of technical
specification, the same shall be carried out without any extra cost to
purchaser.

(viii) The outer diameter of core may exceed diameter of Zebra core however
overall diameter should be less than or equal to Zebra ACSR.
.

(ix) DC resistance at 20ºC and AC resistance at 75ºC should be at least

15% less than ACSR Zebra conductor.

(x) The conductivity at 20 Deg C (corresponding to % IACS) of aluminum

or aluminum alloy used in the offered HTLS conductor should not be
less than the % IACS Conductivity of Aluminum used in ACSR type
conductor (IACS: International Annealed Copper Standard)

(xi) Sag of offered HTLS conductor at maximum temperature

(temperature corresponding to 1400 Amp current ) must be less
than or equal to the corresponding sag of the existing ACSR Zebra
conductor at 75 Deg C considering the same span length (350M).

(xii) Sag of offered HTLS conductor at 0°C Nil wind condition must be
more than or equal to the corresponding sag of the existing ACSR
Zebra conductor considering the same span length (350M) so as to
maintain the sag of earthwire equal to 90% of ACSR Zebra
conductor.

(xiii) Tension of offered HTLS conductor at 32°C Full wind condition

(45kg/sqm) must be less than or equal to the corresponding Tension
of the existing ACSR Zebra conductor the same span length(350M).

The bidder shall indicate the technical particulars and details of the
construction of the conductor in the relevant schedule of GTP. The bidder shall
also guarantee the DC resistance of conductor at 20 deg C and AC resistance

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 at the calculated temperature corresponding to 50Hz alternating current flow
of 1400 amperes per conductor at specified ambient conditions (maximum
continuous operating temperature).

The bidder shall submit the supporting calculations for the AC resistance
indicating details & justifications of values of temperature coefficient of
resistance & DC to AC resistance conversion factor(s) with due reference to
construction / geometry of the conductor.

2.03 Maximum Conductor sag for prevailing span (of the line in which replacement
of conductor is being carried out) at steady state conductor temperature and
no wind corresponding to 50 Hz alternating current of 1400 Amperes per
conductor under ambient conditions will be such that the statutory ground
clearance will be maintained throughout the route keeping (erection)
tension at 25% of UTS of conductor. It is to inform that the conductor has to
be strung on old existing towers.

2.04 The calculations for Ampacity shall be based on IEEE Standard 738. The bidder
in his bid shall furnish calculations for the ampacity based on the above
Standard for the proposed HTLS conductor. The design of conductor shall be
suitable for operation at a steady state conductor temperature experienced
for AC current flow of 1400 Amperes under the above ambient conditions
based on ampacity calculations mentioned above. The bidder shall also
indicate the maximum permissible conductor temperature for
continuous operation without any deterioration of its electrical, mechanical
& metallurgical properties. The bidder shall also furnish the maximum
permissible conductor temperature for short-term operations including
permissible duration of such short-term operation.The HTLS Conductor Shall
meet the following minimum requirements/assumptions for ampacity
calculation.

1. Wind velocity = 0.56m/sec

2. Solar Absorption coefficient =0.8
3. Emisitivity Constant= 0.45
4. Solar Radiation = 1045 watt/sq.m
5. Ambienttemperature: 45 deg C
6. Elevationabovesealevel = 0 m
7. Effective angle of incidence of sun‟s rays= 90 deg

2.05 Current Carrying Capacity / Ampacity Requirements

Each HTLS Conductor shall be suitable to carry minimum 50 Hz

alternating current of 1400 Amperes under the ambient conditions &
maximum conductor sag specified below while satisfying other specified
technical requirements/ parameters.

2.06 Sag-Tension Requirements

2.06.1 The HTLS Conductor shall meet the following sag tension requirements for
existing span of the line.

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 Particulars Limiting value

(i) Tension at every day condition (32°C, no wind) - 25% of UTS of proposed
conductor
(ii) Tension at 32°C, full wind (45 kg/m2) _ 3952.9 kgs & not
exceeding 70% of
UTS of proposed
conductor
(iii) Sag at Maximum continuous operating temp - Less than or equal to
(corresponding to 1400 amperes and no wind) 9.24 meters
including all of the above conditions.

(iv) The UTS of the conductor at ambient temperature and designed maximum
temperature condition shall be declared in the GTP.The UTS of the conductor shall
hold good for each of these conditions.
.

2.06.2 Sag-Tension calculations at various conditions mentioned above

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

Sag-Tension calculations: Shall be submitted comparing existing and

proposed conductor type at various temperature levels with
ampacity. The Bidder shall also furnish sag & tension under no wind, for various
temperatures starting from 0 ºC to maximum continuous operating temperature
in steps of 5 ºC. The Bidder shall also furnish sag & tension under 67% full wind 0
ºC & 100% full wind at 32 ºC for proposed conductor. The limiting values of sag-
tension are given below for ruling span of 350metres

S.no Condition Limiting Value

a 32 °C No Wind - Tension ≤ 25% of proposed
conductor UTS
b 0 °C No Wind – Sag ≥ 6.114 meters
c 0 °C 67% Full Wind - Tension ≤ 4360 kgs. (wind on
wire 30 kg/sq. mtr.)
d 32 °C 100% Full Wind - Tension ≤ 3950 kgs. (wind on
wire 45 kg/sq. mtr.)
Sag of conductor
Designed temperature ≤ 9.24 meters
e (corresponding to 1400 Amp. @
ambient conditions given (c) above)
No Wind -Sag
f Tension at knee point temperature Not exceeding limits
& no wind specified in (d) above

Sag-Tension calculation for HTLS conductor can be carried out using PLSCAD. Values
considered in cable data (.wir) file shall be justified & shared with purchaser. It shall
be existing file for offered conductor on PLS website or derived from existing file for
equivalent conductor or file derived based on type test conducted

2.06.3 The bidder shall also furnish sag & tensions under no wind for various
temperatures starting from 0˚ C to maximum continuous operating
temperature in steps of 5˚ C. After award of the contract, the Supplier shall

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 submit Sag-Tension calculations corresponding to various conditions given
above for all the existing spans and spans ranging from 50 m to 360 m in
intervals of 10m. It is to inform that the ruling span is the prevailing span as
existing conductor on existing towers is being replaced.

2.06.4 Besides above, the Supplier shall also furnish details of creep
characteristics in respect of HTLS Conductor based on laboratory
investigations/ experimentation (creep test as per IEE1138) conducted on
similar type of conductor and shall indicate creep strain values corresponding
to 1 month, 6 month, 1 year & 10 year creep at everyday tension & at
designed maximum operating temperature.

2.06.5 Evaluation of Technical parameters will be based on the following parameters:

i) DC resistance
ii) Sag
iii) Weight

2.06.6 Penalty for deviation from GTP:

On testing or during operation, if it is found that actual parameters are

deviating in excess than that are allowed as per the relevant specifications,
actions like forfeiting the Security Deposit, black listing from the
supplier/contractor etc. will be initiated.

2.06.7 Hardware & accessories should be compatible with the supplied HTLS
Conductor and existing insulators & structures.

2.06.8 Workmanship

i) All the conductor strands shall be smooth, uniform and free from all
imperfections, such as spills and splits, cracks, die marks, scratches,
abrasions, rust etc.
ii) The finished conductor shall be smooth, compact, uniform and
free from all imperfections including kinks (protrusion of wires), wire
cross over, over riding, looseness (wire being dislocated by finger/ hand
pressure and / or unusual bangle noise on tapping), material inclusions, white
rust, powder formation or black spot (on account of reaction with trapped rain
water etc),dirt, grit etc.

2.06.9 Joints in wires

a) Aluminum OR Aluminum Alloy Wires

During stranding no Aluminum/ aluminum Alloy welds shall be made for the
purpose of achieving the required conductor length.

b) Core Wires

There shall be no joint of any kind in the finished wire entering into the
manufacture of the strand. There shall also be no joints or splices in any
length of the completed stranded core. Splices of the fibers in composite cores
are allowed as long as they conform to the requirements of ASTM B987 for
Joints and Splices.

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2.06.10 Tolerances

Manufacturing tolerances on the dimensions to the extent of one percent shall

be permitted for individual strands and the complete conductor. It is to inform
that the manufacturing tolerances shall be as per IEC or relevant standards.
For composite cores, the manufacturing tolerance shall be +/- 0.05 mm of the
stated nominal value.

2.06.11 Materials

The materials used for construction of the conductor shall be such that the
conductor meets the specified technical and the performance requirements.

2.06.12 Outer Layer

The material of outer layer of HTLS Conductor with non-metallic core

shall be of annealed aluminium 1350-O temper, high temperature resistant
aluminum/ aluminum alloy added with zirconium or any other suitable
elements to electrolytic aluminum having purity not less than 99.5% and a
copper content not exceeding 0.04%. Bidder shall guarantee the chemical
composition in the schedule GTP and also furnish description of the
manufacturing process in the bid. It is to inform that the test shall be carried
out as per the relevant standards.

2.06.13 Core

The core wire strands shall be of galvanized steel wires/aluminium clad

steel wires/zinc-5% aluminium-misch metal alloy coated invar
wires/galvanized invar wire/aluminium clad invar wires/composite
materials etc and shall have properties conforming to the technical
performance requirements of the finished conductor. Bidder shall
furnish properties and composition of the core wire strands in the
schedule GTP.

The zinc used for galvanizing in case of steel/invar core shall be

electrolytic High Grade Zinc of 99.95% purity. It shall conform to and
satisfy all the requirements of IS 209. The minimum mass of zinc
coating shall be as per requirements of class –I coating as per IEC888.
Zinc-5% aluminium-misch metal alloy coating if used, shall confirm to
ASTM B803/B958.

The aluminium cladding of invar/steel wires shall be with aluminium

having purity not less than 99.5% and shall be thoroughly bonded to
the core wire strands. The minimum thickness of aluminium cladding
shall be as per relevant IEC.

Where composite material for core is offered, the materials shall be of

such proven quality that its properties are not adversely influenced by
the normal operating conditions of 220KV transmission line in tropical
environment conditions as experienced by the existing line. The Bidder
shall provide adequate details including specifications/test reports/
operating experience details/performance certificates etc. in support of
the suitability of the offered materials.

Page 13
2.06.14 Conductor Length

The Bidder after his survey of the existing line shall determine the
most appropriate individual conductor lengths to be manufactured &
supplied keeping in view of the tower schedules, section lengths, special
crossings etc. The drum drawing as per IS 1778 or any international standard
shall be submitted to purchaser for review and approval. The Bidder shall also
indicate the maximum single length of conductor that they can manufacture, in
the GTP.

2.06.15 Standards

The conductors & accessories shall comply in all respects to the clauses of this
specification as indicated above & with the specified standards.

2.06.16 Stranding

For all, constructions, each alternate layer shall be stranded in opposite

directions. The wires in each layer shall be evenly and closely stranded round
the under laying wire or wires. The final layer of wires shall have a right hand
lay.

2.06.17 Packing

i. The conductor shall be supplied in returnable (except for

conductor to be given as mandatory spares), strong, painted
steel/hybrid (painted steel cum wood) drums provided with lagging of
adequate strength, constructed to protect the conductor against all damage
and displacement during transit, storage and subsequent handling and
stringing operations in the field. The Supplier shall select suitable drums for
supply of conductor and shall be responsible for any loss or damage to
conductor and/or drum during transportation handling and storage due to
improper selection of drum or packing.
ii. The drums shall be suitable for wheel mounting and for letting off the
conductor under a minimum controlled tension of the order of 5000 Kgf.
iii. The Bidder should submit their proposed drum drawings
along with the bid.
iv. One conductor length only shall be wound on each drum.
v. The conductor ends shall be properly sealed and secured on
the side of one of the flanges to avoid loosening of the conductor
layers during transit and handling.

2.06.18 Marking

Each drum shall have the following information stenciled on it in indelible ink
along with other essential data:

(a) Contract/Award letter number.

(b) Name and address of
consignee. (c) Manufacturer‟s
name and address. (d) Drum
number
(e) Size of conductor
(f) Length of conductor in
meters (g) Arrow marking for

Page 14
 unwinding (h) Position of the
conductor ends
(i) Distance between outer-most Layer of conductor and the inner surface
of lagging.
(k) Barrel diameter at three locations & an arrow marking at the
location of the measurement.
(l) Number of turns in the outer most layer.
(m) Gross weight of drum after putting lagging.
(n) Tear weight of the drum without lagging.
(o) Net weight of the conductor in the drum.
(p) Dispatch instruction.

The above should be indicated in the packing list also.

2.06.19 Verification of Conductor Length

The MPPTCL reserves the right to verify the length of conductor after
unreeling at least ten (10) percent of the drums in a lot offered for inspection.

2.06.20 Tests and Standards

2.06.20.1 Type Tests

i. Type Tests on Stranded Conductor/ Stranded wire:

The following tests should have been conducted in last Seven year for which
offer is made and should be submitted along with the bid. The bids without
valid type test reports are liable for rejection. Type test of offered technology
(for Zebra equivalent or higher size) will be acceptable.If any test is not
conducted,the same will have to be conducted by contractor at no extra cost to
MPPTCL. Further Type Test should have been conducted on the samples of
conductor manufactured from same stranding machine by which conductor to
be supplied will be manufactured after award of contract

All the specified type tests on HTLS Conductoroffered by the bidder shall not
be required to be carried out if valid test certificate is available i.e., tests
conducted within last Seven years from the date of bid opening in an
accredited laboratory or witnessed by the representative (s) of a Utility.

In the event of any discrepancy in the test report (i.e., any test report not
applicable due to any design/ material/manufacturing process change
including substitution of components or due to noncompliance with the
requirement stipulated in the Technical Specification) the tests shall be
conducted by the Contractor at no extra cost to MPPTCL.

On complete Conductor:
a) DC resistance test on stranded conductor: As per Annexure-A
b) UTS test on stranded conductor: As per Annexure-A
c) Stress- Strain test on stranded conductor and core at room
temperature as per IEC 1089
d) Stress-strain test on stranded conductor and core at elevated
temperature As per Annexure-A
e) High temperature endurance & creep test on stranded conductor: As
per Annexure-A
f) Sheaves Test : As per Annexure-A
g) Axial Impact Test : As per Annexure-A
h) Crush Strength Test : As per Annexure-A

Page 15
 i) Torsional Ductility Test : As per Annexure-A
j)Salt spray test on stranded carbon core conductor: As per relevant
ASTM

h) In case carbon composite core is offered then heat exposure test as per
ASTM B987 should have been conducted in any NABL Lab and type test report
is required to be submitted in bid. The Bidders are requested to submit the
Type Test Report conducted in any NABL Laboratory or withnessed by
representative of a Laboratory which is accredited to ISO/IEC 17025 other
than the laboratory where tests were performed . The same will be applicable
for Carbon Composite core also

iii. On Conductor Strand/core

a) Bending test on core: As per Annexure-A
b) Compression test on core: As per Annexure-A

c) Coefficient of linear expansion on core/ core As per Annexure-A

strands:

2.06.20.2 Acceptance Tests

a) Visual and dimensional check on drum: As per Annexure-A

b) Visual check for joints scratches etc. and length
measurement of conductor by rewinding : As per Annexure-A
c) Dimensional check on core strands/composite
core and Aluminum Alloy strands: As per Annexure-A
d) Check for lay-ratios of various layers As per Annexure-A
e) Galvanizing test on core strands (if applicable): As per Annexure-A
f) aluminum thickness on aluminum clad wires (if applicable)
g) Torsion and Elongation tests on core strands/composite core:As per Annexure-
A
h) Breaking load test on core strands and Aluminum / Aluminum Alloy strands:
As per Annexure-A
i) Wrap test on core strands and conductor. : As per IEC: 888 & IES:
889
j) Minimum conductivity test on conductor strands: As per IEC:
889
k) Ageing test on filler (if applicable): As per Annexure-A
l) Minimum conductivity test on core strands (if applicable): As per Annexure-A
m) Dimensional check on conductor
n) Galvanic layer thickness test for composite core conductor: As per ASTM
B987 (Not applicable on stranded carbon core conductor)

Note: All the above tests except (j) shall be carried out on Aluminum
/Aluminum Alloy and core strands after stranding only. It is to inform
that the test shall be carried out as per IEC or relevant standards. For
composite core conductors, all acceptance tests shall be carried out before
stranding

2.06.20.3 Routine Test

a) Check to ensure that the joints are as per Specification

b) Check that there are no cuts, fins etc., on the strands.

Page 16
 c) Check that drums are as per Specification
d) All acceptance tests as mentioned above to be carried out on 10% of coil

2.06.20.4 Tests during Manufacture

a) Chemical analysis of zinc used for galvanizing (if applicable): As per

Annexure-A
b) Chemical analysis of Aluminum alloy used form making Aluminum Alloy
strands: As per Annexure-A
c) Chemical analysis of core strands(not applicable for composite core):
As per Annexure-A

2.06.21 Test Reports

i. Record of routine test reports shall be maintained by the Supplier at his

works for periodic inspection by the MPPTCL‟s representative.
ii. Test Certificates of tests during manufacture shall be maintained by the
Supplier.
These shall be produced for verification as and when desired by the MPPTCL.

2.07 Inspection

i) MPPTCL‟s representative shall at all times be entitled to have access to

the works and all places of manufacture, where conductor shall be
manufactured and representative shall have full facilities for unrestricted
inspection of the Supplier‟s works, raw materials and process of manufacture
for conducting necessary tests as detailed herein.
ii) The Supplier shall keep MPPTCL informed in advance of the time of
starting and of the progress of manufacture of conductor in its various stages
so that arrangements can be made for inspection.
iii) No material shall be dispatched from its point of manufacture
before it has been satisfactorily inspected and tested, unless the inspection
is waived off by the MPPTCL in writing. In the latter case also the conductor
shall be dispatched only after satisfactory testing for all tests specified herein
have been completed.
iv) The acceptance of any quantity of material shall in no way relieve the
Supplier of any of his responsibilities for meeting all requirements of the
Specification, and shall not prevent subsequent rejection if such material is
later found to be defective.

2.08 Test Facilities

The following additional test facilities shall be available at the Supplier‟s works:

a) Calibration of various testing and measuring equipment including tensile

testing machine, resistance measurement facilities, burette, thermometer,
barometer etc.
b) Standard resistance for calibration of resistance bridges.
c) Finished conductor shall be checked for length verification and surface
finish on separate rewinding machine at reduced speed (variable from 8
to 16 meters per minute). The rewinding facilities shall have appropriate
clutch system and free of vibrations, jerks etc. with traverse laying facilities.

2.09 Standards

Page 17
i. The conductor shall conform to the following Indian/International
Standards, which shall mean latest revisions, with amendments/changes
adopted and published, unless specifically stated otherwise in the
Specification.
ii. In the event of the supply of conductor conforming to standards other
than specified, the Bidder shall confirm in his bid that these standards are
equivalent to those specified. In case of award, salient features of comparison
between the standards proposed by the Supplier and those specified in this
document will be provided by the Supplier to establish their equivalence.

Sl. No. Indian Title International

1 Standard
IS: 209-1992 Specification for zinc Standard
BS:3436-1986
2 IS: 398-1982 Specification for Aluminum IEC:1089-1991
Conductors for Overhead BS:215-1970
Transmission Purposes
3 IS:398-1990 Aluminum Conductor BS;215-1970
Part-II Galvanised IEC:1089-1991
Steel Reinforced
4 IS:398-1992 Aluminum Conductor IEC:1089-1991
Part-V Galvanised BS:215-1970
Steel- Reinforced For Extra
High
Voltage (400 KV) and above
5 IS : 1778- Reels and Drums for Bare BS:1559-1949
1980 Conductors
6 IS : 1521- Method of Tensile Testing of ISO 6892-1984
1991 Steel Wire
7 IS : 2629- Recommended Practice for
1990 Hot
Dip Galvanising of Iron and
Steel
8 IS : 2633- Method of Testing Uniformity
1992 of
9 IS : 4826- Coating on Zinc
Galvanised Coated
Coating on Round IEC : 888-1987
1992 Articles
Steel Wires BS:443-1969

10 IS : 6745- Methods of Determination of BS:433-1969

1990 Weight of Zinc Coating of Zinc ISO 1460 - 1973
Coated Iron and Steel Articles
11 IS : 8263- Method of Radio Interference IEC:437-1973
1990 Tests on High Voltage NEMA:107-1964
Insulators CISPR
12 IS : 9997- Aluminium Alloy Redraw Rods IEC 104 - 1987
13 1988 Zinc Coated steel wires for IEC : 888-1987
stranded Conductors
14 Hard drawn Aluminium wire IEC : 889-1987
for
15 IS:398 (Part- overhead
Aluminiumline conductors
Alloy stranded IEC : 208-1966
IV) conductor BS-3242-1970
16 Aluminium clad steel wires IEC:1232

Page 18
 17 Method of measurement of EC:468
resistivity of metallic
materials

18 Ampacity IEEE738
19 Creep
Standard Specification for
Carbon Fiber Thermoset
Polymer Matrix Composite
Core(CFC) for use in
Overhead Electrical
20 Conductors1 ASTM B987

The standards mentioned above are available from:

Reference Name and Address

Abbreviation
BS British Standards,
British Standards Institution
101, Pentonvile Road, N - 19-ND, UK
IEC/CISPR International Electro technical Commission,
Bureau Central de la Commission,
electro Technique international, 1 Rue de
verembe, Geneva, SWITZERLAND
BIS/IS Beureau Of Indian Standards.
ManakBhavan,
9, Bahadur Shah
ZafarMarg, New Delhi -
ISO 110001. INDIA
International Organisation for
Standardization.
Danish Board of Standardization
Danish Standardizing Sraat, Aurehoegvej-12
NEMA DK-2900, Heeleprup,
National Electric DENMARK.
Manufacture Association,
155, East 44th Street.
New York, NY 10017 U.S.A.

2.10 Principal Parameters:

The principle parameters of HTLS Conductorare tabulated below

PARAMETER HTLS conductor

a) Current carrying capacity ≥ 1400 Amps

Sectional area of Aluminium
b) > 428.90
(Sq.mm)
c) Total Sectional area (Sq.mm) > 484.50
d) Overall diameter (mm) ≤ 28.62
e) Approximate weight (kg/km) ≤ 1621
Maximum D.C
f) 0.06868
resistance at 20 deg. C
(Ohm/km)UTS (kN)
g) Minimum ≥ 130.32

Page 19
 Modulus of Elasticity
h) ≤ 69
(gN/Sq.meter)
Coefficient of linear expansion -6
i) ≤ 19.3 X 10
per
deg C

Page 20
 SECTION-3
TECHNICAL SPECIFICATIONS FOR HARDWARE FITTINGS &
ACCESSORIES FOR HTLS CONDUCTOR.

Technical Description of Hardware Fittings

3.01 General

3.01.1 This section details technical particulars of fittings viz. suspension clamps and
compression type dead end clamps for the HTLS Conductor to be supplied by
the bidder. Each fitting shall be supplied complete in all respects.

3.01.2 The fittings shall be suitable for attachment to suspension and tension insulator
strings along with hardware fittings and shall include 2.5 % extra fasteners
and Aluminum filler plugs. Indicative drawings of complete insulator
strings along with hardware fittings as well as indicative drawings for
suspension clamps and dead end clamps are enclosed with this specification.
The supplier shall be responsible for satisfactory performance of complete
conductor system along with fittings offered by them for continuous
operation at the maximum temperature specified by them for the conductor.

3.02 Corona and RI Performance

Sharp edges and scratches on all the hardware fittings shall be avoided. All
surfaces must be clean, smooth, without cuts and abrasions or projections. The
Supplier shall be responsible for satisfactory corona and radio interference
performance of the materials offered by him.

3.03 Maintenance

The hardware fittings offered shall be suitable for employment of hot line
maintenance technique so that usual hot line operations can be carried out
with ease, speed and safety. The technique adopted for hot line maintenance
shall be generally bare hand method & hot stick method.

3.04 5 Split Pins

Split pins shall be used with bolts & nuts.

3.05 Suspension Assembly

i. The suspension assembly, the bidder intend to supply, shall be suitable

for the HTLS Conductor. The technical details of the conductor shall be as
proposed by the bidder.
ii. The suspension assembly shall include either free centre type suspension
clamp along with standard preformed armour rods or armour grip suspension clamp
iii. The suspension clamp along with standard preformed armour rods set
shall be designed to have maximum mobility in any direction and minimum
moment of inertia so as to have minimum stress on the conductor in the case
ofoscillation of the same.
iv. The suspension clamp suitable for various type of Conductor along
with standard preformed armor rods/armor grip suspension clamp set shall have
slip strength between 20 to 29 KN.
v. The suspension clamp shall be designed for continuous operation
at the temperature specified by the bidder for conductor.
vi. The suspension assembly shall be designed, manufactured and finished to
give it a suitable shape, so as to avoid any possibility of hammering
between suspension assembly and conductor due to vibration. The suspension

Page 21
 assembly shall be smooth without any cuts, grooves, abrasions, projections,
ridges or excrescence which might damage the conductor.
vii. The suspension assembly/clamp shall be designed so that it shall
minimize the static & dynamic stress developed in the conductor under various
loading conditions as well as during wind induced conductor vibrations. It shall
also withstand power arcs & have required level of Corona/RIV performance.
viii. The magnetic power loss shall not be more than 4 watts per suspension
clamp, at designed rated sub-conductor current of 1400 amperes.

3.06 Free Centre Type Suspension Clamp

For the Free Centre Suspension Clamp seat shall be smoothly rounded and curved
into a bell mouth at the ends. The lip edges shall have rounded bead. There shall
be at least two U-bolts for tightening of clamp body and keeper pieces together.

3.07 Standard Preformed Armour Rod Set

i. The Preformed Armour Rods Set shall be used to minimize the stress
developed in the sub-conductor due to different static and dynamic loads because
of vibration due to wind, slipping of conductor from the suspension clamp as a
result of unbalanced conductor tension in adjacent spans and broken wire
condition. It shall also withstand power arcs. Chafing and abrasion from suspension
clamp and localized heating effect due to magnetic power losses from
suspension clamps as well as resistance losses of the conductor.
ii. The preformed armour rods set shall have right hand lay and the inside
diameter of the helices shall be less than the outside diameter of the conductor to
have gentle but permanent grip on the conductor. The surface of the armour rod
when fitted on the conductor shall be smooth and free from projections, cuts and
abrasions etc.
iii. The pitch length of the rods shall be determined by the Bidder but shall be
less than that of the outer layer of conductor and the same shall be
accurately controlled to maintain uniformity and consistently reproducible
characteristic wholly independent of the skill of linemen.
iv. The length of each rod shall not be less than 1930 ± 25 mm and diameter
shall not be less than 6.35 + 0.10 mm. The tolerance in length of the rods in
complete set should be within 13 mm between the longest and shortest rod. The
ends of armour rod shall be parrot billed.
v. The number of armour rods in each set shall be eleven. Each rod shall be
marked in the middle with paint for easy application on the line.
vi. The armour rod shall not loose their resilience even after five applications.
vii. The conductivity of each rod of the set shall not be less than 40% of the
conductivity of the International Annealed Copper Standard (IACS).

3.08 Armour Grip Suspension Clamp

i. The armour grip suspension clamp shall comprise of retaining strap,

support housing, elastomeric inserts with aluminum reinforcements and AGS
preformed rod set.
ii. Elastomeric insert shall be resistant to the effects of temperature up to
maximum conductor temperature guaranteed by the bidder corresponding to peak
current, Ozone, ultraviolet radiations and other atmospheric contaminants likely to
be encountered in service. The physical properties of the elastomer shall be of
approved standard. It shall be electrically shielded by a cage of AGS performed
rod set. The elastomer insert shall be so designed that the curvature of the AGS
rod shall follow the contour of the neoprene insert.
iii. The length of the AGS preformed rods shall be such that it shall
ensure sufficient slipping strength and shall not introduce unfavourable stress on
the conductor under all operating conditions. However the length of AGS preformed
rods shall not be less than 1760 + 16 mm for HTLS Conductor

Page 22
 i) The dead end assembly shall be suitable for the proposed HTLS Conductor.
ii) The dead end assembly shall be of compression type with provision
for compressing jumper terminal at one end. The angle of jumper terminal to be
mounted should be 30° with respect to the vertical line. The area of bearing
surface on all the connections shall be sufficient to ensure positive electrical and
mechanical contact and avoid local heating due to I2R losses. The resistance of
the clamp when compressed on Conductor shall not be more than 75% of the
resistance of equivalent length of Conductor.
iii) Die compression areas shall be clearly marked on each dead-end
assembly designed for continuous die compressions and shall bear the words „COM
PRESS FIRST‟ suitably inscribed near the point on each assembly where the
compression begins. If the dead end assembly is designed for intermittent die
compressions it shall bear identification marks „COMPRESSION ZONE‟ AND „NON-
COMPRESSION ZONE‟ distinctly with arrow marks showing the direction of
compressions and knurling marks showing the end of the zones. Tapered
aluminum filler plugs shall also be provided at the line of demarcation between
compression & non-compression zone. The letters, number and other markings on
the finished clamp shall be distinct and legible. The dimensions of dead end
assembly before & after compression along with tolerances shall be shall be
guaranteed in the relevant schedules of the bid and shall be decided by
the manufacturer so as to suit the conductor size & conform to electrical
& mechanical requirement stipulated in the specification.
iv) The assembly shall not permit slipping of, damage to, or failure of the
complete conductor or any part thereof at a load less than 95% of the
ultimate tensile strength of the conductor.

3.09 Fasteners: Bolts, Nuts and Washers

i) All bolts and nuts shall conform to IS 6639. All bolts and nuts shall be
galvanised as per IS 1367(Part-13)/IS 2629. All bolts and nuts shall have
hexagonal heads, the heads being forged out of solid truly concentric, and square
with the shank, which must be perfectly straight.
ii) Bolts upto M16 and having length upto 10 times the diameter of the bolt
should be manufactured by cold forging and thread rolling process to obtain
good and reliable mechanical properties and effective dimensional control. The
shear strength of bolt for 5.6 grade should be 310 MPa minimum as per IS 12427.
Bolts should be provided with washer face in accordance with IS 1363 (Part-1) to
ensure proper bearing.
iii) Nuts should be double chamfered as per the requirement of IS 1363 Part-
III 1984. It should be ensured by the manufacturer that nuts should not be
over tapped beyond 0.4 mm oversize on effective diameter for size upto M16.
iv) Fully threaded bolts shall not be used. The length of the bolt shall be such
that the threaded portion shall not extend into the place of contact of the
component parts.
v) All bolts shall be threaded to take the full depth of the nuts and threaded
enough to permit the firm gripping of the component parts but no further. It shall
be ensured that the threaded portion of the bolt protrudes not less than 3 mm
and not more than 8 mm when fully tightened. All nuts shall fit and tight to the
point where shank of the bolt connects to the head.
vi) Flat washers and spring washers shall be provided wherever necessary
and shall be of positive lock type. Spring washers shall be electro-galvanized. The
thickness of washers shall conform to IS: 2016.
vii) The Contractor shall furnish bolt schedules giving thickness of
components connected the nut and the washer and the length of shank and the
threaded portion of bolts and size of holes and any other special details of this
nature.
viii) To obviate bending stress in bolt, it shall not connect aggregate
thickness more than three time its diameter.

Page 23
 ix) Bolts at the joints shall be so staggered that nuts may be tightened with
spanners without fouling.
x) To ensure effective in-process Quality control it is essential that the
manufacturer should have all the testing facilities for tests like weight of zinc
coating, shear strength, other testing facilities etc, in-house. The manufacturer
should also have proper Quality Assurance system which should be in line with
the requirement of this specification and IS-.14000 services Quality System
standard.
xi) Fasteners of grade higher than 8.8 are not to be used and minimum grade
for bolt shall be 5.6.

3.10 Materials
The materials of the various components shall be as specified hereunder. The
Bidder shall indicate the material proposed to be used for each and every
component of hardware fittings stating clearly the class, grade or alloy
designation of the material, manufacturing process & heat treatment details and
the reference standards. The details of materials for different component are listed
as in Table No-1.

3.11 Workmanship

i) All the equipment shall be of the latest design and conform to the best
modern practices adopted in the Extra High Voltage field. The Bidder shall offer
only such equipment as guaranteed by him to be satisfactory and suitable for 220
kV transmission lines and will give continued good performance.
ii) High current, heat rise test shall be conducted by the supplier to
determine the maximum temperature achieved in different components of
fittings under simulated service condition corresponding to continuous operation
of conductor at rated maximum temperature. The material of the components
should be suitable for continued good performance corresponding to these
maximum temperatures. The supplier shall submit relevant type/performance test
certificates as per applicable standards/product specifications to confirm suitability
of the offered material.
iii) The design, manufacturing process and quality control of all the materials
shall be such as to give the specified mechanical rating, highest mobility,
elimination of sharp edges and corners to limit corona and radio-interference, best
resistance to corrosion and a good finish.
iv) All ferrous parts including fasteners shall be hot dip galvanized,
after all machining has been completed. Nuts may, however, be tapped
(threaded) after galvanizing and the threads oiled. Spring washers shall be electro
galvanized. The bolt threads shall be undercut to take care of the increase in
diameter due to galvanizing. Galvanizing shall he done in accordance with IS
2629 / IS 1367 (Part-13) and shall satisfy the tests mentioned in IS 2633.
Fasteners shall withstand four dips while spring washers shall withstand three dips
of one minute duration in the standard Peerce test. Other galvanized materials
shall have a minimum average coating of zinc equivalent to 600 gm/sq.m., shall
be guaranteed to withstand at least six successive dips each lasting one (1) minute
under the standard Peerce test for galvanizing.
v) The zinc coating shall be perfectly adherent of uniform thickness,
smooth, reasonably bright continuous and free from imperfections such as flux,
ash rust, stains, bulky white deposits and blisters. The zinc used for galvanizing
shall be grade Zn 99.95 as per IS: 209.
vi) In case of casting, the same shall be free from all internal defects like
shrinkage, inclusion, blow holes, cracks etc. Pressure die casting shall not be used
for casting of components with thickness more than 5 mm.
vii) All current carrying parts shall be so designed and manufactured that
contact resistance is reduced to minimum.
viii) No equipment shall have sharp ends or edges, abrasions or projections
and cause any damage to the conductor in any way during erection or during

Page 24
 continuous operation which would produce high electrical and mechanical stresses
in normal working. The design of adjacent metal parts and mating surfaces shall
be such as to prevent corrosion of the contact surface and to maintain good
electrical contact under service conditions.
ix) All the holes shall be cylindrical, clean cut and perpendicular to the plane
of the material. The periphery of the holes shall be free from burrs.
x) All fasteners shall have suitable corona free locking arrangement to guard
against vibration loosening.
xi) Welding of aluminum shall be by inert gas shielded tungsten arc or
inert gas shielded metal arc process. Welds shall be clean, sound, smooth,
uniform without overlaps, properly fused and completely sealed. There shall be no
cracks, voids incomplete penetration, incomplete fusion, under-cutting or
inclusions. Porosity shall be minimized so that mechanical properties of the
aluminum alloys are not affected. All welds shall be properly finished as per good
engineering practices.

3.12 Bid Drawings

i) The Bidder shall furnish full description and illustrations of materials offered.
ii) Fully dimensioned drawings of the hardware and their component parts
shall be furnished in two (2) copies along with the bid. Weight, material and
fabrication details of all the components should be included in the drawings.
iii) All drawings shall be identified by a drawing number and contract
number. All drawings shall be neatly arranged. All drafting & lettering shall be
legible. The minimum size of lettering shall be 3 mm. All dimensions &
dimensional tolerances shall be mentioned in mm.
iv) The drawings shall include :
a) Dimensions and dimensional tolerance.
b) Material, fabrication details including any weld details & any specified
finishes & coatings. Regarding material designation & reference of standards
are to be indicated.
c) Catalogue No.
d) Marking
e) Weight of assembly
f) Installation instructions
g) Design installation torque for the bolt or cap screw.
h) Withstand torque that may be applied to the bolt or cap screw without
failure of component parts.
i) The compressions die number with recommended compression pressure. j)
All other relevant terminal details.

v) After placement of award, the Contractor shall submit fully dimensioned

drawing including all the components in three (3) copies to MPPTCL for approval.
After getting approval from the MPPTCL and successful completion of all the
type tests, the Contractor shall submit ten (10) more copies of the same
drawings to the MPPTCL for further distribution and field use at MPPTCL end.

TABLE-1 (Details of Materials)

S. Name of item Material Process of Reference Remarks

No Treatment Standard
1. Security Clips Stainless Steel/ - AISI 302 or -
Phosphor 304-L/ IS-
Bronze 1385

Page 25
2. Arcing Horn Mild Steel Rod/ Hot dip As per IS- -
Tube Type galvanised 226
or IS-2062
3. Ball Fittings, Class-IV Steel Drop forged & As per IS:
Socket, all normalized Hot 2004
shackles Links dip galvanised
Cleves
4. Yoke Plate Mild Steel Hot dip As per IS-
galvanized 226
or IS-2062
5. Sag Mild Steel Hot dip As per IS-
Adjustment galvanized 226
Plate or IS-2062
6(a). Corona Control High Strength Heat treated ASTM-B429 Mechanical
ring/ Grading Al. Hot or as per IS strength of
ring Alloy tube dip galvanized welde
(6061/ d joint
6063/1100 shall not
type or be less
65032/ 63400 than 20
Type) KN
6(b). Supporting High Strength Heat treated ASTM-B429
Brackets & Al Hot or as
Mounting Alloy 7061/ dip galvanized per
Bolts 6063/ IS:226
65032/63400 or
Type) IS:2062
7(a). Dead End or
EC Mild Steel
grade Al of
Assembly purity not
: Outer less than
Sleeve 99.50%
7(b). Steel Sleeve Mild Steel Hot Dip IS:226/
Galvanised IS-2062

Note: Alternate materials conforming to other national standards of other

countries also may be offered provided the properties and compositions of these
are close to the properties and compositions of material specified. Bidder should
furnish the details of comparison of material offered vis a vis specified in the bid
or else the bids are liable to be rejected.

Page 26
 SECTION-4

ACCESSORIES FOR THE HTLS CONDUCTOR

General

This portion details the technical particulars of the accessories for Conductor.

4.01 2.5% extra fasteners, filler plugs and retaining rods shall be provided.

4.02 The supplier shall be responsible for satisfactory performance of complete conductor
system along with accessories offered by him for continuous operation at
temperature specified for the HTLS Conductor .

4.03 Mid Span Compression Joint

i. Mid Span Compression Joint shall be used for joining two lengths of conductor.
The joint shall have a resistively less than 75% of the resistivity of equivalent
length of conductor. The joint shall not permit slipping off, damage to or failure of
the complete conductor or any part thereof at a load less than 95% of the ultimate
tensile strength of the conductor. It must be able to withstand the continuous
design temperature of conductor.

ii. The dimensions of mid span compression joint before & after compression along
with tolerances shall be shall be guaranteed in the relevant schedules of the bid and
shall be decided by the manufacturer so as to suit the conductor size & conform to
electrical & mechanical requirement stipulated in the specification.

4.04 Connector

Connector of compression type shall be used for jumper connection at tension

tower. It shall be manufactured out of 99.5% pure aluminum / aluminum alloy
and shall be strong enough to withstand normal working loads as well as able
to withstand the continuous maximum operating temperature of conductor. The
connector shall have a resistivity across jumper less than 75% resistivity of
equivalent length of conductor. The connector shall not permit slipping off, damage
to or failure of complete conductor. The welded portions shall be designed for 30 kN
axial tensile load. Leg sleeve of connector should be kept at an angle of 15 deg.
from vertical and horizontal plane of the conductor in order to minimize jumper pull
at the welded portion. The dimensions of connector along with tolerances shall be
guaranteed in the relevant schedules of the bid and shall be decided by the
manufacturer so as to suit the conductor size & conform to electrical & mechanical
requirement stipulated in the specification.

4.05 Repair Sleeve

Repair Sleeve of compression type shall be used to repair conductor with not more
than two strands broken in the outer layer. The sleeve shall be manufactured
from 99.5% pure aluminum / aluminum alloy and shall have a smooth surface. It
shall be able to withstand the continuous maximum operating temperature of
conductor. The repair sleeve shall comprise of two pieces with a provision of seat
for sliding of the keeper piece. The edges of the seat as well as the keeper piece
shall be so rounded that the conductor strands are not damaged during installation.
The dimensions of Repair sleeve along with tolerances shall be guaranteed in the
relevant schedules of the bid and shall be decided by the manufacturer so as to
suit the conductor size & conform to electrical & mechanical requirement stipulated
in the specification.

Page 27
4.06 Vibration Damper

i. Vibration dampers of 4R-stockbridge type are installed in the existing line

at suspension and tension points on each conductor in each span along with bundle
spacers to damp out Aeolian vibration as well as sub- span oscillations. One damper
minimum on each side per sub-conductor for suspension points and two dampers
minimum on each side per sub-conductor for tension points has been used for a
ruling design span of the line for which replacement of conductor is being carried
out.
ii. The bidder shall offer damping system including Stockbridge type dampers
and bundle spacers for HTLS Conductorfor its protection from wind induced
vibrations which could cause conductor fatigue /strand breakage near a hardware
attachment, such as suspension clamps. Alternate damping systems with proven
design offering equivalent or better performance also shall be accepted provided the
manufacturer meets the qualifying requirements stipulated in the Specifications.

Relevant technical documents including type test reports to establish the

technical suitability of alternate systems shall be furnished by the Bidder along with
the bid. The damper shall be designed to have minimum 4 nos. of
resonance frequencies to facilitate dissipation of vibration energy through inter
strand friction of the messenger cable and shall be effective in reducing
vibration over a wide frequency range (depending upon conductor dia) or wind
velocity range specified above. The vibration damper shall meet the requirement of
frequency or wind velocity range and also have mechanical impedance closely
matched with the offered HTLS Conductor. The vibration dampers shall be installed
at suitable positions to ensure damping effectiveness across the frequency range.
The power dissipation of the vibration dampers shall exceed the wind power so
that the vibration level on the conductor is reduced below its endurance limit i.e.
150 micro strains. The bidder shall clearly indicate the method for evaluating
performance of dampers including analytical and laboratory test methods. The
bidder shall indicate the type tests to evaluate the performance of offered damping
system.

iii. The clamp of the vibration damper shall be made of high strength
aluminum alloy of type LM-6. It shall be capable of supporting the damper and
prevent damage or chafing of the conductor during erection or continued operation.
The clamp shall have smooth and permanent grip to keep the damper in position on
the conductor without damaging the strands or causing premature fatigue failure of
the conductor under the clamp. The clamp groove shall be in uniform contact with
the conductor over the entire clamping surface except for the rounded edges.
The groove of the clamp body and clamp cap shall be smooth, free from
projections, grit or other materials which could cause damage to the conductor
when the clamp is installed. Clamping bolts shall be provided with self locking nuts
and designed to prevent corrosion of threads or loosening in service.

iv. The messenger cable shall be made of high strength galvanised steel/stain
less steel with a minimum strength of 135 kg/sq.mm. It shall be of preformed and
post formed quality in order to prevent subsequent drop of weight and to
maintain consistent flexural stiffness of the cable in service. The messengers cable
other than stainless steel shall be hot dip galvanised in accordance with the
recommendations of IS: 4826 for heavily coated wires.

v. The damper mass shall be made of hot dip galvanised mild steel/cast iron
or a permanent mould cast zinc alloy. All castings shall be free from defects such as
cracks, shrinkage, inclusions and blowholes etc. The surface of the damper
masses shall be smooth.
vi. The damper clamp shall be casted over the messenger cable and offer
sufficient and permanent grip on it. The messenger cable shall not slip out of the

Page 28
 grip at a load less than the mass pull-off value of the damper. The damper masses
made of material other-than zinc alloy shall be fixed to the messenger cable in
a suitable manner in order to avoid excessive stress concentration on the
messenger cables which shall cause premature fatigue failure of the same. The
messenger cable ends shall be suitably and effectively sealed to prevent corrosion.
The damper mass made of zinc alloy shall be casted over the messenger cable and
have sufficient and permanent grip on the messenger cable under all service
conditions.
vii. The damper assembly shall be so designed that it shall not introduce
radio interference beyond acceptable limits.
viii. The vibration damper shall be capable of being installed and removed
from energized line by means of hot line technique. In addition, the clamp shall
be capable of being removed and reinstalled on the conductor at the designated
torque without shearing or damaging of fasteners.
ix. The contractor must indicate the clamp bolt tightening torque to ensure
that the slip strength of the clamp is maintained between 2.5 kN and 5 kN. The
clamp when installed on the conductor shall not cause excessive stress
concentration on the conductor leading to permanent deformation of the conductor
strands and premature fatigue failure in operation.
x. The vibration analysis of the system, with and without damper and
dynamic characteristics of the damper as detailed under Annexure-A, shall have to
be submitted. The technical particulars for vibration analysis and damping design
of the system are as follows:
S. No. Description Technical particulars
1. Span length in meters
i) Ruling Design Span Prevailing
ii) Maximum span span
iii) Minimum span Prevailing
2. Configuration span
Double / Single Circuit
Prevailing per phase in
conductor
span
prevailing configuration.
3. Tensile load in Conductor at ≤ 2884 kgF
temperature of 0 deg. C and still air
4. Armour rods used Standard preformed armour
rods/AGS
5. Maximum permissible +/- 150 micro strains
Dynamic strain i.e. endurance limit.

xi. The damper placement chart shall be submitted for spans ranging from 50
m to 350 m. Placement charts should be duly supported with relevant technical
documents and sample calculations.

xii. The damper placement charts shall include the following

1) Location of the dampers for various combinations of spans and line tensions
clearly indicating the number of dampers to be installed per conductor per span.
2) Placement distances clearly identifying the extremities between which the
distances are to be measured.
3) Placement recommendation depending upon type of suspension clamps (viz
free centre type/Armour grip type etc.)
4) The influence of mid span compression joints, repair sleeves & armour rods
(standard& AGS) in the placement of dampers.

4.07 Material and Workmanship

i. All the equipment shall be of the latest proven design and conform to the
best modern practice adopted in the extra high voltage field. The Bidder shall offer

Page 29
 only such equipment as guaranteed by him to be satisfactory and suitable for
220 kV transmission line applications with HTLS Conductorand will give continued
good performance at all service conditions.
ii. The design, manufacturing process and quality control of all the materials
shall be such as to achieve requisite factor of safety for maximum working load,
highest mobility, elimination of sharp edges and corners, best resistance to
corrosion and a good finish.
iii. High current, heat rise test shall be conducted by the supplier to
determine the maximum temperature achieved in different components of fittings
under simulated service condition corresponding to continuous operation of
conductor at rated maximum temperature. The material of the components should
be suitable for continued good performance corresponding to these maximum
temperatures. The supplier shall submit relevant type/ performance test certificates
as per applicable standards/product specifications to confirm suitability of the
offered material.
iv. All ferrous parts shall be hot dip galvanised, after all machining has
been completed. Nuts may, however, be tapped (threaded) after galvanising and
the threads oiled. Spring washers shall be electro galvanised as per grade 4 of
IS-1573. The bolt threads shall be undercut to take care of increase in diameter
due to galvanising. Galvanising shall be done in accordance with IS:2629/ IS-
1367 (Part-13) and satisfy the tests mentioned in IS-2633. Fasteners shall
withstand four dips while spring washers shall withstand three dips. Other
galvanised materials shall have a minimum average coating of Zinc
equivalent to 600gm/sq.m and shall be guaranteed to withstand at least six dips
each lasting one minute under the standard Peerce test for galvanising unless
otherwise specified.
v. The zinc coating shall be perfectly adherent, of uniform thickness, smooth,
reasonably bright, continuous and free from imperfections such as flux, ash, rust
stains, bulky white deposits and blisters. The zinc used for galvanising shall be of
grade Zn 99.95 as per IS: 209.
vi. In case of castings, the same shall be free from all internal defects
like hrinkage, inclusion, blow holes, cracks etc.
vii. All current carrying parts shall be so designed and manufactured that
contact resistance is reduced to minimum and localized heating phenomenon is
averted.
viii. No equipment shall have sharp ends or edges, abrasions or projections and
shall not cause any damage to the conductor in any way during erection or
during continuous operation which would produce high electrical and
mechanical stresses in normal working. The design of adjacent metal parts and
mating surfaces shall be such as to prevent corrosion of the contact surface and
to maintain good electrical contact under all service conditions.
ix. Particular care shall be taken during manufacture and subsequent
handling to ensure smooth surface free from abrasion or cuts.
x. The fasteners shall conform to the requirements of IS: 6639-1972. All
fasteners and clamps shall have corona free locking arrangement to guard
against vibration loosening.

4.08 Compression Markings

Die compression areas shall be clearly marked on each equipment designed for
continuous die compressions and shall bear the words „COMPRESS FIRST‟
„suitably inscribed on each equipment where the compression begins. If the
equipment is designed for intermittent die compressions, it shall bear the
identification marks „COMPRESSION ZONE‟ and „NON-COMPRESSION ZONE‟ distinctly
with arrow marks show the direction of compression and knurling marks showing the
end of the zones. The letters, number and other markings on finished equipment
shall be distinct and legible.

4.09 Bid Drawings

Page 30
 i. The Bidder shall furnish detailed dimensioned drawings of the
equipments and all component parts. Each drawing shall be identified by a drawing
number and Contract number. All drawings shall be neatly arranged. All drafting and
lettering shall be legible. The minimum size of lettering shall be 3mm. All dimensions
and dimensional tolerances shall be mentioned in mm.
ii. The drawings shall include
a. Dimensions and dimensional tolerances
b. Material fabrication details including any weld details and any
specified finishes and coatings. Regarding material, designations and reference of
standards are to be indicated.
c. Catalogue No. d. Marking
e. Weight of assembly
f. Installation instructions
g. Design installation torque for the bolt or cap screw
h. Withstand torque that may be applied to the bolt or cap screw without
failure of component parts
i. The compression die number with recommended compression
pressure.
j. All other relevant technical details

iii. Placement charts for spacer/spacer damper and damper

The above drawings shall be submitted with all the details as stated above
along with the bid document. After the placement of award, the contractor shall
again submit the drawings in three copies to the MPPTCL for approval. After
MPPTCL‟s approval and successful completion of all type tests, 20 (twenty) more
sets of drawings shall be submitted to MPPTCL for further distribution and field use
at MPPTCL‟s end.

4.10 Tests and Standards

Type Tests (Type tests should have been completed during last five years)

All the specified type tests on Hardware Fittings and Accessories for HTLS
Conductoroffered by the bidder shall not be required to be carried out if valid test
certificate is available i.e., tests conducted within last five years from the date of bid
opening in an accredited laboratory or witnessed by the representative (s) of a
Utility. In the event of any discrepancy in the test report (i.e., any test report
not applicable due to any design / material/ manufacturing process change including
substitution of components or due to non compliance with the requirement
stipulated in the Technical Specification) the tests shall be conducted by the
Contractor at no extra cost to the MPPTCL.

4.10.1 On Suspension Clamp

a) Magnetic power loss test: As per Annexure-B

b) Clamp slip strength Vs torque: As per Annexure-B

c) Ozone Test on elastomer: As per Annexure-B

4.10.2 On Dead end Tension Assembly

a) Electrical resistance test for dead end Assembly: As per IS:2486-(Part-I)
b) Heating cycle test for dead end Assembly: As per IS:2486-(Part-I)
c) Slip strength test for dead end assembly: As per IS:2486-(Part-I)
d) Ageing test on filler (if applicable): As per Annexure-B

4.10.3 Mid Span Compression Joint for Conductor

Page 31
 a) Chemical analysis of materials: As per Annexure-B
b) Electrical resistance test: As per IS: 2121 (Part-II)
c) Heating cycle test: As per IS: 2121 (Part-II)
d) Slip strength test: As per Annexure-B
e) Corona extinction voltage test (dry): As per Annexure-B
f) Radio interference voltage test (dry): As per Annexure-B

4.10.4 Repair Sleeve for Conductor

a) Chemical analysis of materials: As per Annexure-B

b) b) Corona extinction voltage test (dry): As per Annexure-B
c) c) Radio interference voltage test (dry): As per Annexure-B

4.10.5 Connector for Conductor

a) Chemical analysis of materials: As per Annexure-B
b) Electrical resistance test: As per IS: 2121 (Part-II) Clause 6.5 & 6.6 c)
Heating cycle test: As per IS: 2121 (Part-II)
d) Axial tensile load test on welded portion: As per Annexure-B
e) Corona extinction voltage test (dry): As per Annexure-B
f) Radio interference voltage test (dry): As per Annexure-B

4.10.6 Vibration Damper for Conductor

a) Chemical analysis of materials: As per Annexure-B

b) Dynamic characteristics test*: As per Annexure-B
c) Vibration analysis: As per Annexure-B
d) Clamp slip test: As per Annexure-B
e) Fatigue tests: As per Annexure-B
f) Magnetic power loss test: As per Annexure-B
g) Corona extinction voltage test (dry): As per Annexure-B
h) Radio interference voltage test (dry): As per Annexure-B
i) Damper efficiency test: As per IS:9708

* Applicable for 4 R stock bridge dampers. For alternate type of vibration dampers
(permitted as per clause 4.7), as an alternative to dynamic characteristic test,
damper efficiency test as per IEEE-664 Power Manual may be proposed/ carried out
by the supplier.

4.11 Acceptance Tests

4.11.1 On Both Suspension Clamp and Tension Assembly

a) Visual Examination : As per IS:2486-(Part-I)

b) Verification of dimensions : As per IS:2486-(Part-I)
c) Galvanising/Electroplating test : As per IS:2486-(Part-I)
d) Mechanical strength test of each component : As per Annexure-B
e) Mechanical Strength test of welded joint : As per Annexure-B
f) Chemical analysis, hardness tests, grain size,inclusion rating & magnetic particle
inspection for forgings/castings : As per Annexure-B

4.11.2 On Suspension Clamp only

a) Clamp Slip strength Vs Torque test for suspension clamp: As per Annexure-B
b) Shore hardness test of elastomer cushion for AG suspension clamp
: As per Annexure-B
c) Bend test for armour rod set : As per IS:2121(Part-I),Clause 7.5,7,10 &7.11
d) Resilience test for armour rod set : As per IS:2121(Part-I), Clause 7.5,7,10 & 7.11

Page 32
e) Conductivity test for armour rods set : As per IS:2121(Part-I), Clause 7.5,7,10 &
7.11

Page 33
 4.11.3 On Tension Hardware Fittings only

a) Slip strength test for dead end assembly : As per IS:2486 (Part-I) Clause 5.4 b)
Ageing test on filler (if applicable): As per Annexure-C

4.11.4 On Mid Span Compression Joint for Conductor

a) Visual examination and dimensional verification : As per IS:2121(Part-II), Clause

6.2, 6.3, 7 6.7
b) Galvanising test : As per Annexure-C
c) Hardness test : As per Annexure-C
d) Ageing test on filler (if applicable): As per Annexure-C

4.11.5 Connector for Conductor

a) Visual examination and dimensional verification: As per IS: 2121(Part-II)

b) Axial tensile load test for welded portion: As per Annexure-B

4.11.6 Repair Sleeve for Conductor

a) Visual examination and dimensional verification: As per IS:2121(Part-II) Clause
6.2, 6.3

4.11.7 Vibration Damper for Conductor

a) Visual examination and dimensional verification: As per IS: 2121(Part-II) Clause

6.2, 6.3, 7 6.7
b) Galvanising test: As per Annexure-C
(i) On damper masses: As per Annexure-C
(ii) On messenger cable : As per Annexure-C
c) Verification of resonance frequencies : As per Annexure-C
d) Clamp slip test : As per Annexure-C
e) Clamp bolt torque test : As per Annexure-C
f) Strength of the messenger cable : As per Annexure-C
g) Mass pull off test : As per Annexure-C
h) Dynamic characteristics test* : As per Annexure-C
* Applicable for 4 R stockbridge dampers. For alternate type of vibration dampers
(permitted as per clause 4.2.7), as an alternative to dynamic characteristic test,
damper efficiency test as per IEEE-664 Power Manual may be proposed/ carried out by
the supplier.

4.12 Routine Tests

4.12.1 For Hardware Fittings

a) Visual examination IS:2486-(Part-I)

b) Proof Load Test : As per Annexure-B

4.12.2 For conductor accessories

a) Visual examination and dimensional verification: As per IS:2121(Part-II)
Clause 6.2, 6.3 7 6.7

4.12.3 Tests During Manufacture on all components as applicable

a) Chemical analysis of Zinc used for galvanising IS: 2486-(Part-I)

Page 34
 b) Chemical analysis mechanical metallographic test and magnetic particle
inspection for malleable castings : As per Annexure-B
c) Chemical analysis, hardness tests and magnetic particle inspection for
forging: As per Annexure-B

If any of the above type tests have not been made, the supplier should furnish an
undertaking with the bid that the test reports to be furnished before offering call for
acceptance test. Otherwise the EMD will be forfeited; the bidder will not be eligible to
participate in future tenders of MPPTCL.

4.12.4 Co-ordination for testing

The Contractors shall have to co-ordinate testing of their hardware fittings with
insulators to be supplied by other Supplier to the MPPTCL and shall have to also
guarantee overall satisfactory performance of the hardware fittings with the insulators.

4.12.5 Inspection

i. The MPPTCL‟s representative shall at all times be entitled to have access to

the works and all places of manufacture, where the material and/or its component
parts shall be manufactured and the representatives shall have full facilities for
unrestricted inspection of the Contractor‟s, sub-Contractor‟s works raw materials.
Manufacturer‟s of all the material and for conducting necessary tests as detailed
herein.
ii. The material for final inspection shall be offered by the Contractor only under
packed condition as detailed in clause 4.2.16 of this part of the Specification. The
engineer shall select samples at random from the packed lot for carrying out
acceptance tests.
iii. The Contractor shall keep MPPTCL informed in advance of the time of starting
and of the progress of manufacture of material in its various stages so that
arrangements could be made for inspection.
iv. Material shall not be dispatched from its point of manufacture before it
has been satisfactorily inspected and tested unless the inspection is waived off by
MPPTCL in writing. In the latter case also the material shall be dispatched only after
all tests specified herein have been satisfactorily completed.
v. The acceptance of any quantity of material shall in no way relieve the
Contractor of his responsibility for meeting all the requirements of the Specification,
and shall not prevent subsequent rejection, if such materials are later found to be
defective.

4.12.6 Packing and Marking

i. All material shall be packed in strong and weather resistant wooden

cases/crates. The gross weight of the packing shall not normally exceed 200 Kg
to avoid handling problems.
ii. The packing shall be of sufficient strength to withstand rough handling
during transit, storage at site and subsequent handling in the field.
iii. Suitable cushioning, protective padding, spacers shall be provided to prevent
damage or deformation during transit and handling.
iv. Bolts, nuts, washers, cotter pins, security clips and split pins etc. shall be
packed duly installed and assembled with the respective parts and suitable measures
shall be used to prevent their loss.
v. Each component part shall be legibly and indelibly marked with trade
mark of the manufacturer and year of manufacture.
vi. All the packing cases shall be marked legibly and correctly so as to ensure
safe arrival at their destination and to avoid the possibility of goods being lost
or wrongly dispatched on account of faulty packing and faulty or illegible markings.
Each wooden case/crate shall have all the markings stenciled on it in indelible ink.

Page 35
 4.12.7 Standards

i. The Hardware fittings; conductor and earth wire accessories shall

conform to the following Indian/International Standards which shall mean latest
revisions, with amendments/changes adopted and published, unless specifically stated
otherwise in the Specification.
ii. In the event of the supply of hardware fittings; conductor and earth wire
accessories conforming to standards other than specified, the Bidder shall confirm in
his bid that these standards are equivalent to those specified. In case of award,
salient features of comparison between the Standards proposed by the Contractor
and those specified in this document will be provided by the Contractor to establish
their equivalence.

Sl. Indian Title International

No. Standard Standard
1 IS: 209-1992 Specification for zinc BS:3436-1986
2 IS:398-1992 Aluminum Conductor Galvanised IEC:1089-1991
Part-V Steel-Reinforced For Extra High BS:215-1970
Voltage
3 IS 1573 (400 KV) and Coating
Electroplated above of Zinc on iron
and
4 IS : 2121 Steel
Specification for Conductor and
(Part-II) Earth wire Accessories for Overhead
Power lines:
Mid-span Joints and Repair Sleeves
for
5 IS:2486 Conductors
Specification for Insulator Fittings for
(Part-I) Overhead power Lines with Nominal
Voltage greater than 1000 V:
General Requirements and Tests
6 IS:2629 Recommended Practice for Hot Dip
Galvanising of Iron and Steel
7 IS:2633 Method of Testing Uniformity of
Coating on Zinc Coated Articles
8 Ozone test on Elastomer ASTM- D1 171
9 Tests on insulators of Ceramic IEC:383-1993
material or
glass for overhead lines with a
10 IS:4826 nominal voltage
Galvanised greater
Coating than Steel
on Round ASTM A472729
1000V
Wires BS:443-1969
11 IS:6745 Methods of Determination of Weight BS:433
of ISO : 1460 (E)
Zinc Coating of Zinc Coated Iron and
12 IS:8263 Steel Articles
Method of Radio Interference Tests IEC:437
on NEMA:107
High Voltage Insulators CISPR
13 IS:6639 Hexagonal Bolts for Steel Structures ISO/R-272
14 IS:9708 Specification for Stock
15 IS:10162 Specification for Spacers Dampers for
Twin Horizontal Bundle Conductors

Page 36
 The standards mentioned above are available from:

Reference Name and Address

Abbreviation
BS British Standards,
British Standards Institution
101, Pentonvile Road, N - 19-ND, UK
IEC/CISPR International Electro technical Commission,
Bureau Central de la Commission,
electro Technique international, 1 Rue de
verembe,
BIS/IS Geneva,
Beureau SWITZERLAND
Of Indian Standards.
ManakBhavan,
9, Bahadur Shah ZafarMarg,
New Delhi - 110001. INDIA
ISO International Organisation for
Standardization.
Danish Board of Standardization
Danish Standardizing Sraat, Aurehoegvej-12
NEMA DK-2900, Heeleprup,
National Electric DENMARK.
Manufacture Association,
155, East 44th Street.
New York, NY 10017 U.S.A.

4.13 Guaranteed Technical Particulars

The bidder shall fill in the guaranteed technical particulars in the Schedule and submit
the same with his tender, without which bid will not be considered.

4.14 Sag-Tension Chart and Sag Templates

The contractor shall supply six copies of sag tension charts and sag
templates each in respect of the conductor. The contractor shall also supply
sag template in celluloid, which shall be subject to the approval by the MPPTCL and
without involving any extra charges. The sag template will be used for changing the
tower positions in future.

4.15 Accessories

The Bidder after his survey of the existing line shall determine the quantity and type
of the accessories required for the turnkey job, which are to be supplied by them.
These accessories should be suitable for the supplied conductor for its entire
operating range without degradation of mechanical, metallurgical and electrical
properties. The steady state temperature of hardware and accessories must not
exceed 90°C during no wind and 50°C ambient temperature at minimum
1400Amp load. The contractor shall be responsible for satisfactory performance of
complete conductor, hardware and accessories, offered by him, for continuous
operation at temperatures corresponding to various conditions stipulated at Clause 3
of this technical specification.

Page 37
 ANNEXURE-A
1. Tests on Conductor
1.1 UTS Test on Stranded Conductor

Circles perpendicular to the axis of the conductor shall be marked at two places on a
sample of conductor of minimum 5 m length between fixing arrangement suitably
fixed by appropriate fittings on a tensile testing machine. The load shall be increased
at a steady rate up to 50% of minimum specified UTS and held for one minute. The
circles drawn shall not be distorted due to relative movement of strands. Thereafter
the load shall be increased at steady rate to minimum UTS and held for one minute.
The Conductor sample shall not fail during this period. The applied load shall then be
increased until the failing load is reached and the value recorded.

1.2 D.C. Resistance Test on Stranded Conductor

On a conductor sample of minimum 5m length two contact-clamps shall be fixed

with a predetermined bolt torque. The resistance shall be measured by a Kelvin
double bridge or using micro ohm meter of suitable accuracy by placing the clamps
initially zero metre and subsequently one meter apart. The test shall be repeated at
least five times and the average value recorded. The value obtained shall be
corrected to the value at 200C as per IS:398- (Part-IV)/(Part-V). The resistance
corrected at 20deg C shall conform to the requirements of this Specification.

1.3 Coefficient of linear expansion for core/core strands

The temperature and elongation on a sample shall be continuously measured and

recorded at interval of approximately 15 degree C from laboratory ambient
temperature to maximum designed operating temperature corresponding to rated
current(1400 A) by changing the temperature by suitable means. Coefficient of linear
expansion shall be determined from the measured results.

1.4 Breaking load test on Aluminum Alloy & Core strands and D.C
Resistance test on Aluminum Alloy wire.

The above tests shall be carried out as per IEC: 888/889 and the results shall meet
the requirements of the specification. For composite cores, the breaking load shall be
performed as described in Section 9 of ASTM B987.

1.5 Wrap test on Core strand

The wrap test on steel strands shall be meet the requirements of IEC: 888. In
case of aluminum clad core wire, the same shall be wrapped around a mandrel of
diameter of five times that of the strand to form a helix of eight turns.
The strand shall be unwrapped. No breakage of strand shall occur. It is to
inform that the test shall be carried out as per IEC or relevant standards. Wrap
test on core strand shall not be applicable to composite core.

1.6 Heat Resistance test on Aluminium Alloy wire

Breaking load test as per clause 1.5 above shall be carried out before and after
heating the sample in uniform heat furnace at 280 degC (+5/-3 degC) temperature
for one hour. The breaking strength of the wire after heating shall not be less than
the 90% of the breaking strength before heating. The Heat Resistance Test on

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Aluminium Alloy wire shall be applicable to Aluminium Zirconium alloy and
not applicable to Annealed Aluminium.

1.7 Chemical Analysis of Aluminum Alloy :

Samples taken from the Aluminum and strands shall be chemically/

spectrographically analyzed. The same shall be in conformity to the particulars
guaranteed by the bidder so as to meet the requirements stated in this
Specification. It is to inform that the test has to be carried out as per applicability.

1.8 Visual and Dimensional Check on Drums

The drums shall be visually and dimensionally checked to ensure that they conform
to the approved drawings.

1.9 Visual Check for Joints, Scratches etc.

Conductor drums shall be rewound in the presence of the MPPTCL. The MPPTCL shall
visually check for scratches, joints etc. and that the conductor generally conform to
the requirements of this Specification. Ten percent (10%) drums from each lot shall
be rewound in the presence of the MPPTCL's representative.

1.10 Dimensional Check on Core Strands and Aluminium Alloy Strands

The individual strands shall be dimensionally checked to ensure that they conform to
the requirement of this Specification.

1.11 Check for Lay-ratios of Various Layers

The lay-ratios of various layers shall be checked to ensure that they conform to the
guaranteed values furnished by the Contractor.

1.12 Procedure Qualification test on welded Aluminum Alloy strands.

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

1.13 Chemical Analysis of Zinc

Samples taken from the zinc ingots shall be chemically/ spectrographically analyzed.
The same shall be in conformity to the requirements stated in the Specification.

1.14 Galvanizing Test

The test procedure shall be as specified in IEC: 888. The material shall conform to
the requirements of this Specification. The adherence of zinc shall be checked by
wrapping around a mandrel four times the diameter of steel wire.

1.15 Torsion and Elongation Tests on Core Strands

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The test procedures shall be as per clause No. 10.3 of IEC 888. In torsion test, the
number of complete twists before fracture shall not be less than 18 on a length
equal to 100 times the standard diameter of the strand. In case test sample length is
less or more than 100 times the stranded diameter of the strand, the minimum
number of twists will
be proportioned to the length and if number comes in the fraction then it will
be rounded off to next higher whole number. In elongation test, the elongation of the
strand shall not be less than 1.5% for a gauge length of 250 mm. It is to inform
that the test shall be carried out as per the relevant standards
In case of composite core HTLS conductor, the following procedure shall be
applicable:-
i) Elongation Test:- The elongation of the composite core sample at shall be
determined using extensometer. The load along the core shall be gradually
increased. The elongation achieved on reaching the tensile strength of the core shall
not be less than the value guaranteed in the GTP.
ii) Torsion Test: The purpose of the test is to determine the resilience of the
composite core to twisting and to show that after the composite core has
experienced the prescribed twisting, it will not crack or have a loss in tensile strength
due to the twisting. For Standard and High Strength Grade composite cores as per
ASTM B987 Table 2, a sample shall be cut long enough as to have a gauge length
that is 170 times the diameter of the composite core being tested, between the
gripping fixtures. For Extra High Strength Grade composite core as per ASTM B987
Table 2, a sample shall be cut long enough as to have a gauge length that is 340
times the diameter of the composite core being tested, between the gripping
fixtures. One grip shall then be fixed so that it does not twist and the other end shall
be twisted a full 360 degrees and then fixed in this position for 2 minutes. Once the
twist time is completed, the core is untwisted an inspected for any crazing or other
damage. If no damage is observed, the composite core is then tensile tested to
failure and the final load recorded. For the test to be accepted, the composite core
must withstand at least 100% of its rated tensile strength. Two samples need to be
completed in order to satisfy the testing requirement.

1.16 Bending test on conductor core strand

A sample of conductor core strand measuring 30 cm in length shall be subject to

bending with help of a vise. The vised length of wire should be 5 cm and radius of
bend 4.8 mm. The bending should be first 90 degrees left and 90 degree right. After
this operation the strand should cut at the bending point. There should be no
separation of core and aluminum at the bending point after this operation. It is
inform that the test shall be carried out as per the IEC or relevant standards.
Bending test on polymer composite core (Type test):
Bending test on polymer composite core (CFC) before stranding shall be performed
as per ASTM B987/B987M-17. Samples are to be taken from the composite core
manufacturer site, from the same reels being supplied to conductor manufacturer
subject to proper traceability of the same at the conductor manufacturers works.

Bending test on polymer composite core (CFC) shall also be performed as per ASTM
B987/B987M-17 on polymer composite core samples taken at the stranding facility.
Core sample selected at the stranding facility, either before or after stranding, the
diameter of cylindrical mandrel shall be as following:
1. For high strength grade CFC – 60 times the diameter of CFC
2. For Extra high strength grade CFC – 70 times the diameter of CFC

1.17 Compression test on aluminum clad strand

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 A sample of aluminum clad core strand 10 mm in length is to be compressed by a
plate with a load of 3600 kgs. The aluminum and core strand should not break.

1.18 Aluminum conductivity test on aluminum clad strand

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

as per specification requirement.

1.19 Minimum conductivity test on thermal resistant aluminum alloy strands

Resistivity test as per IEC-468/IEC 889 shall be conducted to confirm minimum

conductivity as per specification requirement.

1.20 Stress-strain test at elevated temperature

Stress-strain test as per IEC-1089 shall be conducted keeping conductor temperature

at designed maximum temperature. It is inform that the test shall be carried out as
per the IEC or relevant standards.
RTS used for final strength and intermediate holds shall be 70% of the ambient UTS
guaranteed in the GTP.

1.21 High Temperature endurance & creep test

A conductor sample of at least 20 m length shall be strung at tension equal to 25 % of

conductor UTS. The conductor temperature shall be increased to design maximum
temperature in steps of 20°C and thermal elongation of the conductor sample shall be
measured & recorded at each step. Further, the temperature of the conductor shall be
maintained at maximum continuous operating temperature according to 1400 A (+/-2.5
°C) for 1000 hours. The elongation/creep strain of the conductor during this period
shall be measured and recorded at end of 1 hour, 10 hour, 100 hour and subsequently
every 100 hour up to1000 hours time period. After completion of the above, the conductor
sample shall be subjected to UTS test as mentioned above at clause 1.1 of Annexure-A.
The conductor core shall withstand a load equivalent to 95% of UTS

The supplier shall furnish details of creep characteristic in respect of the conducted based
on laboratory test and other laboratory investigations/ experimental conducted on similar
type of conductor and shall indicate creep strain values corresponding to 1 month, 6
month, 1 year, 10 year & 20 year creep at everyday tension & continuous designed
temperature. It is inform that the test shall be carried out as per the IEC or relevant
standards.

1.22 Axial Impact Test

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

1.23 Crush Strength Test

A section of conductor is to be crushed between two six inch steel plates. Load shall
be held at 350 Kgs for 1 minute and then released. All the strands shall be
subsequently disassembled and tensile tested. All the strands shall exhibit full
strength retention.

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1.24 Torsional Ductility Test

After removing the outer layer aluminum/ aluminum alloy strands, the conductor
shall be loaded to 25% of UTS and then loaded in increasing steps of +/-180 deg,
the core shall withstand at least 16 such rotation. It is inform that the test shall be
carried out as per the IEC or relevant standards.

In case of carbon-fibre composite core conductors utilizing High Strength composite

cores as per ASTM B987, the sample length shall be at least 10 meters, and not be
shorter than 1500 times the diameter of the composite core. The conductor sample
should be loaded to between 10 and 20% of UTS and then rotated in increasing steps
of +/-180 deg. The twist rate must be a maximum of 1 rotation per minute. After 4
rotations, or after separation of the aluminium strands, the aluminium wires shall be
cut and removed from the conductor. The exposed core shall be twisted and shall
withstand up to 16 rotations.

1.25 Sheaves Test (if required)

The conductor sample of minimum length of 35 meter shall be tensioned at 22 % of the

UTS and shall be passed through pulleys having diameter of 32 times that of the
conductor with angle of 20 deg. between the pulleys. The conductor shall be passed over
the pulleys 36 times a speed of 2 m/sec. After this test, UTS test on the conductor shall
be carried out. It is inform that the test shall be carried out as per the IEC or relevant
standards.

For composite core conductor the conductor sample of minimum length of 35 meter shall
be tested in accordance with IEC 60794-1-2, Section 20, Figure 27 (Procedure 4) with
the following details: Tension shall be between 20 and 25% of the conductor UTS; pulley
diameter shall be at least 32 times that of the conductor; angle between the pulleys shall
be 20 degrees. For composite core conductors, the pulley diameter shall be at least the
diameter of the bottom of the grove of the sheave that the manufacturer requires for the
first and last structure during installation. The conductor shall be passed over the pulleys
36 times at a speed between 0.5 m/sec and 2 m/sec. After this test, an UTS test on the
conductor shall be carried out as mentioned above at clause 1.1 of Annexure-A. In the
case of polymer composite core conductors, the core shall be inspected for damage by
subjecting the core to a dye penetration test per ASTM B987 section 14. Dye penetrant
exposure time shall be 30 +1/-0 minutes.

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 ANNEXURE-B

1.0 Tests on Hardware Fittings

1.1 Magnetic Power Loss Test for Suspension Assembly

Two hollow aluminum tubes of 32 mm diameter for the conductor shall be placed 450
mm apart respectively. An alternating current over the range of 1500 to 2000 amps
shall be passed through each tube. The reading of the wattmeter with and without
suspension assemblies along with line side yoke plate, clevis eye shall be recorded.
Not less than three suspension assemblies shall be tested. The average power loss
for suspension assembly shall be plotted for each value of current. The value of the
loss corresponding to 2456 amperes per phase shall be read off from the graph and
the same shall not be more than the value guaranteed by the supplier.

1.2 Galvanising/Electroplating Test

The test shall be carried out as per Clause no. 5.9 of IS: 2486-(Part-1) except that
both uniformity of zinc coating and standard Preece test shall be carried out and the
results obtained shall satisfy the requirements of this specification.

1.3 Mechanical Strength Test of Each Component

Each component shall be subjected to a load equal to the specified minimum ultimate
tensile strength (UTS) which shall be increased at a steady rate to 67% of the
minimum UTS specified. The load shall be held for five minutes and then
removed. The component shall then again be loaded to 50% of UTS and the load
shall be further increased at a steady rate till the specified UTS and held for one
minute. No fracture should occur. The applied load shall then be increased until the
failing load is reached and the value recorded.

1.4 Clamp Slip Strength Vs Torque Test for Suspension Clamp

The suspension assembly shall be vertically suspended by means of a flexible

attachment. A suitable length of conductor shall be fixed in the clamp. The clamp slip
strength at various tightening torques shall be obtained by gradually applying the
load at one end of the conductor. The Clamp slip strength vs torque curve shall be
drawn. The above procedure is applicable only for free centre type suspension clamp.
For AG suspension clamp only clamp slip strength after assembly shall be found out.
The clamp slip strength at the recommended tightening torque shall be more than 20
kN but less than 29 kN.

1.5 Heating Cycle Test

Heating cycle test shall be performed in accordance with IS 2486 (Part-I) with
following modifications:-

i) Temperature of conductor during each cycle: 40 deg. C above designed

maximum operating temperature of the conductor. but not to exceed the maximum
use temperature of the conductor.
ii) Number of cycle: 100
iii) Slip strength test shall also be carried out after heating cycle test.

1.6 Shore Hardness Test for Elastomer Cushion for AG Suspension Assembly
The shore hardness at various points on the surface of the elastomer cushion
shall be measured by a shore hardness meter and the shore hardness number
shall be between 65 to 80.

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1.7 Proof Load Test

Each component shall be subjected to a load equal to 50% of the specified minimum
ultimate tensile strength which shall be increased at a steady rate to
67% of the UTS specified. The load shall be held for one minute and then removed.
After removal of the load the component shall not show any visual
deformation.

1.8 Tests for Forging Casting and Fabricated Hardware

The chemical analysis, hardness test, grain size, inclusion rating and magnetic
particle inspection for forging, castings and chemical analysis and proof load test
for fabricated hardware shall be as per the internationally recognized procedures for
these tests. The sampling will be based on heat number and heat treatment batch.
The details regarding test will be as in the Quality Assurance program.

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 ANNEXEUE-C

2.0 Tests on Accessories for Conductor

2.1 Mid Span Compression Joint for Conductor and Earth wire

(a) Slip Strength Test

The fitting compressed on conductor shall not be less than one meter in length. The
test shall be carried out as per IS:2121 (Part-ii)-1981 clause 6-4 except that the load
shall be steadily increased to 95% of minimum ultimate tensile strength of
conductor/earth wire and retained for one minute at this load. There shall be no
movement of the conductor/ earth wire relative to the fittings and no failure of the
fittings during this one minute period.

2.2 Connector for Conductor

Axial Tensile Load Test for Welded Portion

The sleeve portion of the T-Connector shall be compressed on conductor. The

compressed portion shall be held rigidly on some fixtures and axial load shall be
applied along with the jumper terminal. The load shall be increased gradually till
breaking of welded joint occurs. The breaking load should be above 30 kN.

2.3 Vibration damper for conductor.

Clamp Slip and Fatigue Tests

(i) Test Set Up: The clamp slip and fatigue tests shall be conducted on a laboratory
set up with a minimum effective span length of 30 m. The conductor shall be
tensioned at tension corresponding to 0 deg& no wind condition and ruling span 400
from sag –tension calculation and shall not be equipped with protective armour rods
at any point. Constant tension shall be maintained within the span by means of lever
arm arrangement. After the conductor has been tensioned, clamps shall be
installed to support the conductor at both ends and thus influence of connecting
hardware fittings are eliminated from the free span. The clamps shall not be used for
holding the tension on the conductor. There shall be no loose parts, such as
suspension clamps, U bolts on the test span supported between clamps
mentioned above. The span shall be equipped with vibration inducing equipment
suitable for producing steady standing vibration. The inducing equipment
shall have facilities for stepless speed control as well as stepless amplitude
arrangement. Equipment shall be available for measuring the frequency, cumulative
number of cycles and amplitude of vibration at any point along the span.

(ii) Clamp Slip test

The vibration damper shall be installed on the test span. The damper clamp, after
lightning with the manufacturer‟s specified tightening torque, when subjected to a
longitudinal pull of 2.5 kN parallel to the axis of conductor for a minimum duration of
one minute shall not slip i.e. the permanent displacement between conductor and
clamp measured after removal of the load shall not exceed 1.0 mm. The load shall be
further increased till the clamp starts slipping. The load at which the clamp slips shall
not be more than 5 kN.

3.0 Tests on All components (As applicable)

3.1 Chemical Analysis of Zinc used for Galvanizing

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Samples taken from the zinc ingot shall be chemically analysed as per IS-209-
1979. The purity of zinc shall not be less than 99.95%.

3.2 Tests for Forgings

The chemical analysis hardness tests and magnetic particle inspection for forgings,
will be as per the internationally recognized procedures for these tests. The, sampling
will be based on heat number and heat treatment batch. The details regarding
test will be as discussed and mutually agreed to by the Contractor and MPPTCL in
Quality Assurance Program.

3.3 Tests on Castings

The chemical analysis, mechanical and metallographic tests and magnetic

particle inspection for castings will be as per the internationally recognized
procedures for these tests. The samplings will be based on heat number and heat
treatment batch. The details regarding test will be as discussed and mutually agreed
to by the Contractor and MPPTCL in Quality Assurance Program.

Acceptance Tests

1 Mid Span Compression Joint for Conductor

(a) Hardness Test

The Brinnel hardness at various points on the steel sleeve of conductor core and
tension clamp shall be measured.

2. Connector for Conductor

(a) Axial Tensile Load Test for Welded Portion

Same as clause 2.2 of Annexure - B.

3. Vibration Damper for Conductor

(a) Verification of Resonance Frequencies

The damper shall be mounted on a shaker table and vibrate at damper clamp
displacement of +/-0.5 mm to determine the resonance frequencies. The resonance
shall be visually identified as the frequency at which damper mass vibrates with
maximum displacement on itself. The resonance frequency thus identified shall be
compared with the guaranteed value. A tolerance of ± 1 Hz at a frequency lower than
15 Hz and ± 2 Hz at a frequency higher than 15 Hz only shall be allowed.

(b) Clamp Slip Test

Same as Clause 2.3 of Annexure - B.

(c) Clamp Bolt Torque Test

The clamp shall be attached to a section of the conductor/earth wire. A torque of 150
percent of the manufacturer‟s specified torque shall be applied to the bolt. There shall
be no failure of component parts. The test set up is as described in Clause 2.4 (c) (i),
Annexure-B.

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(d) Strength of the Messenger Cable

The messenger cable shall be fixed in a suitable tensile testing machine and the
tensile load shall be gradually applied until yield point is reached. Alternatively, each
strand of messenger cable may be fixed in a suitable tensile testing machine and the
tensile load shall be gradually applied until yield point is reached. In such a case, the
95% of yield strength of each wire shall be added to get the total strength of the
cable. The load shall be not less than the value guaranteed by the Contractor.

(e) Mass Pull off Test

Each mass shall be pulled off in turn by fixing the mass in one jaw and the clamp in
the other of a suitable tensile testing machine. The longitudinal pull shall be
applied gradually until the mass begins to pull out of the messenger cable. The pull
off loads shall not be less than the value guaranteed by the Contractor.

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Volume-II

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SECTION- 5
TECHNICAL SPECIFICATION FOR DISC INSULATORS

5.01 STANDARDS

This section provides for the design, manufacture, stage testing and
inspection and testing before dispatch packing and delivery of disc insulators
as per technical requirements furnished in this section. Unless otherwise
specified elsewhere in this specification, the rating as well as performance &
testing of the disc insulators shall conform but not limited to the latest
revision & amendments available at the time of placement of order of all the
relevant standards as listed hereunder, except as modified in this document.

S. No Indian Title
Standard
1 IS:209-1992 Specification for Zinc
2 IS:206-1991 Method for Chemical Analysis of Slab Zinc
3 IS:731-1991 Porcelain insulators for overhead power lines
with a nominal voltage greater than 1000V

4 IS:2071 Method of High Voltage Testing

Part(I)-1993
Part(II)-1991
Part(III)-1991
5 IS:2121 Specification of Conductors and Earth wire
Accessories for Overhead Power Lines.
Part(I) Armour Rods, Binding Wires & Tapes for
Conductors
6 IS:2486 Specification for insulator fittings for
overhead power lines with a nominal voltage
greater than 1000V
Part I-1993 General Requirements & Tests
Part II-1989
Dimensional Requirements
Part III -
Locking Devices
1991
7 IS:2629-1990 Recommended practice for Hot Dip
Galvanization for iron & steel
8 IS:2633-1992 Testing for Uniformity of Coating of Zinc
coated articles
9 IS:3188-1988 Dimensions for Disc Insulators
10 IS:6745-1990 Determination of Weight of Zinc coating on
Zinc coated iron and steel articles
11 IS : 8263-1990 Methods of RIV Test of HV Insulators
12 IS:8269-1990 Methods for Switching impulse test on HV
insulators

5.02 PRINCIPAL PARAMETERS

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5.02.01 DETAILS OF DISC INSULATORS

i) The insulator strings shall consist of standard discs for a three phase
50 Hz, effectively earthed 220KV/132KV transmission system in a
moderately polluted atmosphere. The discs shall be cap and pin, ball
and socket type.

ii) The specified values and disc dimensions, impulse and power
frequency voltages, electromechanical strength [EMS] of individual
insulator units are as under. The values given are minimum which
apply to all cases. Specified withstand and flashover voltages are
referred to standard atmospheric condition.

5.02.02 CHARACTERISTICS OF DISC INSULATORS

The disc insulators should have the following particulars and characteristics:

S.No Particulars Disc Insulators

70KN EMS 90kN EMS 160kN
EMS
i Diameter of the disc (mm) 255 255 280
ii Spacing of the disc (mm) 145 145 170
iii Size and designation of pin- 16 mm 16 mm 20 mm
ball shank
iv Creepage distance (mm) 320 320 330
(minimum)
v Power frequency one minute 70 75 75
dry withstand voltage kV (rms)
vi Power frequency one minute 40 45 45
wet withstand voltage kV
(rms)
vii Power frequency puncture 120 125 125
withstand voltage kV (rms)
viii Minimum dry impulse 110 110 120
withstand voltage 1.2x50
micro second wave, positive
and negative Kv Peak)
ix Maximum Radio interference 50 50 50
voltage with 10 kV RMS to
ground. (microvolts)
x Minimum corona extinction 9 9 18
voltage kV(rms)

5.03 SPECIFICATION DRAWINGS

The specification drawing in respect of the disc insulators indicated above is

attached with this specification. The specification drawing is attached herewith
for information and guidance of the Contractor only. The drawings to be
furnished by the Contractor shall be as per his own design and manufacture
and shall be distinct and separate from these specification drawings.
The drawing shall include but not limited to the following information:-

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a) Shell diameter and ball to ball spacing with manufacturing

tolerances.
b) Minimum creepage distance with positive tolerance.
c) Protected creepage distance
d) Eccentricity of the disc
i) Axial run out
ii) Radial run out
e) Unit mechanical and electrical characteristics
f) Size and weight of ball & socket parts
g) Weight of unit insulator disc
h) Materials
i) Identification mark
j) Manufacturer‟s catalogue number.

After placement of order, the Contractor shall submit full dimensioned

manufacturing drawing of insulator cap, pin & insulator shell in six
copies to the Employer for reference & record.

5.04 GENERAL TECHNICAL REQUIREMENTS

5.04.01 Porcelain
The porcelain used in the manufacture of the shells shall be ivory white,
nonporous of high dielectric, mechanical and thermal strength, free from
internal stresses, blisters, laminations, voids, foreign matter, imperfections or
other defects which might render it in any way unsuitable for insulator shells.
Porcelain shall remain unaffected by climatic conditions, ozone, acid, alkalizes,
zinc or dust. The manufacturing shall be by the wet process and impervious
character obtained by thorough verification.

5.04.02 Porcelain Glaze

Surfaces to come in contact with cement shall be made rough by sand glazing.
All other exposed surfaces shall be glazed with ceramic materials having the
same temperature coefficient of expansion as that of the insulator shell. The
thickness of the glaze shall be uniform throughout and the colour of the glaze
shall be brown. The glaze shall have a visible luster, smooth on surface and
be subject to satisfactory performance under extreme tropical climatic
weather conditions and prevent ageing of the porcelain. The glaze shall
remain under compression on the porcelain body throughout the working
temperature range.

5.04.03 METAL PARTS

5.04.03.1 Cap and Ball Pins

Ball pins shall be made with drop forged steel and caps with malleable cast
iron. They shall be in one single piece and duly hot dip galvanized. They shall
not contain parts or pieces joined together, welded, shrink fitted or by any
other process from more than one piece of material. The pins shall be of high
tensile steel, drop forged and heat-treated. The caps shall be cast with good
quality black hearth malleable cast iron and annealed. Galvanising shall be by

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the hot dip process with a heavy coating of zinc of very high purity. The
Contractor shall specify the grade, composition and mechanical properties of
steel used for caps and pins.
5.04.03.2 Security Clips
The security clips shall be made of phosphor bronze or of stainless steel.2.5%
extra security clip shall be provided.

5.05 FILLER MATERIAL

Cement to be used as a filler material shall be quick setting, fast curing
Portland cement. It shall not cause fracture by expansion or loosening by
contraction. Cement shall not react chemically with metal parts in contact with
it and its thickness shall be as small and as uniform as possible.
The insulator design shall be such that the insulating medium shall not directly
engage with hard metal. The surfaces of porcelain and hard metal should be
coated with resilient paint to offset the effect of difference in thermal
expansions of these materials.

5.06 MATERIAL DESIGN AND WORKMANSHIP

5.06.01 GENERAL

(i) All raw materials to be used in the manufacture of these insulators

shall be subject to strict raw material quality control and to stage
testing/quality control during manufacturing stage to ensure the
quality of the final end product. Manufacturing shall conform to the
best engineering practices adopted in the field of extra high
voltage transmission. Bidders shall therefore offer insulators as
are guaranteed by them for satisfactory performance on
220KV/132KV Transmission lines.

(ii) The design, manufacturing, process and material control at various

stages be such as to give maximum working load, highest mobility,
best resistance to corrosion, good finish, elimination of sharp
edges and corners to limit corona and radio interference voltages.

5.06.02 INSULATOR SHELL

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

5.06.03 METAL PARTS

(i) The pin and cap shall be designed such that it will not transmit
the mechanical stresses to the shell by compression and develop
uniform mechanical strength in the insulator. The cap shall be

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circular with the inner and outer surfaces concentric and of such
design that it will not yield or distort under loaded conditions. The
head portion of the pin ball shall be suitably designed so that
when the insulator is under tension the stresses are uniformly
distributed over the pinhole portion of the shell. The pin ball shall
move freely in the cap socket either during assembly of a string
or during erection of a string or when a string is placed in
position.

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

5.06.04 GALVANISING
All ferrous parts shall be hot dip galvanized in accordance with the latest
edition of IS: 2629. The zinc to be used for galvanizing shall conform to grade
Zn 99.95 as per IS: 209. The Zinc coating shall be uniform, smoothly
adherent, reasonably bright, continuous and free from impurities such as flux,
ash, rust stains, bulky white deposits and blisters. Before ball fittings are
galvanized, all die flashing on the shank and on the bearing surface of the ball
shall be carefully removed without reducing the designed dimensional
requirements.
5.06.05 SECURITY CLIPS (LOCKING DEVICES)

The security clips to be used as a locking device for ball and socket coupling
shall be „R‟ shaped hump type to provide for positive locking of the coupling as
per IS:2486 (Part IV). The legs of the security clips shall allow for spreading
after installation to prevent complete withdrawal from the socket. The locking
device shall be resilient, corrosion resistant and of sufficient mechanical
strength. There shall be no possibility of the locking device to be displaced or
be capable of rotation when placed in position and under no circumstances
shall it allow separation of insulator units and fittings. „W‟ type security clips
are also acceptable. The hole for the security clip could be countersunk and
the clip shall be of such design that the eye of the clip may be engaged by a
hot line clip puller to provide for disengagement under energized conditions.
The force required for pulling the clip into its unlocked position shall not be
less than 50 N (5 kgs) or more than, 500 N (50 kgs).
5.06.06 BALL AND SOCKET DESIGNATION
The dimensions of the balls and sockets for 70 KN & 90 KN discs shall be of 16
mm and for 160KN discs shall be of 20 mm designation in accordance with the
standard dimensions stated in IS:2486 (Part II).

5.07 DIMENSIONAL TOLERANCE OF DISC INSULATOR

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

Rating Standard Maximum Minimum

160 KN Disc 280 293 267
90 KN Disc 255 266 244
70 KN Disc 255 266 244

b. Ball to Ball Spacing between Discs (mm)

Rating Standard Maximum Maximum

160 KN Disc 170 175 165

90 KN Disc 145 149 141
70 KN Disc 145 149 141

5.08 INTERCHANGEABILITY
The insulators inclusive of the ball and socket fittings shall be of standard
design suitable for use with hardware fittings of any make conforming to
relevant Indian Standards.

5.09 SUITABILITY FOR LIVE LINE MAINTENANCE

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

Contractors shall indicate the methods generally adopted in routine hot and
cold line maintenance of EHV lines for similar insulators supplied by them.
Contractors shall also indicate the recommended periodicity of such
maintenance.

5.10 FREEDOM FROM DEFECTS

Insulators shall have none of the following defects:

i) Ball pin shake
ii) Cementing defects near the pin like small blow holes, small hair
cracks, lumps, etc.
iii) Sand fall ferro particle defects on the surface of the insulator.
iv) Shell eccentricity

5.11 INSULATOR STRINGS:

5.11.01 TYPE AND RATING

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The insulator strings shall be formed with standard discs described in this
specification for use on 3 phase, 220kV/132kV, 50Hz effectively earthed
systems in a moderately polluted atmosphere. Suspension insulator strings
for use with suspension towers are to be fitted with discs of 70 kN EMS rating
while tension insulator strings for use with Anchor/Tension towers are to be
fitted with discs of 90 kN & 160 kN EMS rating.

5.11.02 STRING SIZE

The size of the disc insulator, the number to be used in different types of
strings and their electro-mechanical strength shall be as follows:
S. Size of No. of Electro
Type of String
No disc standar mechanica
. insulator d discs l
(mm) strength
of
insulator
string
(kN)
a) Single Suspension for 255x145 13/9 70
220/132KV
b) Double Suspension for 255x145 2x13/2x 2x70
220KV/132KV 9
c) Single Tension for 220KV 280x170 14 160
d) Double Tension for 220KV 280x170 2x14 2x160
e) Single Tension for 132KV 255x145 10 90
f) Double Tension for 132KV 255x145 2x10 2x90

5.11.03 STRING CHARACTERISTICS :

5.11.03.1 The characteristics of the complete string shall be as

follows :

S. Characteristics Single/Double Single/Double

NO. Suspension Suspension
220kV 132kV 220kV 132kV
1 No. of Standard Discs 1x13 1x9 1x14 1x10
2x13 2x9 2x14 2x10
2 Nominal diameter of 255 255 280 255
discs
3 Power frequency 460 280 490 300
Withstand voltage (wet)
kV (rms)
4 Lighting impulse 1200 800 1200 800
withstand voltage
(dry)(kVp)

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S. Characteristics Single/Double Single/Double

NO. Suspension Suspension
220kV 132kV 220kV 132kV

5 Switching surge 900 350 900 350

Withstand
voltage (Dry & wet)
(kVp)
6 Mechanical failing Load 7000/ 7000/ 16500/ 9000/
(kgf) 14000 14000 33000 18000

7 Pollution Moderately Moderately polluted

polluted
8 No deformation load 4690/ 4690/ 11055/ 6030/
(kgf) 9380 9380 22110 12060

9 Corona Extinction 176 - 176 -

voltage (KV rms)

5.11.03.2 Insulator units after assembly shall be concentric and

coaxial within limits as permitted by Indian standards.

5.11.03.3 The string design shall be such that when units are coupled
together there shall be contact between the shell of one unit
and metal of the next adjacent unit.

5.12 TESTS :
5.12.01 The Disc insulators offered should be fully type tested as per the
relevant standards. The following tests shall be carried out on the insulator
string and also on unit disc insulators.
5.12.02 Acceptance Tests shall mean those tests which are to be carried
out on samples taken from each lot offered for pre-despatch inspection for the
purpose of acceptance of the lot.
5.12.03 Routine Tests shall mean those tests, which are to be carried out
on each insulator to check the requirements which are likely to vary during
production.
5.12.04 Stage tests during manufacture shall mean those tests which are
to be carried out during the process of manufacture to ensure quality control
such that the end product is of the designed quality conforming to the intent
of this specification.
5.12.05 The norms and procedure of sampling for the above tests shall be
as per the relevant Indian Standard or other internationally accepted
standards.
5.12.06 The standards according to which these tests are to be carried out
are listed against each test. Where a particular test is a specific requirement
of this specification, the norms and procedure for the same shall be as
specified in Appendix-I attached hereto or as mutually agreed to between the
Contractor and the Employer in the Quality Assurance Programme.

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5.12.07 For all type and acceptance tests, the acceptance values shall be
the value guaranteed by the Contractor in the “Technical Questionnaire” or the
acceptance value specified in this specification or the relevant standard
whichever is more stringent for that particular test.

5.13 DETAILS OF TYPE TESTS :

5.13.01 The Disc insulators offered shall be fully type tested for the
following tests as per relevant International/Indian Standard and the bidder
shall furnish type test reports along with the offer.

a) Visible discharge test IS:731

b) Impulse voltage withstand test IS:731
c) Wet power frequency voltage withstand IS:731
test
d) Verification of dimension test IS:731
e) Temperature cycle test IS:731
f) Electro-Mechanical failing load test IS:731
g) Puncture test IS:731
h) Porosity test IS:731
i) Galvanising test IS:731
j) 24 hours mechanical failing load test IS:731
k) Metallurgical test IS:2108 &
IS:2004

5.14 DETAILS OF ACCEPTANCE AND ROUTINE TESTS :

5.14.01 All Acceptance and Routine tests as stipulated herein shall be

carried out by the Contractor in the presence of Employer‟s representative.
Immediately after finalisation of the programme of acceptance/routine testing,
the Contractor shall give sufficient advance intimation to the Employer, to
enable him to depute his representative for witnessing the test.
5.14.02 For String Insulator Units following Acceptance & Routine tests
shall be conducted:
(A) Acceptance tests:
a) Verification of dimensions IS:731
b) Temperature cycle test IS:731
c) Galvanising test IS:731
d) Mechanical performance test IEC:575
e) Test on locking device for ball and socket IEC:372/IS-
coupling 2486(part-IV)
f) Eccentricity test As per
Specification
g) Electro-mechanical strength test
h) Puncture test IS-731
i) Porosity test

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(B) Routine tests:

a) Visual Inspection IS-731

b) Mechanical routine test
c) Electrical routine test IEC:383

5.15 Tests during Manufacture (STAGE TESTS)

On all components as applicable

a) Chemical analysis of Zinc used for galvanizing

b) Chemical analysis, mechanical and

metallographic test and magnetic particle
inspection for malleable castings
As per this
c) Chemical analysis, hardness test and magnetic Specification
particle inspection for forgings
d) Crack detection test for metal parts

5.16 ADDITIONAL TESTS :

The Employer reserves the right for carrying out any other tests of a
reasonable nature at the works of the Contractor/laboratory or at any other
recognized laboratory / research institute in addition to the above mentioned
type, acceptance and routine tests at the cost of the Employer to satisfy that
the material complies with the intent of this specification.

5.17 COORDINATION FOR TESTING:

For 220KV/132KV insulator strings, the Contractor is required to produce type

test reports to the satisfaction of the Employer. However, in case the
Employer desires, the Contractor shall conduct all the type tests on the
complete string with relevant hardware fittings. Responsibility of arranging
required hardwares for the purpose of type testing will remain with the
Contractor.

5.18 QUALITY ASSURANCE PROGRAM :

The contractor shall submit the Quality Assurance Programme as specified in
clause 1.12 Section-1 of the biding document. A copy of the accepted Quality
Assurance Plan must be available at the manufacturer‟s works of the Plant for
reviewing by inspecting officer of the employer.

5.19 INSPECTION :

5.19.01 As specified in clause 1.13 Section-1 of the biding document,

Plant to be supplied will be subject to inspection and approval by the
Employer's representative before despatch.

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5.19.02 The acceptance of any quantity of insulators shall in no way

relieve the successful Contractor of his responsibility for meeting all the
requirement of this specification and shall not prevent subsequent rejection, if
such disc insulators are later found to be defective.
5.19.03 The Contractor shall submit the routine test certificates of bought
out items and raw material at the time of routine testing of the insulator.

5.20 IDENTIFICATION MARKING :

i) Each disc insulator shall be legibly and indelibly marked with the
trade mark of the manufacturer, the month and year of
manufacture, the guaranteed combined mechanical and electrical
strength in kilo-newtons abbreviated by „KN‟ to facilitate easy
identification and proper use.

ii) The marking shall be on porcelain shell of insulators. The

marking shall be printed and not impressed/embossed and same
shall be applied before firing.

iii) One 10mm thick ring of good quality paint shall be marked on
the cap of each insulator of particular strength for easy
identification of the type of insulator. The paint shall not have
any deteriorating effect on the insulator performance. Following
codes shall be used as identification mark:-
For 70kN disc insulator – Green
For 90kN disc insulator – Blue
For 160kN disc insulator – Red

5.21 DOCUMENTATION

The Contractor shall furnish full description and illustrated catalogues of

insulators offered, alongwith the bid. The supplier shall also furnish
alongwith the bid the outline drawing of each insulator unit including
cross-sectional view of the shell. The drawing shall include the following
information :

i) Shell diameter and unit spacing with manufacturing tolerance.

ii) Creepage distance.
iii) Unit mechanical and electrical characteristics as also for the
complete string-suspension and tension.
iv) Size and weight of ball and socket part.
v) Weight of unit insulator disc.
vi) Materials for the disc, cap and pin.
vii) Identification mark.
viii) Manufacturer‟s catalogue number.
ix) Brief installation instructions.
x) Relevant technical details of significance.

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5.22 PACKING & FORWARDING :

i) All disc insulators shall be packed in strong seasoned wooden

crates. The gross weight of the crates alongwith disc insulators
shall not normally exceed 100 kg. to avoid handling problem.
ii) The packing shall be of sufficient strength to withstand rough
handling during transit, storage at site and subsequent handling
in the field.
iii) Suitable cushioning, protective padding, or dunnage or spacers
shall be provided to prevent damage or deformation during
transit and handling.
iv) All packing cases shall be marked legibly and correctly so as to
ensure safe arrival at their destination and avoid the possibility of
goods being lost or wrongly dispatched on account of faulty
packing and faulty or illegible markings. Each wooden case/crate
shall have all the markings stenciled on it in indelible ink.

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Appendix-I
TEST DETAILS

1. Voltage Distribution Test:

The voltage across each insulator unit shall be measured by sphere gap
method. The result obtained shall be converted into percentage and
proportionate correction be applied so as to give a total of 100% distribution.
The voltage across any disc shall not exceed 9% for suspension insulator
strings and for double tension insulator strings. The total of the voltage
distribution of all discs so computed shall be within 95% and 105%. If not,
the test shall be repeated. The proportions correction shall be made on the
values so as to give a total of 100% distribution.
2. Mechanical Strength Test:
The complete insulator string alongwith its hardware fittings excluding arcing
horn, corona control ring/grading ring and suspension assembly/dead end
assembly shall be subjected to a load equal to 50% of the specified minimum
ultimate tensile strength (UTS) which shall be increased at steady rate to 67%
of the minimum UTS specified. The load shall be held for five minutes and
then removed. After removal of the load, the string components shall not
show any visual deformation and it shall be possible to disassemble them by
hand. Hand tools may be used to remove cotter pins and loosen the nuts
initially. The string shall then be reassembled and loaded to 50% of UTS and
the load shall be further increased at a steady rate till the specified minimum
UTS and held for one minute. No fracture should occur during this period. The
applied load shall then be increased until the failing load is reached and the
value recorded.
3. Vibration Test:
The suspension string shall be tested in suspension mode, and tension string
in tension mode itself in laboratory span of minimum 30 metres. In the case
of suspension string a load equal to 600 kg shall be applied along the axis of
the suspension string by means of turn buckle. The insulator string alongwith
hardware fittings and two sub-conductors (each tensioned at 4500 kg) shall
be secured with clamps. The system shall be suitable to maintain constant
tension on each sub-conductors throughout the duration of test. Vibration
Dampers shall not be used on the test span. Both the sub-conductors shall be
vertically vibrated simultaneously at one of the resonance frequencies of the
insulator string (more than 10 Hz) by means of vibration inducing equipment.
The amplitude of vibration at the antinode point nearest to the string shall be
measured and the same shall not be less than + 120/f , f being the frequency
of vibration. The insulator string shall be vibrated for five million cycles then
rotated by 90 deg. and again vibrated for 5 million cycles without any failure.
After the test, the disc insulators shall be examined for looseness of pins and
cap or any crack in the cement. The hardware fittings shall be examined for
fatigue failure and mechanical strength test. There shall be no deterioration
of properties of hardware components and disc insulators after the vibration
test. The disc insulators shall be subjected to the following tests as per
relevant standards:

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S. Test Percentage of
No. discs to be
tested

a) Temperature cycle test followed by 60

mechanical performance test

b) Puncture test (for porcelain insulator 40

only)

If the results of the second test show a porcelain shell rupture, the
production does not comply with this specification.

4. Chemical Analysis of Zinc used for Galvanising:

Samples taken from the zinc ingot shall be chemically analysed as per IS:209.
The purity of zinc shall not less than 99.95%.
5. Tests for Forgings:
The chemical analysis, hardness tests and magnetic particle inspection for
forgings, will be as per the internationally recognized procedures for these
tests. The sampling will be based on heat number and heat treatment batch.
The details regarding test will be as discussed and mutually agreed to by the
Contractor and Employer in Quality Assurance Programme.
6. Test on Castings:
The chemical analysis, mechanical and metallographic tests and magnetic
particle inspection for castings will be as per the internationally recognized
procedures for these tests. The samplings will be based on heat number and
heat treatment batch. The details regarding test will be as discussed and
mutually agreed to by the Contractor and Employer in Quality Assurance
Programme.
7. Eccentricity Test:
The insulator shall be vertically mounted on a fixture using dummy pin and
socket. A vertical scale with horizontal slider shall be used for the axial run
out. The pointer shall be positioned in contact with the bottom of the
outermost petticot of the disc. The disc insulators shall be rotated with
reference to the fixture and the slider shall be allowed to move up and down
on the scale but always maintaining contact with the bottom of the outer most
petticot. After one full rotation of the disc, the maximum and minimum
position the slider has reached on the scale can be found out. Difference
between the above two readings shall satisfy the guaranteed value for axial
run out. Similarly using a horizontal scale with vertical slider the radial run
out shall be measured. The slider shall be positioned on the scale to establish
contact with the circumference of the disc insulator and disc insulator rotated
on its fixture always maintaining the contact. After one full rotation the
maximum and minimum position of the slider reached on the scale are found
out. The difference between the above readings shall satisfy the guaranteed
value for radial run out.

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8. Crack Detection Test:

Crack detection test shall be carried out on each ball and pin before assembly
of disc unit. The manufacturer shall maintain complete record of having
conducted such tests on each and every piece of ball pin. The Contractor shall
furnish full details of the equipment available with him for crack test and also
indicate the test procedure in detail.
SYSTEM PARTICUALRS

S.No. PARTICULARS Electrical System Data

1 System A.C. A.C. A.C.
3phase 3phase 3phase
2 Line voltage (kV rms) 220 132 400
3 Max.voltage (kV rms) 245 145 420
4 Frequency 50Hz. 50Hz. 50 Hz
5 Neutral grounding system effectively effectively effectively
earthed earthed earthed
6 Lightning impulse with- 1050 550 1425
stand voltage(dry &
wet)(kVp)
7 Power frequency withstand 395 230 630
voltage (wet) (kVp)
8 Switching surge withstand 650 325 1050
voltage (wet) (kVp)
9 Short circuit level (kA) 40 40 40
10 Minimum corona extinction - - 320
voltage at 50 Hz AC system
dry condition (Kv rms)
11 Radio interference voltage - - 500
at one MHz for phase to
earth voltage of 266KV dry
conditions(Microvolt)

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SECTION- 6

TECHNICAL SPECIFICATION FOR ERECTION OF TRANSMISSION LINE

6.01 Execution of Work

6.01.1 The erection works consist of

a. Dismantling of existing ACSR Zebra Conductor, hardware,
accessories and crediting at nearer store of MPPTCL.
b. Transportation, delivery of conductor, hardware, accessories
etc. at erection site and keeping in safe custody.
c. Insurance of materials during storage-cum-erection.
d. Distribution of materials at erection site,
e. Stringing of conductor up to both ends of the lines, with the
help of tensioner and puller machine and if required,
manually with the approval of the MPPTCL.
f. Guarantee of all the activities carried out from (a) to (e) and
submission of FQP for carrying out of all above activities.
g. Other items not specifically mentioned in this Specification
and are required for the successful erection and
commissioning of the transmission lines, unless specifically
excluded in the Specification.

6.01.2 All works shall be carried out in accordance with the revised and
latest provisions under Indian Electricity Act and Rules made there
under.

6.01.3 All the erection tools required during erection of lines shall be
arranged by the Contractor at his own cost. The Contractor shall
also be responsible for any damage to and / or loss of his
erection tools.

6.01.4 It will be the Contractor‟s sole responsibility to take the

materials up to the location. Any pathway, temporary road,
temporary bridge required for the work, same will be provided by
the contractor at his cost. If, for any reasons the above is not
feasible, the contractor at his own cost shall have to arrange
transportation by head loads.

6.02 Stringing
The stringing work shall be carried with the help of tensioner and puller
machines. Wherever it is not possible to install the tensioner, it can be
done manually with the approval of site engineer of MPPTCL. Stringing
shall mean, the activities of paying, jointing, tensioning, clamping
with armor-rod, providing dampers and fixing the conductor at tension
hardware and jumpering etc.

6.02.1 Stringing of conductor shall be done up to gantry at both ends of

the individual lines.

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6.02.2 The stringing work should be planned in such a manner in

consultation with the Engineer in charge of the MPPTCL that
minimum shut down of power line crossings are required.
Revenue loss due to any undue shut down due to contractor‟s
irresponsibility shall be recoverable from the contractor.

6.02.3 Before commencing of stringing work, Contractor shall obtain

approval of sag tension charts showing final sag and tension for
various temperature and spans.

6.02.4 The Contractor shall be responsible and will take care of proper
handling of conductor drums. Sufficient numbers of aluminum
snatch blocks shall be used for paying out the Conductors.
Necessary precautions shall be taken to avoid conductor rubbing on
the ground by providing adequate ground roller, rollers on supports.
Additional rollers shall also be provided to cross thorny hedges,
tower footing and other obstructions to avoid scratching of
conductor. The conductor shall be made to sag correctly as per
stringing charts, before they are finally transferred to the hardware
and clamps. No mid span joint shall be made at less than 30
meters from the tower end and no mid span joint shall be
permitted in road and other important crossings spans. There shall
not be more than one joint in the same span of individual
conductor. The sag shall be adjusted to suit the sag indicated
against actual temperature. The thermometer shall be
provided at the conductor point during the stringing work.
Dynamo meters shall be used in tensioning the conductors. All
conductors shall be stressed to their load at the time of stringing,
as per approved stringing charts.

6.02.5 The minimum clearance between the lowest point of conductor and
ground shall not be less than as specified in the chart. All
compression joints should be carefully made and a record of initial
and final lengths of the joints, jointly signed by contractor and
MPPTCL representatives shall be maintained. Check for sag should
also be made at intervals when conductors are drawn up. Over
stressing, causing damage to towers must be avoided. Care should
be exercised not to over tension the conductor. To avoid contact
with the ground or any object above ground level the conductors
shall be pulled by the controlled tension methods using
neoprene lined double pulled wheel type tension stringing
equipments. The equipment shall be capable of
maintaining continuous tension of not less than of 3000 kg. per
conductor.

6.02.6 When the conductor is on the stringing rollers before sagging-in, it

shall be ensured that the conductor is not damaged due to wind,
vibration, vehicles or other causes. Scaffolding should be used to
cross the important road crossings for minimum interruption to
traffic.

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6.02.7 The conductor shall be pulled up to desired sag and left in serial
stringing sheaves for at least one hour after which the sag shall be
rechecked and adjusted, if necessary, before clipping in and
transferring the conductors from the serial stringing sheaves to the
suspension clamps.

6.02.8 The stringing rollers, when suspended on the transmission

structure for supporting conductors, shall be so adjusted that the
conductor will be on the rollers at the same height as the
suspension clamp to which it is to be secured.

6.02.9 Armour rods and vibration dampers shall be fitted at each

suspension and tension tower before final clamping of conductor
with Insulator strings. Vibration dampers are to be fixed with
clamping bolt and in correct vertical position in relation to
conductor.

6.02.10 Compression type joints are to be used for jointing of conductors.

Each part connected with joints shall be perfectly cleaned &
precautionary measures taken before final compression. All the
joints of conductors shall be made with the best workmanship and
shall be perfectly straight and having maximum possible strength.

6.02.11 Proper guys shall be provided to counter balance the paying out
tension of conductor at the tension locations, to avoid damage to
towers and/or accident.

6.03 FIELD QUALITY PLAN (FQP)

Bidder shall invariably submit the FQP along with Technical Bid for
erection of line including all the activities such as dismantling, stringing
etc. with detailed checklist to be referred.

6.04 WASTAGE

6.04.1 The maximum permitted ceiling for wastages for conductor

permitted is 0.5% (maximum) which takes into account the
additional length for sag & jumpers.

6.04.2 No wastage is allowed for any material except the percentage limit
mentioned for Conductor here in above in Clause No. 6.20.1.

6.05 LOSSES
In the event of any material used for transmission line found broken
or damaged or received short during transit or failed during the erection
/ testing at site before commissioning of line, the contractor shall replace
the same free of cost.

6.06 COMMISSIONING

6.06.1 The contractor shall ensure that at the end of each sub-activity the
surplus material is immediately removed from the work-site to avoid
loss and injury to the public.

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6.06.2 The contractor has to make reconciliation of material account and

to settle final bill including signature in all relevant papers
required for passing of final bill within three months from the date
of charging / commissioning of line.

6.07 TAKING OVER:

When all performance tests called for by the Specification have been
successfully carried out, the transmission line shall be accepted and taken
over when it has been satisfactorily put into operation on site, or within one
month of its being ready to be put into operation, whichever shall be the
earlier and the Engineer shall forthwith issue a taking over certificate. The
Engineer shall not delay the issue of any taking over certificate
contemplated by this clause on account of minor defects in the plant which
do not materially effect the commercial use thereof, provided that the
Contractor shall undertake to make good the same in due course.

Digitally signed by AJAY

AJAY KUMAR SHRIVASTAVA

DN: cn=AJAY KUMAR
SHRIVASTAVA, c=IN,
st=Madhya Pradesh,

KUMAR o=CHEIF ENGINEER

(PROCUREMENT) M.P.
POWER TRANSMISSION

SHRIVA CO. LTD, ou=ALL,

serialNumber=2599d2c693
acb7db93d8807892b10a33
7c51050f66491a4c468220
STAVA 8a449590e3
Date: 2023.10.04 17:42:38
+05'30'

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