Insulator

The Porcelain shall be sound, free from defects, thoroughly vitrified and smoothly glazed.

Unless otherwise specified, the glaze shall be brown in color. The glaze shall cover all the porcelain parts
of the insulator except those areas which serve as supports during firing or are left unglazed for the
purpose of assembly.

The design of the insulator shall be such that stresses due to expansion and contraction in any part of
the insulator shall not lead to deterioration. The porcelain shall not engage directly with hard metal.

Cement used in the construction of the insulator shall not cause fracture by expansion or loosening by
contraction and proper care shall be taken to locate the individual parts correctly during cementing. The
cement shall not give rise to chemical reaction with metal fittings, and its thickness shall be as uniform
as possible.

The insulators shall comply with the following tests as per IS:2544-1973 & IS: 5350(PT – III)-1971.

 Visual examination
 Verification of dimensions
 Visible discharge test
 Impulse voltage withstand test.
 Wet power-frequency voltage withstand test.
 Temperature cycle test.
 Electro-mechanical failing load test.
 Mechanical failing load test (for those of type B string insulator units to which electromechanical
failing load test is not applicable.
 Twenty-four hours mechanical strength test (for string insulators only when specified by the
purchaser).
 Puncture test k) Porosity test and
 Galvanizing test

Each Insulator shall be legibly and indelibly marked to show the following.

 Name and trademark of the manufacturer.

 Month and year of manufacture
 Minimum failing load in Newtons
 Country of the manufacturer and
 ISI Certification mark, if any.
 Specific Parameters & Layout Conditions.

Packing
All insulators (without fittings) shall be packed in wooden crates suitable for easy but rough handling
and acceptable for rail transport. Where more than one insulator are packed in a crate, wooden
separators shall be fixed between the insulators to keep individual insulators in position without
movement within the crate.
TECHNICAL SPECIFICATION 11 KV
POST INSULATOR
Scope- This specification covers the manufacture, testing and works supply and delivery of 11KV post
insulators. The Porcelain insulators shall conform to IS: 731-1971 amended up to date. Small fittings like
spring washers, nuts etc may be electro-galvanized.

1. Frequency: (50 ± 3%) Hz

2. Nominal System Voltage: 6.6 K V
3. Maximum System Voltage: 7 KV
4. No. of phases: 3
5. Power frequency one minute withstand (Dry): 75 KV
6. Neutral Earthing arrangement System: Effectively Earthed

Creepage Distances:
The minimum creepage distance shall 30 mm/KV.

Requirements:
The post type insulators shall be suitable for outdoor use and cap & base type. Caps & base shall have
plain machined faces & zigs shall be used for drilling bolt holes on the cap & in the base for easy &
perfect assembly. Regarding Test for Mechanical strength for post Insulators, all the necessary tests are
as per 9.6.5.1, 9.6.5.2, & 9.6.5.3 of IS:2544-1973 with latest amendments are to be carried out at the
manufacturer’s premises. For each of the Post Insulators / Insulator sets Bolts, Nuts, Set Screws &
Washers shall be supplied as follows:

 Requisite numbers of set Screws & Spring Washers for assembling the Post Insulator unit.
 Requisite numbers of set screws & spring washers for fixing bus-bar Support to the cap in the
top Post Insulator.
 One set of Bolts, Nuts & Washers or Lock nuts & plain washers for mounting the Insulators on
the support steel structures of bus support
 5% spare Nuts & Bolts with washers shall have to be supplied of no extra cost by the purchaser
with each consignment.

Galvanization:
 All ferrous parts of insulator hardware of power conductors shall be galvanized in accordance
with IS: 2629/1966 (with latest aendment) ‘Recommended practice for hot dip galvanizing of
Iron and Steel’. The method for testing weight, thickness and uniformity of coating of hot dip
galvanized articles shall be in accordance with IS: 2633/1972 (with latest amendment). The
hardware shall have Zinc coating of 610 gm/m2.
 The Zinc used for galvanizing shall conform to IS: 209 (with latest amendment)
  The threads in nuts and tapped holes shall be cut after galvanizing and shall be well lubricated or
greased. All other threads shall be cut before galvanizing. The bolt threads shall be under cut to
take care of increase in diameter due to galvanizing.
 Spring washers shall be electro-galvanized.

Conductor: (Panther)
The material shall be of best quality and workmanship. The stranded steel re-inforced conductors shall
be manufactured from hard-drawn electrolytic aluminium wires of E.C grade having purity more than
99.5%. Galvanized steel wire strand shall be drawn from High Carbon steel rods with following chemical
composition:

Materials must have the mechanical and electrical properties specified in Schedule –B. The coating of
the galvanized steel wires shall be applied by the hot process or electrolysis process in accordance with
IS: 4826–1968 or latest amendment thereof. The Zinc used for galvanizing shall be electrolytic High
Grade (HG) quality of 99.95% purity and shall conform IS : 209. The wires shall be smooth and free from
all imperfections such as soils and splits.

SIZE AND PROPERTIES:

The sizes of stranded steel re-inforced aluminium conductors shall be as given in Schedule –B which also
indicate the values of resistance and strengths etc.

Transmission line
Transmission lines are based on 11 kV voltage and comprise of overhead conductor (ACSR) mounted on
9 m or 12 m concrete or steel poles. Pole spacing and selection of required strength shall be based on
the site conditions including the need to locate poles:
 To adequately service the electrical load in the immediate area
 Clear of roads and vehicle and pedestrian access ways
 To ensure all safety and legal clearances above ground and separation from buildings and structures
are obtained all times
 For satisfactory access for construction, future maintenance and operational purposes
 To conveniently service consumer premises.
The average span for MV is anticipated to be approximately 80 m. For longer spans the design adopted
shall provide satisfactory mid‐span separation between conductors and sufficient free board.
The average span for joint MV/LV construction is anticipated to be approximately 50 m
The detailed design of the overhead line routes shall be based on existing routes. Routes shall be
surveyed and pegged prior to the preparation of the drawings. Construction shall follow the approved
drawings.

ACSR conductors will be used, because they comply with the Pakistani standards. In addition, they do
have cost advantages over other conductor material and can at best withstand the climatic conditions in
the project area. Supporting poles are made of concrete of 9 – 12 m height. Special arrangements are
foreseen for road crossings in order to achieve sufficient ground clearance. The overhead line span
lengths vary with alignment conditions from between 50 to 110 m.

The technical data of the 11 kV transmission system are as follows:

 Transmission:
o Voltage: 11 kV
o Conductor: ACSR; 120 mm²
o Poles: Concrete 9 ‐ 12 m

Earthing system
Proper earthing is required to ensure consumer personal safety and equipment protection. It is
therefore imperative to achieve a sufficiently low earth resistance to allow the passage of sufficient
current to operate relays or blow fuses. The switchyard and sub‐station earthing system resistances
should therefore be less or equal to 2.0 Ώ. A detailed description of earthing system is compiled in
chapter 6.3.7.
The earthing system includes the following components:
 Switchyard and substations: Separate connections for surge arrestors, neutral point of transformers,
all metal fittings; mixed LV/MV earthing with resulting system lower resulting resistivity or separate
HV and LV earthing system with comparable higher tolerable system resistivity
 Earthing of all poles of the 11 kV transmission line
 0.4 kV distribution line: solidly earthed at substation; earthing of every 10 ‐12th pole, and the
terminal pole of every feeder
 3‐phase workshops: Separate earthing and installation of T‐N system.

Feeder lines
The calculation of conductor/cable size is based on the maximum permissible voltage drop of about 8%
and the minimum current flow required to safely activate the respective tripping devices in the
substation in the event of a fault and feeder loading in excess of the maximum permissible current
rating of the cable.

General requirements and works

5.1 Electrical equipment/materials
5.1.1 General
All components shall be of an approved and reliable design. The highest extent of uniformity and
interchange ability shall be reached. The design shall facilitate maintenance and repair of the
components.
Unless otherwise stated, ratings of main electrical works (in feeds, bus‐ties), whether originally specified
or not, shall generally include a safety margin of 10% under consideration of the worst case to be met in
service.
Short‐circuit calculations shall be evaluated giving full evidence that every electrical component can
withstand the maximum stresses under fault conditions, for fault levels and durations obtained under
the worst conditions e.g. upon failure of the corresponding main protection device and time delayed
fault clearing by the back‐up protection device.
All works shall be suitable for the prevailing climatic conditions.

Earthing
Provision shall be made for earthing all equipment intended for connection in an A.C. mains supply. All
structural metal work and metal chassis shall be connected to earth. Connection between circuits and
metal work shall only be made for reasons of safety and / or reduction of interference. Where such
connections are made, they shall not be used as normal current carrying earth returns.
Earthing conductors shall be at least equal in cross sectional area to the supply conductors and shall be
capable of carrying the fault current.

Quality and procedure control

Quality control methods e.g. radiography, ultrasonic crack detection etc. shall be done in accordance
with the appropriate manufacturing code. However, the Supplier shall indicate clearly in the technical
data sheets the extent to which these methods shall be used.
All welded joints, which have to be tight, shall be inspected or tested by dye penetration tests.
All major welds carried out on parts under hydraulic pressure shall be at least 10% radio‐graphically and
100% ultrasonic examined. All welds on the skin‐plates shall be additional dye penetration tested as
directed by the Engineer.
The Supplier shall indicate in the corresponding drawings

Bolts, screws, nuts, etc.

All bolts, studs, screws, nuts and washers shall be to the ISO metric system. Mild steel bolts and nuts
shall be of precision cold forged or hot forged type with machined faces parallel to one another.
All parts, other than structural steel work, bolted together shall be spot faced on the back to ensure that
nuts and bolt heads bed down satisfactorily. Mild steel nuts and bolts shall be zinc or cadmium plated.
Stainless steel bolts, nuts, washers and screws shall be used for holding renewable parts in water or
when exposed to high humidity
All bolts or studs which will be subject to high stress and / or temperature shall be of approved high
tensile material with nuts of approved material. All bolts and studs larger than M60 shall be drilled for
heaters or shall have an extension for pre‐tensioning by hydraulic tools.
Fitted bolts shall be a driving fit in the reamed holes they occupy, shall have the screwed portion of a
diameter such that it will not be damaged in driving and shall be marked in a conspicuous position to
ensure correct assembly at site.
Standards
The equipment supplied shall conform to the latest edition of the appropriate IEC Specifications and/or
other recognised international standards. In particular:
 IEC 60028 International Standard of resistance of copper
 IEC 6088 Zinc‐coated steel wires for stranded conductors
 IEC 60104 Aluminium – magnesium – silicon alloy wire for overhead line conductors

EN 50 182.2001 (Table F.19)

 DIN 48204
 DIN 48201/8.
8.1.3 Physical characteristics ACSR CONDUCTOR
The physical, mechanical and electrical characteristics of the required ACSR conductors according to DIN
48 204 are compiled in Table 8‐2.
Table 8‐2: Characteristics of ACSR conductors
Conductor Weight
(kg/km)table
Nominal breaking load
(N)
Max. DC resistance at 20 °C
(Ohm/km)
50/8 196 16,870 0.595
70/12 284 26,790 0.413
95/15 383 37,200 0.306
120/20 494 45,650 0.243
120/70 904 98,160 0.236
150/25 604 55,250 0.194
Source: Own compilations
8.1.4 Material
The aluminium wires used in the construction of the ACSR stranded conductors shall be made of quality
aluminium material, type GIE in condition H9 as specified in IEC 60889 or equivalent. The galvanised
steel wires used in the construction of the ACSR stranded conductors shall be of the standard tensile
strength grade given in IEC 60888 or equivalent.
Both, aluminium and steel wires shall be smooth and free from inequalities. The aluminium and steel
wires shall have the physical, mechanical and electrical characteristics given in Tables 3‐1 and 3‐2 above.
8.1.5 Constructional features
The constructional features of the round wire, concentric lay, ACSR stranded conductors, starting from
aluminium and steel wires will conform with constructional features of IEC 60889 (aluminium wire), IEC
60888 (steel wire) and IEC 61089 (stranded conductors) and/or DIN 48 204.
In all conductor construction, successive layers shall have opposite directions of lay, the outermost layer
being right handed. Right handed lay and left handed lay shall be as defined in the latest edition of IEC
61089. The wires in each layer shall be evenly and closely stranded. In conductors having multiple layers
of aluminium wires, the lay ratio of each aluminium layer shall not be larger than the lay ratio of the
aluminium layer directly below it. Steel wires shall be formed during stranding so that they remain inert
when the conductor is cut. The finished conductor shall be free from dirt, grit, excessive amounts of
drawing oil and other foreign deposits.

a) Insulators:
 Pin Insulators (Fog Type)

The Porcelain shall be sound, free from defects, thoroughly vitrified and smoothly glazed. Unless
otherwise specified, the glaze shall be brown in color. The glaze shall cover all the porcelain parts of
the insulator except those areas which serve as supports during firing or are left unglazed for the
purpose of assembly. The design of the insulator shall be such that stresses due to expansion and
contraction in any part of the insulator shall not lead to deterioration. The porcelain shall not engage
directly with hard metal. Cement used in the construction of the insulator shall not cause fracture by
expansion or loosening by contraction and proper care shall be taken to locate the individual parts
correctly during cementing. The cement shall not give rise to chemical reaction with metal fittings,
and its thickness shall be as uniform as possible.

The minimum creepage distance shall 30 mm/KV.

11 KV pin type glazed porcelain insulators with the following characteristics shall be used for 6.6 KV
lines.

Leakage Distance 400mm

Minimum pin height 152 mm
Low frequency flashover-dry 100 KV
Low frequency flashover-wet 65 KV
Power Frequency Puncture Voltage 150 KV
Max. radio influence voltage at 1000 KHz 100 micro volts

Insulator Pins:

The pins shall be suitable for the pin insulators specified. The pins shall be of galvanized mild steel
with a mechanical strength of 1000 kg. the mechanical strength of the pin will be the load at which
deflection of pin shall not exceed 20 percent of the distance from the support when the load is
applied at right angle to a point 1 inch above the head of a rigidly mounted pin.

Dead End Clamps: Dead end clamps shall be used for holding the conductor at dead end in the
overhead line system. The clamps shall be of bolted type and its size shall be suitable for ACSR
Panther conductors. It shall be made of high strength corrosion resistant aluminum ultimate strength
of 8200 kg.

Disc Type Glazed Porcelain Insulators:

(Fog Type) Tension insulators sets for 6.6 KV shall be glazed porcelain disc. Insulators (254 mm dia.
Clevis Type coupling distribution class) with the following characteristics:

Porcelain disc diameter 245 mm

Unit spacing 146 mm

Leakage distance 432 mm

 Low frequency flashover-dry 100 KV

Low frequency flashover-wet 60 KV

Low frequency puncture voltage 130 KV
Max. radio frequency voltage at 1000 KHZ 50 micro volts
Combined M&E strength 82Kg

The insulators shall comply with the following tests as per IS:2544-1973 & IS: 5350(PT – III)-1971.

 Visual examination
 Verification of dimensions
 Visible discharge test
 Impulse voltage withstand test.
 Wet power-frequency voltage withstand test.
 Temperature cycle test.
 Electro-mechanical failing load test.
 Mechanical failing load test (for those of type B string insulator units to which electromechanical
failing load test is not applicable).
 Puncture test
 Galvanizing test

Each Insulator shall be legibly and indelibly marked to show the following.

 Name and trademark of the manufacturer.

 Month and year of manufacture
 Minimum failing load in Newtons
 Country of the manufacturer and
 ISI Certification mark, if any.
 Specific Parameters & Layout Conditions.

Packing

All insulators (without fittings) shall be packed in wooden crates suitable for easy but rough handling
and acceptable for rail transport. Where more than one insulator are packed in a crate, wooden
separators shall be fixed between the insulators to keep individual insulators in position without
movement within the crate.