E20-Conductor, Earth Wire, Insulator, HW, CC

ODISHA POWER TRANSMISSION CORPORATION LIMITED
TECHNICAL SPECIFICATION
FOR
CONDUCTOR, AL TUBE G.I GROUND WIRE, INSULATORS,
HARDWARE, CLAMPS & CONNECTORS
TS-Vol-III E20-COND, E/W, INSULATORS- Page 1/69

CONDUCTORS
SECTION-I
TECHNICAL SPECIFICATION OF ACSR “MOOSE”,”ZEBRA”,
AND “ PANTHER” CONDUCTORS
1. SCOPE :-
1.1. This specification provides for the manufacture, testing, supply and delivery at destination
of the steel cored aluminum conductors as per Appendix-I attached.
2. STANDARDS :-
2.1 The conductors shall comply in all respects to the clauses of this specification as indicated
below & with the Indian Standard Specification, International standards with latest amendments.
Some of the standards are :-
i) IS 398 - Specification for Aluminium Conductors for overhead transmission
purposes,
IS 398, Part-II-Aluminium conductors for overhead Transmission purpose -
Specification
ii) IS 1521, 1972 - Method of tensile testing of steel
iii) IS 1778 -1989 – Reel & drums for bare conductors.
iv) IEC - 1098
3. MATERIALS :-
3.1 The material offered shall be of best quality and workmanship. The steel Cored
Aluminum conductor strands will consist of hard-drawn aluminum wire manufactured from 99.5%
pure electrolytic aluminum rods of E.C. Grade. The steel wire shall be made from materials
produced either by the acid or basic open hearth process or by electric process. No steel wire
drawn from pressmen process shall be used. The steel wire shall not contain sulphur or
phosphorus exceeding 0.05 percent, and the total of sulphur and phosphorus shall not exceed
0.085 percent.
3.2 The steel wires shall be evenly and uniformly coated with zinc complying with Indian
Standard 4826-1979 specification for galvanized coatings on round steel wires. The uniformity of
zinc coating and the weight of coating shall be in accordance with Appendix-II. The coating on the
galvanized steel wires may be applied by the hot process or the electrolytic process.
4. SIZES :-
4.1 The size of steel-cored Aluminum Conductors shall be as given in Appendix-I. The
resistance and weights shall be in accordance with the values given in the same appendix.
5. TOLERANCES :-
5.1 The following tolerances shall be permitted on standard diameter of aluminum wires.
Tolerance on standard diameter of aluminum wire + 1 percent. wires.
Note : - The cross-section of any wire shall not
depart from circularity by more than an
amount corresponding to a tolerance of
2 percent on the standard diameter.
5.2 A tolerance of + 2 percent shall be permitted on the standard diameter of the galvanized
steel wires. The variation from the approximate weights shall not be more than plus or minus 5
percent.

6. MECHANICAL PROPERTIES : -
6.1 The value of the final modules of elasticity for steel cored aluminum conductor in the
average of values obtained from actual stress strain tests. The co-efficient of linear expansion for
steel Cored Aluminum Conductors has been calculated on the basis of co-efficient of linear
expansion of 23.0 x 10-6 per degree centigrade of aluminum and 11.5 x 10-6 per degree
centigrade for steel and represent only the average values. These values shall however, be given
by the bidder under the guaranteed technical particulars.
7. SURFACE CONDITIONS :-
7.1 The wires shall be smooth and free from inequalities, spills and splits. The surface
conductor shall be free from points, sharp-edges, abrasions or other departures from smoothness
or uniformity of surface contour that would increase radio interference and corona losses. When
subjected to tension up to 50% of the ultimate strength of the conductor, the surface shall not
depart from its cylindrical form nor any part of the component, parts or strands, move relative to
each other in such a way as to get out of place and disturb the longitudinal smoothness of the
conductor.
8. JOINTS IN WIRES : -
8.1 Aluminium wires : No joints shall be permitted in the aluminium wires in the outermost layer
of the ACSR conductor. Joints in the inner layers are permitted, in addition to those made in the
base rod or wire before final drawing, but no two such joints shall be less than 15 meter. apart in
the complete stranded conductor. Such joints shall be made by cold pressure butt-welding.
Joints are not permitted in the outermost layer of the conductor in order to ensure a smooth
conductor finish and reduce radio interference levels and corona losses on the extra high voltage
lines.
8.2 Galvanized steel wires : - There shall be no joints except those in the base rod or wire
before final drawing, in steel wires forming the core of the steel-reinforced aluminum conductor.
Joints have not been permitted in the steel wires after final drawing in order to avoid
reduction in the breaking strength of the conductor that may occur as a result of failure of the
joints.
9. STRANDING :-
9.1 The wires used in construction of a stranded conductor shall before stranding, satisfy all
requirements of IS-398/ (part-II)1976 with latest amendments. For steel-cored aluminum
conductors the lay ratio of the different layers shall be within the limits given under Appendix-I.
9.2 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.
10. PACKING AND MARKING : -
10.1 The conductor shall be wound in non-returnable reels or drums conforming to Indian
Standard 1978-1961 specification for Reels and Drums for Bare Wire, or any other authoritative
standard and marked with the following : -
a) Trade name, if any b) Contract/Award letter Number
c) Name of manufacturer d) Name & Address of Consignee
e) Drum Number f) Length of conductor
g) Size of conductor h) Gross Weight of drum with conductor
i) Weight of empty drum j) Net and gross of conductor.
with lagging.
k) Arrow marking of un-winding
10.2 The reel shall be of such construction as to assure delivery of conductor in the field from
displacement and damage and should be able to withstand all stresses due to handling and the
stringing operations so that conductor surface is not dented, scratched or damaged in any way during
manufacture, transport and erection. The conductor shall be properly lagged on the drums and the
method of lagging to be employed may be clearly stated in the tender. It should be stocked to suit the
reel and held in place by steel strapping. Lagging shall not be nailed or bolted in place.
10.3 The conductor drum should be suitable for wheel mounting. Before reeling, the card-
board or other suitable material shall be secured to the drum and inside flanges of the drums. After
reeling the conductor, the exposed surfaces should be wrapped with suitable soft material to
prevent the conductor from dirt and grit. Any space between the drum lagging and conductor
should be suitably filled with soft filler material compactly packed. The conductor drum shall be
made as per the relevant IS.
11. LENGTHS : -
11.1 The conductor shall be supplied in the standard lengths as below with a permitted
variation of 5%. Not less than 90% of the total quantity of the conductor shall be supplied in the
standard lengths. Thus the quantity of the conductor in lengths shorter than standard ones shall
not exceed 10% of the total quantity to be supplied. Further no single conductor lengths in respect
of such 10% (Maximum supply) in random lengths, shall be shorter than 50% of the standard
lengths.
Type of conductor Length per drum.
MOOSE ACSR 1.1 K.M
ZEBRA ACSR 1.1 K.M.
PANTHOR ACSR 2.2 K.M.
12. TESTS AND TEST CERTIFICATES :-
The following type tests ,(& any other tests if purchaser decides to do), shall be conducted on
the conductor at any Govt. approved laboratory or CPRI, in presence of the representatives of
OPTCL, on the samples collected and sealed by the representative of OPTCL from the
manufactured & offered drums of conductor at random at free of cost to OPTCL or firm may quote
their test charges which will be taken in to account during bid price evaluation. If test charges will
not be quoted by the firm, it will be treated as nil during bid price evaluation & firm have to do the
type tests at free of cost to OPTCL. Also the tenderer shall furnish valid type test reports, the
tests are as per the IS 398 (part-2) conducted in any govt. approved laboratory or CPRI
within last 5 years, from the date of opening of the bid (Techno-commercial) document,
without which their bids will not be considered for evaluation.
12.1 Individual wire and finished steel cored Aluminum Conductor shall be subjected to before
dispatch from the works, to the tests as per the provision of the Indian standard Specification 398
(Part-II-1976) with the latest amendments & as per the tests indicated in this specification below.
12.2 Samples for individual wires for test shall be taken before stranding form not less than 10
percent of the spiels in the case of aluminum wire and ten percent of the wire coils in the case of
steel wires. If samples are taken after stranding, they shall be obtained by cutting 5 meters from
the outer end of the finished conductor from not more than 10 percent of the finished reels.
12.3 The mechanical tests shall be carried out on single wires only.
12.4 The Tensile test shall apply to wires of all diameters forming part of steel cored aluminum
conductors. If it is not possible to test the component wires before stranding the test may be made
on wires taken from stranded conductors. The tensile strength of any of the wires shall not be less
than the minimum values given in Appendix-II.
12.5 A suitable tensile testing machine shall be used the accuracy of which can easily be
checked and the machine adjusted if necessary. The test sample before being placed in the

machine, shall be straightened, if necessary in such a way as to cause the minimum alteration in
its physical properties.
The load shall be applied gradually and rate of separation of the Jaws of the testing
machine shall not be greater than 10cm/min. and less than 2.5cm/min.
TYPE TESTS
12.6 Wrapping Test : -
12.6.1 Samples of aluminium wires shall be wrapped round a wire of its own diameter to
form a close helix of eight turns. Six turns shall then be unwrapped and again clearly wrapped in
the same direction as before. The wire shall not break.
12.6.2 Samples of steel wires shall be closely wrapped eight times round a mandrel of
diameter equal to four times the wire diameter. Six turns shall then be unwrapped and again
closely wrapped in the same direction as before. The wire shall not break.
12.7 Galvanizing Test : -
12.7.1 The uniformity of zinc coating and the weight of coating shall be as given in Appendix-II
and shall be determined according to Indian Standard Specification 4826-1979. with latest
amendments.
12.7.2 This test shall be made whenever practicable, on wires before stranding and before the
specimen has been bent, straightened or tested in any other way.
12.8 Ductility Test : -
This test shall be made on galvanized steel wires only by any of the proceedings given in
12.8.1 and 12.8.2.
12.8.1 Torsion Test : - One specimen cut from each of the sample shall be gripped at its ends in
two vices, one of which shall be free to move longitudinally during the test. A small tensile bond not
exceeding 2% of the breaking load of the wire, shall be applied to the sample during testing. The
specimen shall be twisted by consisting one of the vices to revolve until fracture occurs and the
number of twists shall be indicated by a counter or other suitable device. The rate of twisting shall
not exceed 60 rev/min.
When tested before stranding, the number of complete twists before fracture occurs shall
not be less than 18 on a length equal to 100 times the diameter of the wire. The fracture shall
show a smooth surface at right angles, to the axis of the wire.
When tested after stranding, the number of complete twists before fracture occurs
shall be not less than 16 on a length equal to 100 times the diameter of the wire. The fracture shall
show a smooth surface at right angles to the axis of the wire.
12.8.2 Elongation Test : - The elongation of one specimen cut from each of the samples shall be
determined. The specimen shall be straightened by hand and on original gauge length of 200 mm
shall be marked on the wire. A tensile load shall be applied as described in 12.5 and the
elongation shall be measured after the fractured ends fitted together. If the fracture occurs outside
the gauge marks, or within 25mm of either mark and the required elogation is not obtained, the
test shall be disregarded and another test made. When tested before stranding, the elongation
shall be not less than 4 percent. When tested after stranding, the elongation shall be not less than
3.5 percent.
12.9 Surface Condition Test
A sample of the finished conductor having a minimum recommended length of 5 meters
with compression type dead end clamps compressed on both ends in such a manner as to permit
the conductor to take its normal straight line shape, shall be subject to a tension of 50% of the
UTS of the conductor. The surface shall not depart from its cylindrical shape nor shall the strands
move relative to each other so as to get out of place of disturb the longitudinal smoothness of

conductor. The measured diameter at any place shall be not less than the sum of the minimum
specified diameters of the individual aluminum and steel strands.
12.10 Ultimate Strength (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 suitably compressed with dead end clamps at either
end. The load shall be increased at a steady rate up to specified 50% of 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 a steady rate to the minimum UTS specified in Appendix-I and held
for one minute. The applied load shall then be increased until the failing load is reached and the
value recorded.
12.11 Corona Extinction Voltage Test
One sample of conductor of 5m length shall be strung. In case of twin conductor, two
samples shall be arranged with the actual sub-conductor spacing between them. This sample
assembly when subjected to power frequency voltage shall have a corona extinction voltage of not
less than 320 KV (rms) for 400 KV and 176 KV (rms) for 220 KV system line to ground under dry
condition. There shall be no evidence of corona on any part of sample when all possible sources
of corona are photographed in a darkened room. The test shall be conducted without corona
control rings. The voltage shall be corrected for standard atmospheric conditions.
12.12 Radio Interference Voltage Test
Under the conditions as specified in 12.11 above, the conductor samples shall have a radio
interference voltage level below 1500 microvolts at one MHZ when subjected to 50HZ AC voltage
of 1.1 times maximum line to ground voltage under dry condition. This test may be carried out with
corona control rings and arcing horns.
12.13 D.C. Resistance Test on Stranded Conductor
On a conductor sample of minimum 5 m length two contact clamps shall be fixed with a pre-
determined bolt torque. The resistance shall be measured by a Kelvin double bridge by placing
the clamps initially zero meter 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 20 degree centigrade as per clause No.12.8 of IS : 398 (part V). The resistance corrected
at 20 degree centigrade shall conform to the requirements of this specification.
12.14 Stress-Strain Test
12.14 (i)This test is contemplated only to collect the creep data of the conductor from the supplier.
A sample of conductor of minimum 10 metres length shall be suitably compressed with dead end
clamps.
12.14 (ii)Test Set-up
12.14 (ii) (a) The test sample shall be supported in a trough over its full length and the trough
adjusted so that the conductor will not be lifted by more than 10 mm under tension. This shall be
ascertained by actual measurement.
12.14 (ii) (b) The distance between the clamp and the sleeve mouth shall be monitored with
callipers during the test to ensure that, after the test, it does not change by more than 1 mm +/-
0.1mm from the value before the test.
12.14 (iii) (c) The conductor strain shall be evaluated from the measured displacements at the two
ends of the gauge length of the sample. The gauge reference targets shall be attached to the
clamps which lock the steel and aluminum wires together. Target plates may be used with dial
gauges or displacement transducers and care shall be taken to position the plates perpendicular
to the conductor. Twisting the conductor, lifting it and moving it from side-to-side by the maximum
amounts expected during the test should introduce no more than 0.3mm error in the reading.
12.14 (iii)Test Loads for Complete Conductor
The loading conditions for repeated stress-strain tests for complete conductor shall be as
follows :
12.14 (iii) (a) 1 KN load shall be applied initially to straighten the conductor. The load shall be
removed after straightening and then the strain gauges are to be set at zero at zero tension.
12.14 (iii) (b) For non-continuous stress-strain data, the strain reading at 1 KN intervals at lower
tensions and 5KN intervals above 30% of UTS shall be recorded.
12.14 (iii) (c) The sample shall be reloaded to 50% of UTS and held for 1 hour. Readings are to be
noted after 5, 10, 15, 30, 45 and 60 minutes during the hold period. The load shall be released
after the hold period.
12.14 (iii) (d) Reloading up to 70% of UTS shall be done and held for 1 hour. Readings are to be
noted after 5, 10, 15, 30, 45, and 60 minutes and then the load shall be released.
12.14 (iii) (e) Reloading up to 85% of UTS shall be done and hold for 1 hour. Readings are to be
noted after 5, 10, 15, 30, 45 and 60 minutes and then the load shall be released.
12.14 (iii) (f) Tension shall be applied again and shall be increased uniformly until the actual
breaking strength is reached. Simultaneous readings of tension and elongation shall be recorded
up to 90 % of UTS at the intervals described under Clause 12.14 (iii) (e).
12.14 (iv)Test Loads for Steel core Only.
The loading conditions for repeated stress-strain tests for the steel core of ACSR shall be
as follows :
12.14 (iv) (a) The test shall consist of successive application of load applied in a manner similar to
that for the complete conductor at 30%, 50%, 70% and 85% of UTS.
12.14 (iv) (b) The steel core shall be loaded until the elongation at the beginning of each hold
period corresponds to that obtained on the complete conductor at 30%, 50%, 70% and 85% of
UTS respectively.
12.14 (v)Stress Strain Curves

The design stress-strain curve shall be obtained by drawing a smooth curve through the 0.5
and 1 hour points at 30%, 50%, and 70% of UTS loadings. The presence of any aluminum slack that
can be related to any observed extrusion entering the span from the compression dead ends shall be
removed from the lower ends of the design curves. Both the laboratory and design stress-strain curves
shall be submitted to the purchaser along with test results. The stress-strain data obtained during the
test shall be corrected to the standard temperature i.e. 20 degree centigrade.
12.15 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 this specification.
12.16 Chemical Analysis of Aluminum and Steel
Samples taken from the Aluminum ingots/ coils/ strands shall be chemically/ spectrographically analyzed.
The same shall be in conformity to the requirements stated in this specification.
ROUTINE/ACCEPTANCE TESTS
12.17 Visual and Dimensional Check on Drums
The drums shall be visually and dimensionally checked to ensure that they conform to the requirements of
this specification. Drum dimensions should confirm to IS: 1778.The flange diameter, traverse width, barrel
diameter and flange thickness are to be as per relevant standard.
12.18 Visual Check for Joints, Scratches etc.
Conductor drums shall be rewound in the presence of the inspector. The inspector shall visually check for
scratches, joints, etc. and that the conductor generally conforms to the requirements of this specification.
12.19 Dimensional Check of Steel and Aluminum Strands
The individual strands shall be dimensionally checked to ensure that they conform to the
requirements of this specification.
12.20 Check for Lay-ratios of various Layers
The lay-ratios of various layers shall be checked to ensure that they conform to the requirements of
this specification.
12.21 Breaking load test on welded Aluminum strand & Individual wires
Two Aluminum wires shall be welded as per the approved quality plan and shall be subjected
to tensile load. The welded point of the wire shall be able to withstand the minimum breaking load of
the individual strand guaranteed by the supplier.
12.22 Ductility Test
12.23 wrapping test
12.24 Resistance test
12.25 Galvanising Test
13. RETEST AND REJECTION : -
13.1 Each coil or spool selected for testing shall be tested for compliance with the requirements of Indian
Standard Specification 398 (part-II) 1976 with latest amendment if any selected coil or spool not fulfill any
of the test requirements, that particular coil or spool shall be withdrawn. In respect of each failure, two test
pieces shall be selected from two different coils in the lot and subjected to the test under which the failure
occurred. If either of the two retest pieces fails to pass that test, the lot concerned shall be rejected.
If samples are taken for test after stranding and if any selected reel fails in the retest, the
manufacturer may test each and every reel and submit them for further inspection. All rejected
materials shall be suitably marked and segregated.
14. GUARANTEED TECHNICAL PARTICULARS : -
The bidder shall fill in the guaranteed technical particulars in the Performa at
Appendix-IV and submit the same with his tender, without which bid will not be considered.
15. SAG TENSION CHARTS AND SAG TEMPLATES : -
The contractor shall supply each six copies of sag tension charts and sag templates
in respect of each type of the steel core aluminum conductor. The Contractor shall also supply
sag template in celluloid which shall be subject to the approval by the purchaser and without
involving any extra charges. The design data of the lines on which these conductors will be used
are given in Appendix-III.

APPENDIX-I
ACSR CONDUCTOR: MOOSE ZEBRA
1. Size of conductor: 54/7/3.53 mm 54/7/3.18 mm

2. Stranding and wire diameter
Aluminum 54/3.53 mm 54/3.18 mm
Steel 7/3.53 mm 7/3.18 mm
3. Sectional area of Aluminum (in mm2) 528.50 428.90
4. Approximate total mass (in Kgs/KM) 2004 1622
5. Calculated resistance at 20°C Max.: 0.05552 0.06868
( in Ohms/Km.)
6. Calculated breaking load of: 161.20 KN 130.32 KN.
composite conductor (in KN)
(U.T.S.) (Min)
7. Lay Rating :-
Steel core Max – 18 Max- 28
Min - 16 Min-13
Aluminium Layers
12 Wire Layer Max – 14 Max-17
(Innermost Layer) Min – 12 Min - 10
18 Wire Layer Max -13 Max - 16
(Lay immediately beneath outside Layer) Min – 11 Min - 10
24 wire layer (outside layer) Max -12 Max - 14
Min -10 Min - 10
8. Modulus of elasticity (in Kg / mm2 ): 6860 8158
0.7036 x 106 Kg x CM2

( 69 GN per Sq. meter )
9. Co-efficient of linear expansion -------------19.3 x 10-6 -------------------

of conductor per degree centigrade.
10. Standard area of Cross Section in 597.0 mm2 484.5 mm2

Sq. mm of conductor.
11. Diameter of complete conductor in 31.77 mm 28.62 mm

A P P E N D I X - II
Solid Steel and Aluminum Wires used in Steel cored
Aluminum Conductors
ZEBRA MOOSE
1. Diameter Steel Aluminum Steel Aluminium
Standard (in mm) 3.18 3.18 3.53 3.53
Maximum (in mm) 3.24 3.21 3.60 3.55
Minimum (in mm) 3.12 3.15 3.46 3.51
2. Cross Sectional Area 7.942 7.942 9.791 9.791
of nominal Diameter
Wire (in mm2)
3. Weight (in Kg/KM) 61.95 21.47
4. Minimum tensile strength:As per relevant ISS
5. Minimum breaking load 10.43 1.29 12.86 1.57
before stranding (in KN)
6. Minimum breaking load: 9.91 1.23 12.22 1.49

after stranding (in KN)
7. Zinc coating of steel

strands
Number and duration: 3 (1 Min. dip) 3 dips of 1min
of dips
Minimum Weight of : 260 260
Coating (in gm/ m2)
(A s per IS-4826 –1979)
8. Maximum resistance at: 3.626 2.974 2.921 20°C of

Aluminum strands
( in Ohms / KM)
9. Minim Purity of aluminum rod: ------------------------99.5 %-------------------

A P P E N D I X – III
ACSR CONDUCTOR: ZEBRA MOOSE
1. Conductor ---------Steel cored Aluminum-----
2
(a) Copper equivalent: mm
(b) Stranding (in mm) 54/7/3.18 54/7/3.53
2. Normal Span. 320 Meters
Wind Span. 320 Meters
Weight Span.
(a) Max. 500 Meters
(b) Min. 50 Meters
2
3. Wind Pressure on full 52 Kgf per M
project area.
4. Temperature
(a) Minimum 5°C
(b) Maximum 67 ° C
(c) Every day 32°C
5. Factors of safety : Minimum
(i) Every day temperature
and no wind. 4.00
(ii) Minimum temperature
and 2/3 maximum wind : 2.00
(iii) Every day Temperature and
full wind 2.00
This is as per Indian Electricity Rules, 1956.
6. Relative Humidity.
Maximum. 100 Percent
Minimum. 60 Percent
7. Isoceramic level. 100/Years
8. Number of rainy days per year. 100 days
9. Average rainfall per year 1150 mm. approx.
10. Altitude. Less than 350 Metres.

Technical parameters
Sl. No. Description ACSR MOOSE
1 Stranding and wire diameter 54Al /3.53 mm+7 Steel/3.53 mm
2 Number of Strands
Steel centre 1
1st Steel Layer 6
1st Aluminium Layer 12
2nd Aluminium Layer 18
3rd Aluminium Layer 24
3 Sectional area of aluminium 528.5 mm2
4 Total sectional area 597.00 mm2
5 Overall diameter 31.77 mm
6 Approximate weight 2004 kg/km
7 Calculated DC resistance at 2O oC 0.05596 /km
8 Minimum UTS 161.2 kN
9 The details of aluminium strand are as follows:
Minimum breaking load of strand before stranding 1.57 kN
Minimum breaking load of strand after stranding 1.49 kN
Maximum DC resistance of strand at 2O oC 2.921/km

10 The details of steel strand are as follows
Minimum breaking load of strand before stranding 12.86 kN
Minimum breaking load of strand after stranding 12.22 kN
11 Minimum number of twist to be with stood in torsion test when tested on a 18 - before stranding
gauge length of 100 times diameter of wire 16 - after stranding
12 Tolerances
12a Diameter of aluminium strands Standard 3.53 mm
Maximum 3.55 mm
Minimum 3.51 mm
Diameter of steel strands Standard 3.53 mm
Maximum 3.60 mm
Minimum 3.46 mm
13 Lay ratio of Conductor
13a Steel - 6 wire layer Maximum 18
Minimum 16
13b Aluminium - 12 wire layer Maximum 14
Minimum 12
13c Aluminium - 18 wire layer Maximum 13
Minimum 11
13d Aluminium - 24 wire layer Maximum 12
Minimum 11
14 Materials composition
14a Aluminium 99.5% with copper content less than 0.4%
14b Steel Carbon 0.50 to 0.85 %

Manganese 0.50 to 1.10 %
Phosphorous not more than 0.035 %
Sulphur not more than 0.045 %
Silicon 0.10 to 0.35 %
14c Zinc for galvanising electrolytic high grade zinc of 99.95% purity
conforming to IS 209-1979.

A P P E N D I X – PANTHER
1. Size of conductor 30/7/3.00 mm
2. Stranding and wire diameter
Aluminum 30/3.00 mm
Steel 7/3.00 mm
3. Sectional Area of Aluminum 212.10 mm2
4. Approximate total mass 974 Kgs/KM
5. Calculated resistance at 0.139 Ohm/KM
20° C Max.
6. Calculated breaking load 89.67 KN
of composite conductor
(U.T.S) (Min)
7. Lay Ratio :-
Steel Core Max - 28
Min - 13
Aluminum Layers
12 Wire layer (Layer below Max - 16
outside layer) Min - 10
18 Wire layer (Outside Layer) Max - 14
Min - 10
8. Modulus of elasticity 0.815 x 106Kg/CM2 (80GN/M2)
9. Co-efficient of Linear 17.8 x 10-6 / °C
expansion of conductor.
10. Standard area of cross 261.50 Sq. mm
Section in sq. mm of
conductor
11. Diameter of complete 21 mm
conductor in mm

A P P E N D I X - II
PANTHER
Solid Steel and Aluminium Wires used in Steel cored
Aluminium Conductors
1. Diameter Steel Aluminum
Standard 3.00 mm 3.00 mm
Maximum 3.06 mm 3.03 mm
Minimum 2.94 mm 2.97 mm
2. Cross Sectional Area
of nominal Diameter Wire 7.069 mm2 7.069 mm2
3. Weight 55.13 Kg/KM 19.11Kg/Km
4. Minimum tensile strength 134Kg/mm2 16.87Kg/mm2
5. Minimum breaking load 9.29 KN 1.17 KN
before stranding
6. Minimum breaking load 8.83 KN 1.11 KN
after stranding
7. Zinc coating of steel strands
No and duration of dips 3 (1 Min. dip)
Minimum Weight of As per IS 4826-1979
coating
8. Maximum resistance at 4.079 Ohms/KM
20°C of Aluminum strands
9. Purity of aluminum rod 99.5%

A P P E N D I X - III
PANTHER
1. Conductor Steel cored Aluminum

(a) Copper equivalent 130 mm2
(b) Stranding 30/7/3.00 mm
2. Normal Span. 320 Meters
Wind Span. 320 Meters
Weight Span.
(a) Max. 500 Meters
(b) Min. 50 Meters
3. Wind Pressure on full 52 Kgf per M2
projected area.
4. Temperature
(a) Minimum 5 °C
(b) Maximum 67°C
(c) Every day 32°C
5. Factors of safety : Minimum
(i) Every day temperature
and no wind. 4.00
(ii) Minimum temperature
and 2/3 maximum wind : 2.00
(iii) Every day Temperature and
full wind 2.00
This is as per Indian Electricity Rules, 1956.
6. Relative Humidity.
Maximum. 100 Percent
Minimum. 60 Percent
7. Isoceramic level 100/years
8. Number of rainy days per year. 100 days
9. Average rainfall per year 1150 mm. approx.
10. Altitude. Less than 350 Meters

G.I EARTH WIRE
SECTION – II
S.NO. DESCRIPTION
1. SCOPE
2. STANDARDS
3. MATERIALS
4. SIZE AND CONSTRUCTION
5. LENGTH OF JOINING
6. TESTS AND TEST CERTIFICATES
7. PACKING AND MARKING
8. SAG AND TENSION CHARTS AND SAG TEMPLATE
9. OVERHEAD EARTH CONDUCTORS

TECHNICAL SPECIFICATION FOR G.I. GROUND WIRE.
( 7/3.15 mm and 7/3.66mm )
1. SCOPE :
1.1 This specification provides for the manufacture, testing before despatch, supply and delivery of
Ground wire for the purpose of earthing and protection of power transmission line, as per the particulars
given in Appendix-I attached. The ground wire shall consist of standard galvanized steel wire.
2. STANDARDS :
2.1 The ground wire shall comply in all respect with the Indian Standard (IS) 2141-1979
3. MATERIALS :
3.1 The material offered shall be of best quality and workmanship. The steel wires (Strands) shall be
manufactured from steel produced by any suitable process. The steel wire shall not contain sulphur and
phosphorous exceeding 0.040 percent each as per IS : 2141-1971.
3.2 The steel wires shall be evenly and uniformity quoted with zinc complying with IS: 209-1965
specification for zinc (Retired). Only virgin zinc shall be used and reclaimed zinc is not permitted. The
virgin zinc shall be of zn 99.95 percent quality.
3.3 The content of carbon shall not be more than 0.55 percent, manganese and silicon contents shall be
0.40 to 0.90 and 0.15 to 0.35 respectively.
4. SIZE AND CONSTRUCTION :
4.1 The size of ground wire shall be as given in Appendix-I. The physical properties have been given in
the same Appendix. The lay of the strands shall be of lengths as given in the Appendices. The wires shall be
so stranded together that when any evenly distributed pulls applied at the end of the completed strands each
wire will take on equal share of the pull.
5. LENGTH OF JOINING:
5.1 The ground wire may be supplied in the standard length as per manufacturers standard practice and
such length will be specifically indicated in the tender. However random length of ground wire upto a
maximum of 10 (Ten) percent may be allowed.
5.2 The length of strand which may be supplied without joints in the individual wires comprising it
depends on the length of wire which may be carried by the bobbin in a normal stranding machine. The
normal lengths of strand which shall be supplied without joints in individual wires, excluding welds made in
the rod before drawing shall be as given in Appendix – I.
5.3 Each coil shall be warranted to contain no weld joints or splice ether than in the rod before it is
drawn and those permitted in 5.3 above. The wire shall be circular and shall be free from scale or
irregularities, imperfections, flow spite and other defects. The zinc coating shall be smooth even and bright.
6. TESTS AND TEST CERTIFICATES:
6.1 Ground wire shall be subjected to the tests as specified in the IS:2141-1979 before despatch.
6.2 Al the coils of the galvanized strand shall be of the same grade, diameter and construction
manufactured under similar condition shall be grounded to constitute one lot.
6.3 Samples from each lot shall be tested for ascertaining the conformity to the requirements of the
ground wire specified herein. The coils selected shall be tested for length of the lay and joints. The lot shall
be declared conforming to the requirements of these characteristics if all the coils are found satisfactory.
One test specimen from each wire of the strand shall be drawn, from every selected coil and subjected to
tensil tests, ductility test and coating test. One specimen of the completed strand from each coil shall be
subjected to tensil strength. The lot shall be declared conforming to the requirements of these characteristics
if the entire best specimen satisfy the relevant requirements.
6.4 Chemical Analysis : One sample shall be drawn from the lot for chemical analysis. Unless otherwise
agreed to between the purchase and supplier the chemical analysis shall be carried out.
6.5 Tensile Test : The wire when tested in accordance with IS : 1521-1960 shall have minimum tensile
strength specified in the Appendix – I. The tensile strength of the finished strand shall not be less than 95%
of the aggregate of the single wires.
6.6 Ductility test : The wire shall be subjected to wrapping test in accordance with IS : 1755-1961.
When wrapped eight times round its own diameter and on being subsequently straightened the wire shall not
break or split.

6.7 Coating test : The uniformity of zinc coating shall be tested as per IS: 2633-1964. The wire shall
withstand the number of dips specified in Appendix – I.
6.8 Three copies of manufacturers test certificate shall be submitted by the contractor to the purchaser
for approval immediately after such tests have been conducted on the strands and the wire.
6.9 The purchaser reserves the right to inspect the material at Manufacturer‟s works before despatch.
7. PACKING AND MARKING :
7.1 The ground wire shall be supplied in non-returnable reals or drums of non-perishable or treated wood
conforming to IS: 1778-1991 specification for Reals and Drums for Bare wire. Each coil shall be provided
with a level fixed firmly on the inner part of the coil, bearing the following information.
(a) Trade name, if any.
(b) Name of manufacturer
(c) Type of wire, size and length of wire.
(d) Not weight of the wire.
(e) Total weight, and
(f) Number of lengths on the real or drum unless otherwise agreed to between the purchaser and the
supplier, the stranded wire shall be supplied in 50 Kg. coil.
8. SAG AND TENSION CHARTS AND SAG TEMPLATE :
8.1 The successful tenderer shall be required to submit six copies of sag templates and strings charts for
different temperatures and spans, One set of charts shall be ink on tracing cloth. The design date of the lines
on which the ground wire will be used are given in Appendix – II

APPENDIX–I
TECHNICAL SPECIFICATION OF GROUND WIRE
(i) Material : Steel

(ii) Purity of material : Sulphur and phosphorous contents
not exceeding 0.040 percent each.
Carbon content not exceeding 0.55
percent. Total silicon contents
shall be 0.15 to 0.35 and
Manganese contents shall be 0.40
to 0.90 respectively.
(iii) Standing and wire diameter : 7/3.15 mm
(iv) Weight : 428 Kg / Km.
(v) Single wire before stranding
Diameter of wire : 3.15 mm
Tolerance : + 0.060 mm
- 0.030 mm
Minimum elongation in 100 mm. : 4 mm.
Minimum breaking strength : 857 kg.
Minimum tensile strength : 85.7 kgf / mm2
(vi) Stranded wire length of lay
Maximum : 175 mm
Minimum : 145 mm
Minimum breaking load : 5810 kg
Over all diameter : 9.45 mm
Modulus of elasticity : 1.938 x 106 Kg/Cm2
Co-efficient of linear expansion : 11.50 x 10–6 per deg. C.
D.C. resistance at 200C : 3.375 Ohms/Km.
(vii) Zinc coating :

Number of one minute dips : Three
Number of half-minute dips : One
Quality of zinc : Zn 98
IS:209/1966
Weight of coating on wire process : 275 g/m2
of galvanising
Process of galvanising : Hot-dip.
(viii Joints : There shall be no joint in any of
) the wires constituting the ground
wire.
(ix) Lengths -
Standard length : 1500 metres.
Tolerance on standard length : + 5 percent
Random lengths : Not more than 5 percent of the
lengths ordered.
(x) Tests : - : A sample of the finished ground
Type tests Ultimate tensile wire when tested in tensile testing
strength test. machine shall not fail at a stress
less than 100% of UTS value of
the ground wire. The length of the
test sample shall be not less than 5
meters.
Electrical Tests : As per BS : 182/1972 and BS :
3229/1960
Routine Tests : As per clause No. 6 of IS: 2141
1968. In addition to these tests, the
weight and adherence of Zinc
coating tests shall be conducted as
per clause 4 and 5 of IS :
4826/1968.
(xi) Test Reports : Three copies of manufacturer test
certificates shall be submitted by
the Contracts to the purchaser for
approve immediately after such
test have been conducted on the
galvanised steel strand and the
wire.

9. Overhead earth conductors
General(7/3.66mm)
Where earth conductors are erected to provide the specified degree of lightning protection, they shall consist
of stranded galvanised steel and shall comply with IEC 888 and IEC 1089 in so far as it applies to steel
wires.
Galvanising shall comply with the requirements of IS 2141.
The arrangement of earth conductors shall be such that failure of a single conductor cannot predictably result
in a fall across both bus bars in a duplicate bus bar substation.
SI No. Parameter Value
1 Stranding and wire diameter 7/3.66mm
2 Number of strands 1/6
3 Total sectional area 73.65 mm2
4 Overall diameter 10.98mm
5 Approximate weight 583 kg/km
6 Calculated DC resistance at 20C 2.5 ohms/m
7 Minimum ultimate tensile strength 68.4kN
8 Direction of outer lay Right hand
9 Tolerances
9a Diameter standard 3.66mm
maximum 3.75mm
minimum 3.57mm
9b Lay length standard 181mm
maximum 198mm
minimum 165mm
10 Steel composition Carbon  0.55%
Manganese 0.4 to 0.9%
Phosphorous  0.04%
Sulphur  0.04%
Silicon 0.1 to 0.35%
11 Zinc for galvanising Electrolytic high grade zinc of
99.95% purity to 209 1979
Table for Technical parameters for earth wires

INSULATORS
SECTION-III
S.NO. DESCRIPTION
1. SCOPE
2. STANDARDS
3. PRINCIPAL PARAMETERS
4. GENERAL TECHNICAL REQUIREMENTS
5. DETAILS OF SOLID CORE ROD INSULATORS
6. SPECIFICATION DRAWINGS
7. GENERAL TECHNICAL REQUIREMENTS
8. MATERIAL DESIGN AND WORKMANSHIP
9. TESTS (FOR DISC INSULATORS)
10 INSPECTION
11. QUALITY ASSURANCE PLAN
12. TEST DETAILS

INSULATORS
TECHNICAL SPECIFICATION FOR DISC INSULATORS FOR SUBSTATION
AND TRANSMISSION LINE WORK
1.0 SCOPE.
1.1 This specification provides for design, manufacture, engineering, inspection and testing
before despatch packing and delivery FOR (destination) for Indian manufacturers of disc.
Insulators as per technical requirements furnished in this specification.
These insulators are to be used in suspension and tension insulators strings for the
suspension and anchoring of the conductors on EHV transmission line towers.
1.2 Following is the list of documents constituting this package.
(i) Technical specification.
(ii) Technical data sheet.
(iii) Drawings of insulators
(ii)
1.3 All the above volumes along with amendments there of shall be read and interpreted
together. However, in case of a contradiction between the “Technical Specification” and any other
volume, the provisions of this volume will prevail.
1.4 The insulators shall conform in all respects to high standards of engineering, design
workmanship and latest revisions of relevant standards at the time of offer and purchaser shall
have the power to reject any work or material which in his judgment, is not in full accordance
therewith.
2.0 STANDARDS:
2.1 Except as modified in this specification, the disc insulators shall conform to the following
Indian Standards, which shall mean latest revisions and amendments. Equivalent International
and Internally recognized standards to which some of these standards generally correspond are
also listed below.
Sl. Indian Standard Title. International Standard.

No.
1. IS: 206 Method for Chemical Analysis of Slab
Zinc.
2. IS: 209 Specification for Zinc. BS: 3436
3. IS: 731 Porcelain insulators for overhead BS: 137(I&II);

power lines with a normal voltage IEC 274 IEC 383
greater than 1000V
4. IS: 2071 Method of High Voltage Testing.
Part-(I)
Part-(II)
Part-(III)
5. IS: 2121 Specification of Conductors and Earth
wire Accessories for Overhead Power
(Part-I) lines.
Armour Rods, Binding wires and
tapes for conductor.
6. IS: 2486 Specification for Insulator fittings for
overhead power lines with a nominal
voltage greater than 1000V.
Part – I General Requirement and Tests. BS: 3288
Part – II Dimensional Requirements. IEC: 120
Part – III Locking devices. IEC: 372
7. IS: 2629 Recommended practice for Hot Dip
Galvanisation for iron and steel.
8. IS: 2633 Testing for Uniformity of Coating of
Zinc coated articles.
9. IS: 3138 Hexagonal Bolts & Nuts. ISO/R 947 &
ISO/R 272
10. IS: 3188 Dimensions for Disc Insulators. IEC: 305
11. IS: 4218 Metric Screw Threads ISO/R 68-1969
R 26-1963,
R 262-1969 &
R965-1969
12. IS: 6745 Determination of weight of zinc
coating on zinc coated iron and steel
articles.
13. IS: 8263 Methods of RIV Test of HV insulators. IEC 437 NEMA Publication
No.107/1964 CISPR
14. IS: 8269 Methods for switching impulse test on IEC: 506
HV insulators.
15. Thermal mechanical performance test IEC: 575
and mechanical performance test on
string insulator units.
16 IEC Long Rod Insulators IEC-433
2.2 The standards mentioned above are available from:
Reference. Abbreviation. Name & Address:

BS British Standards, British Standards
Institution, 101, Pentonvile Road, N-19 ND,U
IEC / CISPR International Electro technical commission

Electro Technique International. 1, Rue de
verembe Geneva SWITZERLAND.
IS Bureau of Indian Standards, Manak Bhavan,

9 Bahadurshah Zafar Marg, New Delhi-
110001, ORISSA
ISO International Organisation for
Standardization. Danish Board of
Standardization Dansk Standardizing Sraat
Aurehoegvej-12 DK-2900 Helleprup
DENMARK.
NEMA National Electric Manufacturers Association
1`55, East 44th. Street New York, NY 10017
USA
3.0 PRINCIPAL PARAMETERS.
3.1 DETAILS OF DISC INSULATORS:

3.1.1 The Insulator strings shall consist of standard discs for use in three phases. 50 Hz
effectively earthed 33/132/220 KV transmission system of OPTCL in a moderately polluted
atmosphere. The discs shall be cap and pin, ball and socket type, radio interference and
have characteristics as shown in Table-I and all ferrous parts shall be hot dip galvanized as

per the latest edition of IS 2629. The zinc to be used for making sleeves shall be 99.95 %
pure.
3.1.2 The size of disc insulator, minimum creepage distance the number to be used in different
type of strings, their electromechanical strength and mechanical strength
3.1.3 of insulator string along with hardware shall be as follows:
PRINCIPAL PARAMETERS OF THE DISC INSULATORS:-
Sl. Type of String. Size of disc. Minimum No. of standard Electro-mechanical
No. Insulator creepage discs 132 strength of insulator
(mm) distance of KV /220/400 KV string fittings (KN)
each disc
(mm),
1. Single suspension 255 x 145 320 1x9/1x14 70 KN/90 KN Normal
Disc Insulator
2. Double -do- -do- 2x9/2x14 70 KN/90 KN Normal

suspension. Disc Insulator
3 Single suspension 255 x 145 430 1x9/1x14 70 KN/90 KN Antifog

Insulator
4 Double -do- -do- 2x9/2x14 70 KN/90 KN Antifog
suspension. Disc Insulator
5 Single Tension 280x145 430 1x10/1x15 120 KN Antifog Disc

Insulator
6 Double Tension -do- -do- 2x10/2x15 120 KN Antifog Disc
Insulator
7 Single Tension 305x170 475 1x10/1x15/1x25 160 KN Antifog Disc
Insulator
8 Double Tension -do- -do- 2x10/2x15/2x25 160 KN Antifog Disc
Insulator
5 Single 280x145 430 1x10/1x15/1X25 120 KN Antifog Disc
Suspension Insulator
6 Double -do- -do- 2x10/2x15/2X25 120 KN Antifog Disc
Suspension Insulator
3.2 SPECIFICATION DRAWINGS:

3.2.1 The specification in respect of the disc insulators are described.These specification for
information and guidance of the Bidder only. The drawings to be furnished by the supplier
shall be as per his own design and manufacture and in line with the specification.
4.0 GENERAL TECHNICAL REQUIREMENTS:

4.1 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, forgone matter imperfections or other defects which might render it in any way
unusable for insulator shells. Porcelain shall remain unaffected by climatic conditions
ozone, acid, alkalis, zinc or dust. The manufacturing shall be by the wet process and
impervious character obtained by through vetrification.
The insulator shall be made of highest grade, dense, homogeneous, wet-process porcelain,
completely and uniformly vitrified throughout to produce uniform mechanical and electrical
strength and long life service. The porcelain shall be free from warping, roughness, cracks,
blisters, laminations, projecting points foreign particles and other defects, except those
within the limits of standard accepted practice. Surfaces and grooves shall be shaped for
easy cleaning. Shells shall be substantially symmetrical.
4.1.1 Porcelain glaze:
Surface to come in contact with cement shall be made rough by stand 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 down. The Glaze shall have a
visible luster and smooth on surface and be capable of satisfactory performance under
extreme tropical climatic weather conditions and prevent ageing of the porcelain. The glaze
shall remain under compression on the porcelain body through out the working temperature
range.
4.2 METAL PARTS:
4.2.1 Cap and Ball Pins:
Ball pins shall be made with drop forged steel 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
materials. The pins shall be of high tensile steel, drop forged and heat-treated. The caps
shall be cast with good quality black heart malleable cast iron and annealed. Galvanizing
shall be by the hot dip process with a heavy coating of zinc of very high purity. The bidder
shall specify the grade composition and mechanical properties of steel used for caps and
pins. The cap and pin shall be of such design that it will not yield or distort under the
specified mechanical load in such a manner as to change the relative spacing of the
insulators or add other stresses to the shells. The insulator caps shall be of the socket type
provided with nonferrous metal or stainless steel cotter pins and shall provide positive
locking of the coupling.
4.2.2 Security Clips:

The security cops shall be made of phosphor bronze or of stainless steel.
4.3 FILTER MATERIAL:
Cement to be used, as a filler material 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.
4.4 MATERIALS DESIGN AND WORKMANSHIP:

4.4.1 GENERAL:
(II) 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 Transmission lines.
(III) 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.
4.4.2 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.
4.4.3 METAL PARTS:

i) The pin and cap shall be designed to transmit the mechanical stress to the shell by
compression and develop uniform mechanical strength in the insulator. The cap shall be 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 pinball 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 pinball 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, blowholes and rough
edges. All metal surfaces shall be perfectly smooth with no projecting part or irregularities, which
may cause corona. All load bearing surfaces shall be smooth and uniform so as to distribute the
loading stress uniformly. Pins shall not show any microscopically visible cracks, inclusions and
voids.
4.4.4 GALVANIZING:
All ferrous parts, shall be hot dip galvanized in accordance with IS: 2629. The zinc to be
used for galvanizing shall conform to grade Zn 99.5 as per IS: 209. The zinc coating shall
be uniform, smoothly adherent, reasonably light, 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.
4.4.5 CEMENTING:
The insulator design shall. Be such that the insulating medium shall not directly engaged
with hard metal. The surface of porcelain and coated with resilient paint to offset the effect
of difference in thermal expansions of these materials. High quality Portland cement shall
be used for cementing the porcelain to the cap & pin.
4.4.6 SECURITY CLIPS (LOCKING DEVICES)
The security clips to be used as 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 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, which 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 shall be counter sunk 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 positions shall not be less than 50 N (5 kg.) or more than 500 N (50 kgs.).
4.4.7 MARKING:
Each insulator shall have the rated combined mechanical and electrical strength marked
clearly on the porcelain surface. Each insulator shall also bear symbols identifying the
manufacturer, month, and year of manufacture. Marking on porcelain shall be printed, not
impressed, and shall be applied before firing.
4.5 BALL AND SOCKET DESIGNATION:

The dimensions of the ball and sockets for 70 and 90 KN discs shall be of 16 mm and
for 120 KN and 160 KN discs shall be of 20 mm designation in accordance with the
standard dimensions stated in IS: 2486 (Part-II).
4.6 DIMENSIONAL TOLERANCE OF INSULATOR DISCS:

It shall be ensured that the dimensions of the disc insulators are within the limits specified
below:

4.6 DIMENSIONAL TOLERANCE OF INSULATOR DISCS:
It shall be ensured that the dimensions of the disc insulators are within the limits specified below:
(a)
Sl. Diameter of Disc (mm) Standard in mm Maximum Minimum
No.
1. 70 KN/90 KN & 120 KN 255/255 & 280 As per IS As per IS
2. 160 KN 305 As per IS As per IS

(b)
Sl. Ball to Ball spacing Standard in mm Maximum Minimum
No. Between Discs (mm)
1. 70 KN/90 KN/120 KN 145 As per IS As per IS

2. 160 KN 170 As per IS As per IS
(C) GUARANTEED TECHNICAL PARTICULARS

FOR ANTIFOG DISC INSULATORS
Sl. DESCRIPTION 70 KN 120KN 160 KN
No. 90 KN
1. Manufacture‟s name &address
2 Type of Insulator Ball & socket Ball & socket Ball & Ball & socket
socket
3 Size of ball & socket 16B 16B 20 20
4 Dimensions
(a) Disc diameter 255 255 280 305
(b) Unit spacing 145 145 145 170
(c) Creepage distance of the single 430 430 430 475
insulator-mm
5 Electro-mechanical strength of 70 90 120 160
single inslator-kN
6 Materials of shell Porcelain Porcelain Porcelain Porcelain
Electrical value
7.
7.1 Power frequency Withstand voltage
disc
(a) Dry-kV (rms) 80 80 85 90
(b) Wet-kV (rms) 45 45 50 50
7.2 Power frequency flash over voltage
single-disc
(a) Dry-kV (rms) 85 85 90 95
(b) Wet-kV (rms) 50 50 55 55
7.3 Impulse withstand voltage 1.2/50
micro second
1.Positive –kV(peak) 125 125 130 135
2.Negative –kV (peak) 125 125 130 135
7.4 Impulse Flashover voltage 1.2/50
micro second
1.Positive –kV(peak) 135 135 140 145
2.Negative –kV (peak) 130 130 135 140
* Tolerance as per relevant IS (Latest edition).
4.7 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.
4.8 CORONA AND RIV PERFORMANCE:

All surfaces shall be even, smooth, without cuts, abrasions or projections. No part shall be
subject to excessive localized pressure. The metal parts and porcelain shall not produce
any noise-generating corona under all operating conditions.
4.9 SUITABILITY FOR LIVE LINE MAINTENANCE:

The insulator shall be compatible for use with hot line or live line maintenance techniques
so that usual hot line operation can be carried out with easy speed and safety.
4.10 FREEDOM FROM DEFECTS:

Insulators shall have none of the following defects:
1) Ball pin shake.
2) Cementing defects near the pin like small blow holes, small hair cracks lumps etc.
3) Sand fall defects on the surface of the insulator.
4.11 INSULATOR STRINGS:
4.11.1 TYPE AND RATING:
The insulator strings shall be formed with standard discs described in this specification for
use on 3 phases 132/22 KV 50 Hz effectively earthed systems in an atmosphere with
pollution level as indicated in project synopsis. Suspension insulator strings for use with
suspension/tangent towers are to be fitted with discs 70/90 KN EMS rating while tension
insulator strings for use with Anchor/ Tension towers are to be fitted with discs of 120 KN /
160 KN EMS level rating.
4.11.2 STRING SIZE:
The sizes of the disc insulator, the number to be used in different types of strings, their
electro-mechanical strength and minimum nominal creep age distance shall be as given in
clause 3.12
4.12 STRING CHARACTERISTICS:

4.12.1 The characteristics of the complete string shall be as follows:
Sl. Description. Suspension. Tension.

No. 132KV 220kV 132KV 220KV
I Switching surge withstand voltage (dry - - - -
& wet) KV peak.
Ii Lighting impulse withstand voltage (dry) 650 1050 650 1050
KV Peak.
Iii Power frequency without voltage (wet) 275 460 275 460
KV r.m.s.
Iv. Corona extinction voltage level KV rms - 176 - 176
v. Max. RIV for comp. Etc. strong including - 500 - 500
corona rings at 156 KV (rms). … hours
clamps etc. at 1.1. times maximum knee
to ground voltage (micro volts).
vi. Mechanical failing load for each sting 6500 11500 11500 15500
(kgf)
Vii. No deformation load for each string - 7705 - 10385
(kgf)
Viii. Max. voltage across any disc. 13% 13% 13% 13%

4.12.2 Insulator units after assembly shall be concentric and coaxial within limits as permitted by
Indian Standards.
4.12.3 The strings design shall be such that when units are coupled together there shall be contact
between the shell of one unit and metal of the adjacent unit.
5.0 DETAILS OF SOLID CORE LONG ROD INSULATORS:

5.1 The insulator shall consist of standard-discs for a three-phase 50 Hz effectively earthed 132
KV transmission system heavily polluted atmosphere. The insulator shall be ball and socket
type.
5.2 The size of long rod insulator, minimum creepage distance, the number to be used in
different type of strings, their electromechanical strength and mechanical strength of insulator
string along with hardware shall be as follows:
Sl. Type of string. Size of long rod Minimum No.of unit Electromechanical
No. insulator creepage 132/220 KV) strength of insulator
(mm)/(Unit) distance (mm) (KN) 132/220 KV)
132/220 KV 132/220 KV
1. Single 200X 1305 4000 / 6125 '1/2 90 KN

suspension /210X2030
2. Double -do- -do- '2/4 90 KN
suspension
3. Single tension. 205 X 1450 / 4300/7130 '1/2 120 KN/160 KN
215X2550
4. Double Tension. -do- -do- '2/4 120 KN/160 KN
6.0 SPECIFICATION DRAWINGS:

6.1 The specification in respect of the long rod insulators indicated above is given at Annexure-
II. These specification is for information and guidance of the bidder only. The drawings to
be furnished by the supplier shall be as per his own design and manufacture and shall be in
line with the specification.
7.0 GENERAL TECHNICAL REQUIREMENT:

7.1 PORCELAIN:
The porcelain used in the manufacture of the shell shall be ivory white, nonporous of high
dielectric, mechanical and thermal strength free from internal stress blisters and thermal
strength 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 alkalis, and zinc of dust. The
manufacturing shall be by the wet process and impervious character obtained by through
vetrification.
7.2 PORCELAIN GLAZE:

Surfaces to come in contact with cement shall be made rough by stand 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 and smooth on surface and be capable of 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.
7.3 METAL PARTS:

7.3.1 Cap and Ball pins:
Twin 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 g 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 malleable
cast iron and annealed. Galvanizing shall be by the hot dip process with a heavy coating of
zinc of very high purity with minimum of 6 dips. The bidder shall specify the grade,
composition and mechanical properties of steel used for caps and pins.
7.3.2 SECURITY CLIPS:

The security clips shall be made of phosphor bronze or of stainless steel.
7.4 FILLER MATERIAL:

Cement to be used as a filler material shall be quick setting, for curing Portland
cement. It shall not cause fracture by expansion or loosening by contraction. Cement shall
not react chemically with metal parts in contract with it and its thickness shall be as small
and as uniform as possible.
8.0 MATERIAL DESIGN AND WORKMANSHIP:

8.1 GENERAL:
i) All raw materials to be used in the manufacture of these insulators shall be subject to strict
raw materials 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 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 voltage
8.2 INSULATOR SHELL:

The design of the insulator shell 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 temperature cycle test followed by
mallet test. Shells shall be dried under controlled conditions of humidity and temperature.
8.3 METAL PARTS:

i) The twin ball pin and cap shall be designed to transmit the mechanical stresses to the shell
by compression and develop uniform mechanical strength in the insulator. The cap shall be
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 insulator or is under tension the stresses
are uniformly distributed over the pinhole portion of the shell. The pinball 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, blowholes 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 macroscopically visible cracks, insulations and
voids.

8.4 GALVANIZING:
All ferrous parts shall be hot dip galvanized six times in accordance with IS: 2629. The zinc
to be used for galvanizing shall conform to grade Zn 99.5 as per IS: 209. The zinc coating
shall be uniform, smoothly adherent, reasonably light, 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.
8.4.1 CEMENTING:
The insulator design shall be such that the insulating medium shall not directly engage with
hard metal. The surfaces of porcelain and coated with resilient paint to offset the effect of
difference in thermal expansions of these materials.
8.5 SECURITY CLIPS (LOCKING DEVICES

The security clips to be used as 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 sore adding 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 fitting „W‟ type security clips
are also acceptable. The hole for the security clip shall 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 500N (50 Kgs.)
8.6 BALL AND SOCKET DESIGNATION:

The dimensions of the balls and sockets for 80 KN long rod insulators shall be of 16mm and
for 120 KN shall be of 20mm designation in accordance with the standard dimensions
stated in IS: 2486 (Part-III).
8.7 DIMENSIONAL TOLERANCE OF INSULATORS DISCS

It shall be ensured that the dimensions of the long rod insulators are within the limits as per
relevant IEC/ISS.
9.0 TESTS (FOR DISC INSULATORS) :

9,1 The following tests shall be carried out on the insulator string and disc insulators.
9.2 TYPE TEST:

This shall mean those tests, which are to be carried out to prove the design, process of
manufacture and general conformity of the material and product with the intents of this
specification. These tests shall be conducted on a representative number of samples prior
to commencement of commercial production. The Bidder shall indicate his schedule for
carrying out these tests.
9.3 ACCEPTANCE:
This shall mean these 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.
9.4 ROUTINE TESTS:

This shall mean those tests, which are to be carried out on each insulator to check the
requirements, which are likely to vary during production.
9.5 TESTS DURING MANUFACTURE:

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.
9.6 TEST VALUE:
For all type and acceptance tests the acceptance values shall be the value guaranteed by
the bidder in the guaranteed technical particulars of the acceptance value specified in this
specification of the relevant standard whichever is more stringent for that particular test.
9.7 TEST PROCEDURE AND SAMPLING NORMS:

The norms and procedure of sampling for the above tests shall be as per the relevant
Indian Standard or the Internationally accepted standards. This will be discussed and
mutually agreed to between the supplier and purchaser before placement of order. The
standards and normal 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
land procedure for the same shall be as specified in Annexure-IV attached hereto as
mutually agreed to between the supplier and the purchaser in the quality assurance
programme.
9.8 TYPE TESTS:

The following type test shall be conducted on a suitable number of individual unit
components, materials or complete strings.
9.8.1 On the complete insulator string with hardware fittings.
a) Power frequency voltage withstand test with : BS:137(Part-I)
corona control rings and under wet condition.
b) Switching surge voltage withstand test under :
wet condition (400 only)
c) Impulse voltage withstand test under dry : IEC: 383
condition.
d) Impulse voltage flashover test under dry :
condition.
e) Voltage distribution test. :
f) Corona & RIV test under dry condition. : As per this
specification.
g) Mechanical strength test. : As per this
specification.
h) Vibration. :
9.8.2 On Insulators:
a) Verification of dimensions. : IS: 731
b) Thermal mechanical performance test: : IEC:575
c) Power frequency voltage withstand and : BS: 173
flashover
(I) dry (ii) wet.
d) Impulse voltage withstand flashover test (dry) : IEC: 383
e) Visible discharge test (dry) : IS:731
f) RIV test (dry) : IS:8263
9.8.3 All the type tests given under clause No.6.8.1
above shall be conducted on single suspension
and Double Tension insulator string alongwith
hardware fittings.
9.9 ACCEPTANCE TESTS:
9.9.1 For insulator:
a) Visual examination : IS:731
b) Verification of dimensions. : IS:731
c) Temperature cycle test. : IS:731
d) Galvanizing test. : IS:731
e) Mechanical performance test. : IEC:575
f) Test on locking device for ball and socket : IEC:372
coupling.
g) Eccentricity test. : As per this
specification.
h) Electro-mechanical strength test. :
i) Puncture test. : IS:731
j) Porosity test. : IS:731
9.10 ROUTINE TESTS:
9.10. For insulators:
1
a) Visual inspection. : IS:731
b) Mechanical routine test. :
c) Electrical routine test. : IEC:383
9.11 TEST DURING MANUFACTURE:
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.
c) Chemical analysis, hardness test and : As per this
magnetic particle inspection for forgings. specification.
d) Hydraulic Internal Pressure tests on shell. :
e) Crack detection test for metal parts. :
9.12 ADDITIONAL TEST:

The purchaser reserves the right for carrying out any other tests of a reasonable nature at
the works of the supplier/ 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 purchaser to satisfy that the material complies with the intent of this specification.
9.13 CO-ORDINATION FOR TESTING:

For insulator strings, the supplier shall arrange to conduct testing of their disc insulators
with the hardware fittings to be supplied to the purchaser by other suppliers. The supplier is
also required to guarantee overall satisfactory performance of the disc insulator with the
hardware fittings.
NOTE:
In respect of electrical tests on a complete string consisting of insulators and
hardware guarantee of values of responsibility of testing shall be with hardware
manufacturer of RIV corona and voltage distribution test and with insulator manufacturer for
all other tests.
9.14 TEST CHARGES AND TEST SCHEDULE:

9.14.1 TYPE TEST:
The insulator offered shall be fully type tested as per this specification. In case the
equipment of the type and design offered, has already been type tested in an independent
test laboratory. The bidder shall furnish four sets of type test reports alongwith the offer.
These tests must not have been conducted earlier than five years. The purchaser reserves
the right to demand repetition of some or all type tests in the presence of purchasers‟
carrying representative. For this purpose the bidder may quote unit rates for carrying out
each type test. These prices shall be taken into consideration for bid evaluation. For any
change in the design/type already type tested and the design/type offered against this

specification, purchaser reserves the right to demand repetition of tests without any extra
cost.
9.14.2 ACCEPTANCE AND ROUTINE TEST:

All acceptance and routine tests as stipulated herein shall be carried out by the supplier in
the presence of purchaser‟s representative.
9.14.3 Immediately after finalisation of the programme of type/ acceptance/ routine testing, the
supplier shall give sufficient advance intimation to the purchaser to enable him to depute his
representative for witnessing the tests.
9.14.4 For type tests involving tests on a complete insulator string with hardware fittings, the
purchaser will advice the supplier of the hardware fittings to provide the necessary fittings to the
place of the test.
9.14.5 In case of failure of the complete string in any type tests, the supplier whose product has
failed in the tests, shall get the tests repeated at his cost. In case of any dispute, assessment of
the purchaser as to the items that has caused the failure in any of the type tests shall be final and
binding.
10. INSPECTION:
10.1 i. Purchaser and its representative shall at all times be entitled to have access to the
works and to all places of manufacturer where insulators are manufactured and the
supplier shall afford all facilities to them for unrestricted inspection of the works,
inspection of materials, inspection of manufacturing process of insulators and for
conducting necessary tests as specified herein.
ii. The supplier shall keep the purchaser informed in advance of the time of starting and
of progress of manufacture of insulators in its various stages so that arrangements
could be made for inspection.
iii. No material shall be dispatched from its point of manufacture unless the materials
has been satisfactorily inspected and tested.
iv. The acceptance of any quantity of insulators shall in no way relieve the supplier of
his responsibility for meeting all the requirement of this specification and shall not
prevent subsequent rejection, if such insulators are later found to be defective.
10.2 IDENTIFICATION MARKING:
10.2.1 Each unit of insulator shall be legibly and indelibly marked with the trade mark of the
supplier, the year of manufacture, the guaranteed combined mechanical and electrical strength in
kilo-newtons abbreviated by „KN‟ to facilitate easy identification and proper use.
10.2.2 The marking shall be on porcelain for porcelain insulators. The marking shall be printed and
not impressed and the same shall be applied before firing.
11. QUALITY ASSURANCE PLAN:

11.1 The bidder hereunder shall invariably furnish following information alongwith his offer,
failing which the offer shall be liable for rejection.
i. Statement giving list of important raw materials, names of sub-suppliers for the raw
materials, list of standards according to which the raw material are tested, list of tests normally
carried out on raw materials in presence of bidder‟s representative, copies of test certificates.
ii. Informations and copies of test certificates as in (i) above in respect of bought out materials.
iii. List of manufacturing facilities available.
iv. Level of automation achieved and lists of area where manual processing exists.
v. List of areas in manufacturing process, where stage inspections are normally carried out in
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 equipping available with the bidder for final testing of equipment specified
and test plant limitation, if any, vis-à-vis the type, special, acceptance and routine tests specified in
the relevant standards. These limitations shall be very clearly brought out in schedule of deviations
from specified test requirements.
11.2 The supplier shall within 30 days of placement of order submit the following information to
the owner.
i) List of raw material and the names of sub-suppliers selected from those furnished alongwith
the offer.
POST INSULATORS.
Post insulator shall conform in general to IS 2544, IEC 168 and IEC 815.
3.1 constructional features

Post type insulators shall consist of a porcelain part permanently secured in a metal base to
be mounted on the supporting structures. They shall be capable of being mounted upright
and be designed to with stand any shocks to which they may bed subjected to by the
operation of the associated equipment. Only solid core insulators will be acceptable.
Porcelain used shall be homogeneous, free from lamination, cavities and other flaws or
imperfections that might after the mechanical or dielectric quality and shall be thoroughly
vitrified, tough and impervious to moisture.
Glazing of the porcelain shall be of uniform brown in colour, free from blisters, burrs and
other similar defects.
The insulator shall have alternate long and short sheds with aerodynamic profile. The shed
profile shall also meet the requirements of IEC 815 for the specified pollution level.
When operated at normal rated voltage there shall be no electric discharge between
conductor and insulators which would cause corrosion or injury to conductors or insulators
by the formation of substance produced by chemical action.
The design of the insulators shall be such that stresses due to expansion and contraction in
any part of the insulator shall not lead to deterioration.
All ferrous parts shall be hot dip galvanized in accordance with the latest edition of IS 2633,
and IS 4579. The zinc used for galvanizing shall be grade Zn 99.95 as per IS 209. The zinc
coating shall be uniform, adherent, smooth, reasonably bright, continuous and free from
imperfections such as flux ash, rust stains, bulky while deposits and blisters. The metal
parts shall not produce any noise generating corona under the operating conditions. Flat
washer shall be circular of a diameter 2.5 times that of bolt and of suitable thickness. Where
bolt heads/nuts bear upon the beveled surfaces they shall be provided with square tapered
washers of suitable thickness to afford a seating square with the axis of the bolt.
Bidder shall make available data on all the essential features of design including the
method of assembly of shells and metals parts, number of shells per insulator, the manner
in which mechanical stresses are transmitted through shells to adjacent parts, provision for
meeting expansion stresses, results of corona and thermal shock tests, recommended
working strength and any special design or arrangement employed to increase life under
service conditions.

12. 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 as to
give a total of 100% distribution. The voltage across any disc. Not exceed the values given
in clause 4-12.1
2. CORONA EXTINCTION VOLTAGE TEST (DRY):

The sample assembly when subjected to power frequency voltage shall have a corona
extinction voltage of not less than the value specified at clause 4.12.1 (iv) under dry
condition. There shall be no evidence of corona on any part of the sample when all possible
sources of corona are photographed in a darkened room.
3. RIV TEST (DRY):

Under the conditions as specified in (2) above, the insulator string along with complete
hardware fittings shall have a radio interference voltage level below 500 micro volts at one
MHz when subjected to 50 Hz AC voltage of 1.1 times maximum time to ground voltage
under dry condition. The test procedure shall be in accordance with IS: 8263.
4. The complete insulator string along with its hardware fitting excluding arcing horn corona
controlling/grading ring and suspension assembly/dead end assembly shall be subject to a
load equal to 50% of the specified minimum ultimate tensile strength (UTS) which shall be
increased already rate to 68% 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 loads reached
and the value recorded.
5. VIBRATION TEST:
The suspension string shall be tested in suspension mode, and tension string in tension
mode itself in laboratory span of minimum 30 meters. In the case of suspensions string a
load equal to 600 Kg. shall be applied along with the axis of the suspensions string by
means of turn buckle. The insulators string along with hardware fittings and two sub
conductors throughout the duration of the 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 10Hz) by means of vibration
inducing equipment. The amplitude of vibration at the antipode point nearest to the string
shall be measured and the same shall not be less than 120.4 being the frequency of
vibration. The insulator strings 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 to fatigue fatter 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.
Test. Percentage of disc

To be tested.
a) Temperature cycle test followed by 60
Mechanical performance test. 40
b) Puncture test (for porcelain insulator only)
6. CHEMICAL ANALYSIS OF ZINC USED FOR GALVANIZING.

Samples taken from the zinc ingot shall be chemically analysed as per IS: 209. The purity
of zinc shall not be less than 99.95%.
7. TEST 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 supplier and purchaser in quality assurance programme.
1. TEST ON CASTING:
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 supplier and purchaser in quality assurance programme.
2. HYDRAULIC INTERNAL PRESSURE TEST ON SHELLS:

The test shall be earned out on 100% shells before assembly. The details regarding test will be as
discussed and mutually agreed to by the suppliers and purchaser in Quality Assurance
Programme.
3. THERMAL MECHANICAL PERFORMANCE TEST:

The thermal mechanical performance test shall be carried out on minimum 15 number of disc
insulators units as per the procedure given in IEC 575. The performance of the insulator unit shall
be determined by the same standard.
4. ECCENTRICITY TEST:
The insulator shall be vertically mounted on a future 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 petticoat 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 petticoats. 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 veridical slider the radial run out shall be measured. The
slider shall be positioned on the scale to establish contact with the circumstance of the disc
insulator and disc insulator rotated on its future always maintaining the contact. 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.
5. CRACK DETECTION TEST:

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

6. Tubular bus conductors:
General
Aluminium used shall be grade 63401 WP conforming to IS 5082. The tube shall be seamless and shall be
manufactured by either of the following processes:
 Hot extrusion process through die and mandrel (Hollow billet process). Heat treatment shall be
carried out after hot extrusion of tube.
 Bridge extrusion process and then cold drawn. Heat treatment shall be carried out after cold drawing
of tube.
Constructional features
For outside diameter (OD) and thickness of the tube there shall be no minus tolerance, other requirements
being as per IS 2678 and IS 2673.
The aluminium tube shall be supplied in suitable cut length to minimise wastage.
Sl Size 4" IPS 3”IPS 4.5”IPS
No.
(EH type) (EH type) (EH type)
1 Outer diameter (mm) 114.20 88..9 120.0
2 Thickness (mm) : 8.51 7.62 12.0
3 Cross-sectional area 2825.61 2373.63 4071.5
(sq.mm) :
4 Weight (kg/m) : 7.7 6.44 10.993
5 Chemical composition
i) Cu 0.05 max 0.05 max 0.05 max
ii) Mg 0.4 to 0.9 0.4 to 0.9 0.4 to 0.9
iii) Si 0.3 to 0.7 0.3 to 0.7 0.3 to 0.7
iv) Fe 0.5 max 0.5 max 0.5 max
v) Mn 0.03 max 0.03 max 0.03 max
vi) Al Remainder Remainder Remainder
6 Minimum ultimate Tensile 20.5 20.5 20.5
strength Kg/Sq mm
7 Temp co-eff of resistance 0.00364 per Deg C
8 Minimum electrical 55% of IACS
conductivity at 20 deg C
9 Modulus of Elasticity 6700 Kg/sq mm
7. Post insulators:
Post insulators shall conform in general to IS 2544, IEC 168 and IEC 815.
Post type insulators shall consist of a porcelain part permanently secured in a metal base to be mounted on
the supporting structures. They shall be capable of being mounted upright and be designed to withstand any
shocks to which they may be subjected to by the operation of the associated equipment. Only solid core
insulators will be acceptable.
Porcelain used shall be homogeneous, free from lamination, cavities and other flaws or imperfections that
might affect the mechanical or dielectric quality and shall be thoroughly vitrified, tough and impervious to
moisture.
Glazing of the porcelain shall be of uniform brown in colour, free from blisters, burrs and other similar
defects.
The insulator shall have alternate long and short sheds with aerodynamic profile. The shed profile shall also
meet the requirements of IEC 815 for the specified pollution level.

When operating at normal rated voltage there shall be no electric discharge between conductor and
insulators, which would cause corrosion or injury to conductors, or insulators by the formation of substance
produced by chemical action.
The design of the insulators shall be such that stresses due to expansion and contraction in any part of the
insulator shall not lead to deterioration.
All ferrous parts shall be hot dip galvanised in accordance with the latest edition of IS 2633, and IS 4579.
The zinc used for galvanising shall be grade Zn 99.95 as per IS 209. The zinc coating shall be uniform,
adherent, smooth, reasonably bright, continuous and free from imperfections such as flux ash, rust stains,
bulky white deposits and blisters. The metal parts shall not produce any noise generating corona under the
operating conditions.
Flat washer shall be circular of a diameter 2.5 times that of bolt and of suitable thickness. Where bolt
heads/nuts bear upon the bevelled surfaces they shall be provided with square tapered washers of suitable
thickness to afford a seating square with the axis of the bolt.
Bidder shall make available data on all the essential features of design including the method of assembly of
shells and metals parts, number of shells per insulator, the manner in which mechanical stresses are
transmitted through shells to adjacent parts, provision for meeting expansion stresses, results of corona and
thermal shock tests, recommended working strength and any special design or arrangement employed to
increase life under service conditions.
Services to be performed by the equipment being furnished

The equipment shall be able to withstand forces due to wind load on the equipment and approach conductor
and due to short circuit, all forces considered together.
The Contractor shall submit detailed calculations proving the satisfactory performance of the equipment
under short circuit conditions to meet the layout requirements.
Technical Parameters
SI No. Parameter 400kV 245kV 132kV 33klV
1 Type Confirming to IEC 273 (solid core )
2 Voltage class (kV) 420 245 145 36
3 Dry and wet one minute withstand 630 460 235 70
voltage (kVrms)
4 Dry lightning impulse withstand  1550  1050  650  250
voltage (kVp)
5 Wet switching surge withstand  1175 NA NA NA
voltage (kVp)
6 Max. RIV at corona extinction 500 500 500 NA
voltage (microvolts)
7 Corona extinction voltage 320 (min) 156 (min) 105

(kVrms)
9 Total minimum cantilever not 800 not 800 not 600 not 600
strength (kg)
10 Minimum torsional moment As per IEC 273
11 Total height of insulator (mm) 3650 2300 1100 325
12 PCD (mm) 127/300 127/254 127/254 76/76

top/bottom
13 No. of bolts 4/8 4/8 4/8 4/8
top/bottom
14 Diameter of bolt holes (mm) M16/18 M16/18 M16/18 M16/18
top/bottom
15 Pollution level as per IEC 815 Heavy Heavy Heavy Heavy
16 Minimum total creepage 10500 6125 3625 900

distance (mm)

If corona extinction voltage is to be achieved with the help of corona ring or any other similar device, the
same shall be deemed to be included in the scope of the Supplier.
8. Spacers
General
Spacers shall conform to IS 10162. Spacers are to be located at a suitable spacing to limit the short circuit
forces and also to avoid snapping of sub conductors during short circuit conditions.
No magnetic material shall be used in the fabrication of spacers except for GI bolts and nuts.
Spacer design shall be made to take care of fixing and removing during installation and maintenance.
The design of the spacers shall be such that the conductor does not come in contact with any sharp
edge.

SECTION-IV HARDWARES
S.NO. DESCRIPTION
1. SCOPE
2. STANDARDS
3. MATERIALS AND DESIGN
4. GALVANISING
5. ACCESSORIES FOR CONDUCTOR AND GROUND WIRE
6. VIBRATION DAMPER FOR ACSR PANTHER, ZEBRA, MOOSE

AND GROUND WIRE
7. REPAIR SLEEVE FOR ACSR PANTHR, ZEBRA, MOOSE AND

GROUND WIRE
8. SUSPENSION CLAMPS : FOR GROUND WIRE

9. TENSION CLAMPS (DEAD AND ASSEMBLY) FOR GROUND WIRE
10. BONDING PIECES
11. INSULATORS HARDWARE
12. CLAMP
13. TESTS, TEST CERTIFICATE AND PERFORMANCE REPORTS

TECHNICAL SPECIFICATION FOR HARDWARE FITTINGS.
SUITABLE FOR GALVANISED STEEL STRANDED GROUNDWIRE (7/3.15mm

and 7/3.66 mm) ACCESSORIES AND POWER CONDUCTOR ACSR PANTHER
,ACSR ZEBRA AND MOOSE.
1.0 SCOPE
This Specification covers design (if required), manufacture, testing at manufacturer‟s Works,
supply and delivery of GSS), power conductor and ground wire accessories, insulator and hardware fittings
for string insulators suitable for use in 220 and 132 KV Over-head transmission lines and sub- stations of
OPTCL. The hard wares to be supplied shall be as per approved drawings of OPTCL. Any change there
of shall be with due permission of Sr. G.M (CPC).The firm shall submit his drawings for approval of
OPTCL and only after which the manufacturing shall be started.
The materials/equipment offered, shall be complete with all components, which are necessary or
usual for the efficient performance and satisfactory maintenance. Such part shall be deemed to be
within the scope of contract.
2.0 STANDARDS
The materials covered under this Specification shall comply with the requirement of the latest
version of the following standards as amended upto date, except where specified otherwise.
i) IS;2486 Part-II & : Insulator fitting for overhead power lines with a
III nominal voltage greater than 1,000 volts.
ii) IS:2121 Part I & II Conductor & earth wire accessories for overhead power
lines.
iii) IS:9708 Stock Bridge Vibration Dampers on overhead power
lines.
iv) IS:2633 Method of testing of uniformity of coating on zinc
coated articles
v) IS:209 Specification for Zinc.
vi) BS:916 Specification for Hexagonal bolts and nuts.
3.0 MATERIALS AND DESIGN

Aluminium and aluminium alloys, malleable iron and forget steel, having required mechanical
strength, corrosion resistance and mach inability depending on the types of application for which accessories
/ fittings are needed, shall be employed.
In manufacturer of the accessories / fittings, the composition of the aluminium alloys used shall be
made available to Employer if required for verification.
The materials offered shall be of first class quality, workmanship, well finished and approved design. All
castings shall be free from blow-holes, flaws, cracks of other defects and shall be smooth, close grained and
true forms and dimensions. All machined surfaces should be free, smooth and well finished.
Metal fittings of specified material for conductor and earth wire accessories and string insulator fittings are
required to have excellent mechanical properties such as strength, toughness and high resistance against
corrosion. All current carrying parts shall be so designed and manufactured that contact resistance is reduced
to the minimum.
All bolts, nuts, bolt-heads shall be the white worth‟s standard thread. Bolt heads and nuts shall be hexagonal.
Nuts shall be locked in an approved manner. The treads in nuts and tapped holes shall be cut after
galvanising an shall be well fabricated and greased. All other treads shall be cut before galvanising. The bolt
treads shall be undercut to take care of increase in diameter due to galvanising.
All nuts shall be made of materials to Clause 4.8 of IS:1367 (latest edition) with regard to its mechanical
properties.
The general design conductor and earthe wire accessories and insulator fittings shall be such as to ensure
uniformity, high strength, free from corona formation and high resistance against corrosion even in case of
high level of atmosphere pollution.
All hooks, eyes, pins, bolts, suspension clamps and other fittings for attaching to the tower or to the line
conductor or to the earthwire shall be so designed that the effects of vibration, both on the conductor and the
fittings itself, are minimized.
Special attention must be given to ensure smooth finished surface throughout. Adequate bearing area
between fittings shall be provided and point or line contacts shall be avoided.
All accessories and hardwares shall be free from cracks, shrinks, slender air holes, burrs or rough edges.
The design of he accessories and hardwares shall be such as to avoid local corona formation or discharge
likely to cause interference to tele-transmission signals of any kind.
4.0 GALVANISING :
All ferrous parts of conductor and ground wire accessories and insulator hardwares shall be
galvanised in accordance with IS:2629-Recommended Practice for hot dip galvanising of iron and
steel or any other equivalent authoritive standards. The weight of zinc coating shall be determined as
per method stipulated in IS:2633 for testing weights, thickness and uniformity of coating of hot dip
galvanished articles or as per any other equivalent authoritative standards. The zinc used or
galvanisation shall conform to grade zn 98 of IS:209. The galvanised parts shall withstand four (4)
dips of 1 minute each time while testing uniformity of zinc coating as per IS:2633.
Spring washers shall be elctro galvanised.
5.0 ACCESSORIES FOR CONDUCTOR AND GROUND WIRE,

MID SPAN COMPRESSION JOINTS:FOR ACSR- PANTHER ,ZEBRA, MOOSE AND
GROUNDWIRE OF 7/3.15 and 7/3.66 mm.
The Mid-Span Joints for conductor and earthwire shall be of compression type. The conductor mid-span
joints shall comprise of outer aluminium sleeve of extruded aluminium (99.5% purity) and inner sleeve
HDG Steel. All filler plug shall also be provided. The ground wire mid-span joints shall be of HDG steel.
The sleeves shall be of circular shape suitable for compression into hexagonal shape.
The compression type mid-span straight joints shall be suitable for making joints in the ACSR
“PANTHER,ZEBRA & MOOSE” conductor or in the galvanised steel stranded ground wire.
The joints shall be so designed that when installed no air space is left within the finished joints. The
joints shall have the conductivity as specified in relevant Clause.
The joints shall conform to IS:2121 (latest edition) unless specified otherwise. The details of the
joints both suitable for ACSR- Panther,Zebra & Moose and ground wire are given in the technical
particulars.
The inner and outer diameters and lengths of the offered joints before and after compression shall be clearly
shown in the drawings.
6.0 VIBRATION DAMPER FOR ACSR PANTHER,ZEBRA MOOSE AND

GROUND WIRE(7/3.15 and 7/3.66 mm)
Vibration Damper having 4 resonance frequency characteristic commonly called 4R Damper shall be
offered. The Damper shall eliminate fatigue on the conductor due to vibration and damp out the vibration
effectively so that no damage due to vibration is caused to conductor / ground wire / string.
The dampers are proposed to be used at all tension locations and also at suspension locations. One or
more dampers are proposed to be used on tension/suspension locations depending upon the span.
Bidder shall also recommend the number of damper required to effectively damp out conductor or
ground wire vibration for different values of span lengths and the distance of fixation.
Vibration dampers shall be of approved design. The clamps of the vibration dampers shall be made
of aluminium alloy, so designed as to prevent any damage while fixing on the conductor during erection or

in continued operation. The fastening bolts should be approved by the Employer. The spring washers should
be elctro galvanised and of minimum 2 mm thickness.
The messenger cable shall be made from high tensile strength steel strands in order to prevent subsequent
drop of weight in service.
Clamping bolts shall be provided with self locking nuts as designed to prevent corrosion of the
threads. All ferrous parts including the messenger cable shalal be bot dip galvanised. The end of the
messenger cable shall be effectively sealed to prevent corrosion.
The vibration dampers and its attachment shall have smooth surface so that no corona occurs on
them.
The clamps of the stock bridge vibration dampers shall be so designed that in case of loosening of
the bolt or changing free parts of the clamp, it does not allow the damper to disengage from the conductor.
7.0 REPAIR SLEEVE FOR ACSR PANTHER,ZEBRA,MOOSE AND GROUNDWIRE :
Compression type repair sleeves shall be offered to provide reinforcement for conductor with broken or
damaged aluminium strands/galvanished steel ground wire broken in damaged steel strands. The repair
sleeve shall be designed to make good a conductor of which not more than one-sixth (1/6th) of the strands in
the outermost layer and damaged or severed. The repair sleeves after compression should present a smooth
surface.
8.0 SUSPENSION CLAMPS : FOR GROUND WIRE

Suspension clamps of suitable size are require for holding the galvanised steel stranded ground wire at
suspension points. The suspension clamps shall be suspended from the lower hanger or „D‟ belt of 16 mm.
dia. And should, therefore, be supplied with a suitable attached that would allow the clamps to swing freely
both in the transverse and longitudinal direction. The clamps shall be so designed that the effect of vibration
both on the groundwire and the fittings itself is minimum.
The clamps shall be manufactured and finished so as to avoid sharp radia of curvature, ridges which
might lead to localized pressure and damage the ground wire in service.
The clamps shall be made of heat treat malleable iron one Eye hook made of forced steel. The entire
assembly shall be hot dip galvanised.
The clamping surface shall be smooth and formed to support the groundwire on long easy curves to
take care or required steel vertical and horizontal angles.
The clamps shall permit the groundwire to slip before the failure of the latter occurs. The leg of U-
bolt holding the keeper piece of the clamps shall be kept sufficient long and shall be provided with threads,
nuts and locking nuts for fixing the flexible earthing hond between the suspension clamps and tower
structures.
9.0 TENSION CLAMPS (DEAD AND ASSEMBLY) FOR GROUND

WIRE.
Compression type dead end assembly of G.S.S. ground wire shall be required for use on the tension towers.
The dead end assembly shall be supplied with complete jumper terminals, nuts and bolts suitable link pieces
between the steel clevis and tower strain plates so as to provide sufficient flexibility not less than that of
G.S.S. ground wire and the tensile strength not less than 90% that of the G.S.S. ground wire.
The assemblies shall comprise of compression type dead end clamps and one anchor shackle made of
forget steel. The entire assembly shall be hot dip galvanised.
One of bolt holding joint per terminal of dead end assemblies shall be kept sufficiently long and
threaded and shall be provided with nuts, washers and locking nuts for fixing the flexible earthing bond
between the dead-end clamp and tower structures.
10.0 BONDING PIECES (FLEXIBLE COPPER EARTHING BOND FOR

EARTHWIRE 7/3.15 and 7/3.66 mm)
The tenderer shall offer flexible copper earthing bonding pieces for connecting the ground wire suspension
and tension clamps and tower legs suitable for earthing.

Each bond piece shall have suitable compression type galvanises steel lug or thimble on either and for
making connections to clamp and tower legs. The size, strength, etc. of the bonding piece is given in this
Specification.
11.0 INSULATOR HARDWARES
The insulator disc hardwares and string assemblies to be offered by the tenderer shall be suitable to meet the
requirement given in the specific technical particulars as detailed hereinafter.
Hardwares for suspension and tension insulator shall be suitable for insulator with normal pin shank
diameter of 20 mm. in case of tension string unit and 16mm. for suspension string unit.
Each insulator string shall generally include the following hardware components.
Single Suspension Set. Double Suspension Set.
a) Ball Hook a) Ball Hook.

b) tower side arcing horn b) Socket clevis with R-Type
security clip-3 Nos.
c) Socket Eye with R-Type security clip. c) Yoke Plate-2 Nos.

d) Line side arcing horn. d) Tower side arcing horns-
2Nos.
e) Armour grip suspension clamps e) Ball clevis – 2 Nos.
f) Line side arcing homs-2
Nos.
g) Clevis Eye.
h) Armour Grip Suspension
Clamp.
Single Tension Set : Double Tension Set :
a) Anchor Shackle. a) Anchor Shackle.
b) Ball Eye. b) Chain Link
c) Tower side arcing horn. c) Yoke Plate – 2 Nos.
d) Socket Clevis with R-Type security clip. d) Tower side arching horn.
e) Line side arcing horn e) Ball Clevis – 2 Nos.
f) Compression type dead end clamp. f) Socket Clevis with R-
Type security clip – 2 Nos.
g) Line side arcing horns.
h) Compression type dead end
clamps.
12.0 CLAMP
12.1 ARMOUR GRIP SUSPENSION CLAMPS
Armour Grip Suspension Clamp shall consist of 2 neoprene insert, one set of armour rods made of
aluminium alloy, two aluminium housing having inner profile matching with the profile of the armour rods
page and supporting strap made of aluminium alloy. The A.G. type suspension clamp shall be designed,
manufactured and finished as to have a suitable shape without sharp edges at the end and to hold the
respective conductor properly. It should, however, have sufficient contact surface to minimise damagedue to
fault current. The clamp shall be or Armour Grip Type.
The A.G. type suspension clamp shall permit the conductor to slip before the occurrence of failure of
the conductor and shall have sufficient slip strength to resist the conductor tension under broken wire
conditions. The clamp shall have slip strength of not less than 15 % of respective conductors.
12.2 TENSION CLAMPS
The Tension Clamps shall be made out of aluminium alloy and of compression type suitable for
PANTHER,ZEBRA & MOOSE conductor. The tension clamps shall not permit slipping or damage to
failure of the complete conductor or any part thereof at a load less than 90% of the ultimate strength of
conductor. The mechanical efficiency of tension / clamps shall not be affected by method of erection
involving come / along or similar clamps or tension stringing operation during or after assembly and
erection of tension clamp itself. The tension clamp shall be of a design that will ensure unrestricted flow of
current without use of parallel groove clamps.
The clamps shall be as light as possible.
12.3 ARCING HORNS

Each hardware assembly shall have provision for attaching arcing horns of both adjustable and
non/adjustable type across the suspension and tension strings or tower side. However each hardware
assembly shall be provided with arching horn of fixed type on line side only.
12.4 UNIVERSAL JOINTING COMPOUND

BENDEX-HV’ Universal jointing compound which is a chemically inert compound to be used as filler
for the compression joints and dead end clamps to be supplied.
13.0 TESTS, TEST CERTIFICATE AND PERFORMANCE REPORTS
The fittings and accessories for the power conductor and G.S.S. ground wire, insulator and hardwares shall
be tested in accordance with IS:2121, IS:2486, IS:9708 (For V Dampers), BS:916 for hexagonal bolts and
nuts or any other authoritative equivalent standards. Six sets of type and routine test certificates and
performance reports are to be submitted by the bidder.
The Employer however, reserves the right to get all the tests performed in accordance with the relevant I.S.
Specification as Acceptance Test in presence of Employer-s representatives.
The tenderer shall clearly state the testing facilities available in the laboratory at his Works and his ability to
carry out the tests in accordance with this Specification. All the specified tests shall be carried out without
any extra cost.
Acceptance Test for power conductor and G.S.S. ground wire accessories.
a) Visual examination
b) Dimensional verification
c) Failing load test
d) Slip strength test (for clamps)
e) Electrical resistance test
f) Resonance frequency test (for vibration dampers)
g) Fatigue test (for vibration dampers)
h) Mass pull off test (for vibration dampers)
i) Galvanising test.
13.1 ACCEPTANCE TEST FOR HARDWARES
a) Dimensional verification.
b) Ultimate tensile test.
c) Slip strength test.
d) Electrical resistance test.
e) Heating cycle test
f) Breaking strength of full string assembly.
g) Galvanising test.

13.2 SPECIFIC TECHNICAL REQUIREMENTS FOR CONDUCTOR
ACCESSORIES AND INSULATOR HARDWARES
Conductor Panther/zebra/Moose GSS ground wire
a) Type ACSR Panther/zebra/Moose Ground wire.
b) Material Aluminium conductor steel reinforced. Galvanised stranded

steel wire.
Panther/Zebra/Moose
c) Strand & Wire Aluminium 30/3mm 7/3.15 mm. and 7/3.66
diameter. Steel 7/3mm,/all.54/3.18mm mm
steel-7/3.18mm,/ all.54/3.53mm
steel-7/3.53mm
resp.
974/1622 /2004Kg/Km. 426 Kg/Km.and

d) Weight per Km. 583Kg/Km
21/28.62/31.7 mm 9.4mm. and 10.98 mm
e) Overall diameter 3.375 Ohms/KM
0.13750/0.06915/0.05552 Ohms/KM.
f) D.C. Resistance at
20 deg. C when corrected
to standard weight. 144/13289/16120 Kg 5710 Kg.and 10580 Kg
g) Minimum Breaking
load/Ultimate tensile
strength.
1393 Kg.
h) Maximum working 3806/4325 Kg.
tension at minimum
temperature & 2/3 full
wind.
i) Maximum Sag at 5150mm.

maximum temperature & 6120/9240 mm.
no wind.

DISC Insulator (for suspension & tension Insulator strings) (132 ,220 and 400 KV)
Disc Insulators Suspension Tension
a) Type Ball & Socket Ball & Socket.

b) Ball size 16mm. Alt. B 20mm. Alt.
c) Diameter (IS:2486 Pt.II) B/20mm
d) Spacing 254/255 mm. (IS:2486 Pt.II)
e) E.M. 146/145 mm. 255/280 mm
strength 90/120 KN,. 145/170mm.
120/160 KN.
Single Single Double Double

Suspension Tension Suspension Tension
132 KV / 220 KV /400 KV
String Arrangements :
a) No. of insulator 10/14/25 10/14/25 2x10/2X14 2x10/2
discs. /2X25 X14/
b) Length of string 1672/2340 1851/3003 1837/2243 2X25
assembly (mm) 2132/30
82

GENERAL REQUIREMENT FOR POWER CONDUCTOR &
GROUND WIRE:
I) ACCESSORIES.
GENERAL REQUIREMENTS
POWER CONDUCTOR AND GROUND WIRE ACCESSORIES
A) MID-SPAN COMPRESSION JOINTS
Suitable for ACSR Suitable for G.S.S. groundwire
“Panther‟/zebra/Moose 7/3.15 and 7/3.66 mm.
i) Type Compression Compression
ii) Material Extruded Extruded

a) Outer sleeve Aluminium aluminium.
b) Inner sleeve Steel (galvanised) Steel (Galvanised)
Before After Before After

Compress-ion Compre- Compression Compressi
ssion on
iii) Dimension of Outer Adjacent

Compression joint for dia:38mm Size 32 mm.
Aluminium part. Inner Diagonal
Dia:23mm. Size : 37nn.
Minimum
length :
610mm.
Minimum
weight
1.2 kg.
(approx)
iv) Dimension of Outer Adjacent Outer dia.18mm. Adjacent
compression joint for Steel dia:18mm size : Inner dia : size : Size :
Part Inner dia. 9.3 15.1mm. 17.4mm Length Diagonal
mm Adjacent 10mm. 203mm.
Size : 15.1mm Minimum
Minimum
Length :
203mm.
Minimum
weight :
0.28Kg (app.)
v) Minimum failing load. 95% of ultimate tensile 95% of ultimate tensile strength
strength of conductor of groundwire
vi) Electrical resistance 20 75% of measured resistance

Deg. C of the equivalent length of
conductor.
vii) Galvanising :
a) Ferrous Parts. Hot-dip galvanised (HDG) Hot dip galvanised.
4 dips
b) No.of dips 4 dips for 1 4 dips
minute withstand.
viii) Minimum Corona 110% of maximum line to

formation voltage ground voltage
B) VIBRATION DAMPERS:
(SUITABLE FOR ACSR CONDUCTOR: PANTHER/ZEBRA /MOOSE AND G.S.S.

GROUND WIRE 7/3.15 and 7/3.66 mm.
i) Type : 4R Stock Bridge Type

ii) Distance between conductor : 74.5 mm. & axis of the Vibration Damper.
iii) Messenger Cable : 130 Kg/mm sq. quality (19 strands)
iv) Bolt size : 16 mm. (dia.)
v) Slip strength of messenger Cable : 500 Kgs.
vi) Mass pull-of : As per I.S.S.
C) REPAIR SLEEVES:
SUITABLE FOR ACSR PANTHER/ZEBRA/MOOSE CONDUCTOR AND
G.S.S. GROUND WIRE.
Suitable for ACSR Suitable for G.S.S.

panther/Zebra/Moose. Ground wire.
i) Type Compression Compression.
ii) Material Extruded aluminium. Steel
iii) Min. failing load 95% of UTS of 95% of UTS of ground

conductor. wire.
iv) Length 241/279 mm. 200 mm (150 mm. min.)
v) Dimension :
a) After compression 21mm 11.5 mm

(i) Adjacent side
(b) Before Compression

: 21mm.
(i)Outerdiameter 11.5mm.
38/48mm.
(ii)Innerdiameter
23/40mm
vii) Electrical Not more than

Resistance at 75% of the resi-
20 deg. C stance of equivalent
length of conductor.
vii) Galvanising :
Hot – dip galvanized
a) Ferrous parts
b) No. of dips for 4 dips

one-minute stand.
D) SUSPENSION CLAMP:
FOR GROUND WIRE 7/3.15 and 7/3.66 mm
i) Type : Envelop type
ii) Material : Forged Steel / NCL.
iii) Minimum slip strength : 25% of UTS of ground wire.
iv) Dimension :
(a) Overall length : 230mm
(b) Inner dia. (before : 10mm.

compression).
(c) Outer diameter : 18mm.

(before compression).
(d) After Compression :
Adjacent : 15.1 mm.
Diagonal side : 17.4mm.
(e) Galvanising :
(i) Fwerrous parts. : Hot-dip galvanised.
(ii) No. of dips for one- : 4 dips

minute withstand.
E) BONDING PIECES:
a) material : flexible copper bond (37/7/
0.417 mm. tinned copper flexi-
ble stranded cable).
b) Length : Not less than 750 mm.
c) Bolt size : 16mm x 40 mm.
d) Copper area. : 34 sq.mm.
e) Thickness of long : 6 mm.
f) Material for connect - : Tinned Brass

ing socket.
F) INSULATOR HARDWARES
A) String hardwares :
Material and strength
Description of item. Material UTS
i) Bolt hook Forged Steel 11,500 Kgs (90 KN)
ii) Anchor Shackle -do- 15,500 Kgs (120 KN)
iii) Socket Eye Horn - do- 11,500 Kgs (90 KN)

Holder.
iv) Socket Clevis. -do- 15,500 Kgs.
v) Ball Clevis -do- 15,500 Kgs.
vi) Clevis Eye -do- 15,500 Kgs.
vii) Socket Eye. -do- 15,500 Kgs.
vii) Bottom / Top Yoke plate :
Double suspension Mild Steel 11,500 Kgs.
Double Tension -do- 15,500 Kgs.
ix) Arcing Horn -do- ___
x) Suspension Clamp. Aluminium ___

Alloy and
Neoprene.
xi) Tension Clamp. All.Alloy & 11,500 Kgs.

Steel.

xii) Ball Pin High tensile 90% of UTS of
forged steel conductor.
(hot-dip
galvanised)
xiii) Security Clip Brass (R-Type)

Mininum failing load Single Suspension : 11,500
String (KN) Single Tension : 11,500/15,500
Double Suspension : 11,500
Double Tension : 11,500/15,500
II) CLAMPS.
Single Single tension Double Double

suspension string suspension tension
string string string.
i) Type AGS Type Compression AGS Type Compression

Type Type
ii) Material Aluminium Aluminium Aluminium Aluminium

Alloy and Alloy and Steel Ally and Alloy and
neoprene Neoprene Steel
ii) Minimum Not less than 90% of UTS of Not less than 90% of UTS
slip strength 15% conductor 15% of UTS of of conductor
conductor
iv) Minimum 11,500 90% of UTS of 11,500 90% Of UTS of

failing load conductor conductor
(kg)
III). Suspension assembly: armour grip clamp.

1. The armour grip suspension clamp shall comprise of retaining strap, support housing, elastomer
inserts with aluminum reinforcements and AGS preformed rod set.
2. Elastomer insert shall be resistant to the effects of temperature up to 85 deg. C, ozone,

Ultraviolet radiation 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 preformed rod set. The elastomer insert shall be so designed that the
curvature of the AGS rod shall follow the contour of the neoprene insert.
3. The AGS preformed rod set shall be as detailed above in general except that 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.
IV) Fasteners: bolts, nuts & washers.

1. All bolts and nuts shall conform to IS-6639 – 1972. All bolts and nuts shall be galvanized. All
bolts and nuts shall have hexagonal heads, the heads being truly concentric, and square with the
shank, which must be perfectly straight.
2. Bolts upto M16 and having length upto ten 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-I to ensure proper bearing.
3. 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.
4. 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 not 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 be tight to the point where shank of the bolt connects to the head.
5. 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-2016-1967.
6. The bidder shall furnish bolt schedules giving thickness of components connected, the nut and
the washer and the length of shank and the threaded portion of the bolts and size of holes and
any other special details of this nature.
7. To obviate bending stress in bolt, it shall not connect aggregate thickness more than three time
its diameter.
8. Bolts at the joints shall be so staggered that nuts may be tightened with spanners without
fouling.
9. Fasteners of grade higher than 8.8 are not to be used and minimum grade for bolts shall be 5.6.
GENERAL:
1. 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 be done in accordance with IS-2629-
1985 and shall satisfy the tests mentioned in IS 2633-1986. Fasteners shall withstand four dips
while spring washers shall withstand three dips of one-minute duration in the standard Preece
test. Other galvanized materials shall be guaranteed to withstand at least six successive dips each
lasting one minute under the Standard Preece test for galvanizing.
2. 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 of grade Zn 99.95 as per IS 209-1979.
3. Pin balls shall be checked with the applicable “G)” gauges in at least two directions, one of
which shall be across the line of die flashing and the other 90 deg. to this line. „NO GO‟ gauges
shall not pass in any direction.
4. Socket ends, before galvanizing shall be of uniform contour. The bearing surface of socket ends
shall be uniform about the entire circumference without depressions or high spots. The internal
contours of socket ends shall be concentric with the axis of the fittings as per IS 2486/IEC-120.
The axis of the bearing surfaces of socket ends shall be coaxial with the axis of the fittings.
There shall be no noticeable tilting of the bearing surfaces with the axis of the fittings.
5. All current carrying parts shall be so designed end manufactured that contact resistance is
reduced to minimum.
6. Welding of aluminum shall be by inert gas shielded tungsten are or inert gas, shielded metal arc
process. Welds shall be clean, sound, smooth, and 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.
Electrical Design:
The normal duty and heavy duty suspension, light duty, normal duty and heavy duty tension
insulator sets shall all comply with the technical requirements of schedule C and satisfy the test
requirements stated in Section-7.
Mechanical design:
The mechanical strength of the insulators and insulator fittings shall be as stated in Schedule-C
The design shall be such that stresses due to expansion and contraction in any part of the
insulator shall not lead to the development of defects.
Insulating material shall not engage directly with hard metal. All fixing materials shall be of
approved quality, shall be applied in an approved manner and shall not enter into chemical action
with the metal parts or cause fracture by expansion in service. Where cement is used as a fixing
medium, cement thickness shall be as small and even as possible and proper care shall be taken to
correctly centre and locate the individual parts during cementing.
Technical Specification for Design, Supply and Testing of Hard ware fittings.
Type tests:
The following type tests shall be conducted on hardware fittings.
A. On suspension hardware fittings only.
(a) Magnetic power loss test.

(b) Clamp slip strength Vs torque
(c ) Mechanical strength test.
(d) On one test on elastomer.
B. On Tension hard ware fittings only.

Electrical resistance test for IS 2486 (Part-I) 1971
Dead end assembly.
(a) Heating cycle test for -do-

dead end assembly.
(b) Slip strength test for IS 2486 (Part-I)

dead end assembly.
(c ) Mechanical strength test.

C. On both suspension and tension hardware fittings.
(a) Visual examination. IS-2486 (Part-I) 1971
(b) Verification of dimension. -do-
(c ) Galvanizing / electroplating test. -do-
(d) Mechanical strength test of each component

(including corona control ring/grading ring and arcing horn)
(e) Mechanical strength test of welded joint.
(f) Mechanical strength test for corona control ring/

grading ring and arcing horn. BS-3288 (Part-I)
(g) Test on locking device for ball and socket coupling. IEC – 3721984
(h) Chemical analysis, hardness tests, grain size,

inclusion rating and magnetic particle inspection for forging/casting.
D. On suspension hardware fittings only.
(a) Clamp slip strength ver as torque test for suspension clamp.
(b) Shore hardness test of elastomer cushion for AG suspension clamp.
(c) Bend test for armour rod set. IS-2121 (Part-I)
(d) Resilience test for armour rod set. -do-
(e) Conductivity test for armour rod set. -do-
E. On tension hardware fittings only
Unit. 37/4.00 mm2
MID SPAN COMPRESSION JOINTS FOR

CONDUCTORS.
Weight of the joint. Kg. 1.27
Slipping strength. KN 129.6
Resistance of the completed joint. Ohms. 0.000027
Materials of the joints specify alloy type and its 6201
aluminum contents.
Before compression dia of sleeve. mm
(a) Inner diameter. 31+/-0,5
(b) Outer diameter. 48+/-1.0
Dimensions after compression. mm
(a) Corner to corner. 46+/-0.5
(b) Surface to surface. 40+/-0.5
Length of the sleeve. mm
(a) Before compression. 500+/-5.0
(b) After compression. 540+/-5.0
Compression pressure. Tone 100
Whether designed for intermittent or continuous Continuous
compression. compression.
Minimum corona extinction voltage under dry Kv 154

condition.
Radio interference voltage under conditions. Micro Below 1000
volt.
REPAIR SLEEVE FOR CONDUCTOR
Weight of the sleeve. Kgs. 0.63

Before compression dia of sleeve.
(a) Inner diameter. mm 31.05
(b) Outer diameter. mm 48.10
Dimensions after compression.
(a) Corner to corner. mm 48.05
(b) Surface to surface. mm 40.05
Length of sleeve.
(a) Before compression. mm 279.50
(b) After compression. mm 300.50
Compression pressure. Tone. 100
Minimum corona extinction voltage under dry Kv. 154
condition.
Radio interference voltage under condition. Microvolt. Below 1000
(a) Slip strength test for dead end assembly. IS-2121 (Part-I)
All the acceptance tests stated at clause shall also be carried out on composite insulator unit, except
the eccentricity test at clause. In addition to these, all the acceptance tests indicated in IEC 1109 shall
also be carried out without any extra cost to the employer.
F. For hardware fittings.
(a) Visual examination. IS-2121 (Part-I)
(b) Proof & test.
G. Tests on conductor accessories.
H. Type tests.
I. Mid span compression joint for conductor and earthwire.
(a) Chemical analysis of materials.
(b) Electrical resistance tests. IS-2121 (Part-II) 1981 clause 6.5 & 6.6
(c) Heating cycle test. -do-

(d) Slip strength test. -do-
(e) Corona extinction voltage test (dry)
(f) Radio interference voltage test (dry)
J. Repair sleeve for conductor.

(a) Chemical analysis of materials.
VIBRATION DAMPER FOR CONDUCTOR.
Vibration Damper for AAC 37/4.00 mm Unit.
Total weight of the damper. Kgs. 4.5

Left. Right.
Weight of each damper mass. Kgs. 1.6 2.2
Resonance frequencies.
1. First frequency. Hz 12+/- 1 18+/- 2
2. Second frequency. Hz 28+/- 2 36+/- 2
Dimension of each damper mass. Mm 55 Ox165 60 Ox195
Material of:
1. Damper miss. Cast iron hot dip galvanized.
2. Messenger cable. High tensile galvanized steel wire.
No. of strands in messenger cable strands. 19
Lay ratio of messenger cable strands. 9-11

Min tensile strength of messenger cable. Kg./ 135
Sq.mm
Miss pull-off strength. KN 5
Clamping forque. Kg.m 7
Slipping strength of the damper clamp. KN
1. Before fatigue test. 2.5
2. After fatigue test. 2.0
Magnetic power loss per vibration damper. Watts. 1 watt at 500 amps.
Min. corona extinction voltage under dry Kv. 154

conditions.
Radio interference voltage under dry condition Microvolt. Below 1000
1MHz, at 154 KV.
Percentage variation in reactance after fatigue test
in compassion with that before the fatigue test. % 20

SECTION – V
CLAMPS AND CONNECTORS
S.NO. DESCRIPTION
(A)TECHNICAL SPECIFICATION FOR CLAMPS & CONNECTORS
1. SCOPE
2 STANDARDS
3. MATERIAL AND WORKMANSHIP
4. RATING
5. EQUIPMENT CONNECTORS
6. TEMPRATURE RISE
7. WEIGHTS
8. INTERCHANGE ABILITY
(B)TECHNICAL SPECIFICATION FOR ACSR BUS-BAR
1. SCOPE
2. MATERIALS
3. MECHANICAL CHARACTERISTICS
4. DIMENSIONAL TOLERANCE
5. CHEMICAL COMPOSITION
6. ELECTRICAL & MECHANICAL CHARACTERISTICS
AND CURRENT RATINGS

TECHNICAL SPECIFICATION
CLAMPS AND CONNECTORS
(A) TECHNICAL SPECIFICATION FOR CLAMPS & CONNECTORS
1. SCOPE
This specification covers design, manufacture, assembly, testing at manufacturer‟s works, supply and
delivery at site of all terminal connectors of 220,132 & 33KV equipments (mainly breaker, isolator,
CT,PT,CVT,BPI and LA) and all other clamps and dropper connectors required for the switch yard
as per approved lay out and system design.
2. STANDARDS
The terminal connectors under this specification shall conform strictly to the requirements of the
latest version of the following standards as amended up-to-date, except where specified otherwise.
i) IS: 5561 Power Connectors.

ii) IS:617 Aluminium & Aluminium Alloy
iii) IS: 2629 Recommended Practice for hot dip galvanizing of iron and
steel.
iv) IS: 2633 Method of testing uniformity of coating of zinc coated articles.
The materials conforming to any other authoritative standards which ensure equal or better
performance shall also be acceptable. The salient point of these specifications and points of
difference between these and the above specifications, shall be clearly brought out in the bid.
3. MATERIAL & WORKMANSHIP
The terminal connectors shall be manufactured from Aluminium Silicon Alloy and conform to
designation A6 of IS: 617 (latest edition)
The connectors shall be of best quality and workmanship, well finished and of approved design.
Specific materials for clamps and connectors should have high current carrying capacity, high
corrosion resistance and be free from corona formation.
All connectors or its components to be connected with ACSR conductor shall be of compression
type having aluminium purity not less than 99.5%.
All bus bar clamps shall be made preferably from forged aluminium of purity not less than
99.5%. The thickness and contact surface should be maintained in such a way that the clamp should
conform to IS:5561/1970 or any latest revision thereof.
4. RATING
The connector rating shall match with the rating of the respective equipments for the terminal
connectors and the connectors for bus bar and dropper should be of the following rating. Minimum
thickness at any part of connector shall be 10(ten)mm. Indicative ratings are given below:

Rating 400/220 / 132 KV
1. Main bus bar connectors high level and 3600/2000/2000

low level (Amps)
2. High level bus sectionalisation 3600/2000/2000
isolator(Amps)
3. Connectors along the bay (Amps) 3600/2000/2000
4. Terminal connectors for CB(Amp.) as per rating of CB
5. -do- for Isolator(Amps) as per rating of ISO
6. -do- for CT As per CT rating
7. -do- for PI As per PI rating
8. -do- for LA As per LA rating
9. -do- for PT As per PT rating
10. -do- for CVT As per CVT rating
11. -do- for WT As per WT rating.
5. EQUIPMENT CONNECTORS
Bimetallic connectors shall be used to connect conductors of dissimilar metal. The following
bimetallic arrangement shall be preferred.
i) copper clodding of minimum 4 mm. thickness on the aluminium portion of connector coming
in contact with the copper palm or stud of the equipment.
ii) alternatively, to provide cold rolled aluminium
copper strip between the aluminium portion of the connection, the sheet thickness shall not be less than 2
mm.
Sufficient contact pressure should be maintained at the joint by the provision of the required number
of bolts or other fixing arrangements, but the contact pressure should not be so great as to clause
relaxation of the joint by cold flow, the joint should be such that the pressure is maintained within
this range under all conditions of service, to avoid excessive local pressure, the contact pressure
should be evenly distributed by use of pressure plates, washers or suitable saddles of adequate area
of thickness should be less than that of an equal length of conductor where measured individually
test results showing the milli drop test and resistance should be enclosed with the bid.
All connectors shall be so designed and manufactured as to offer ease of installation as these
are to be used in overhead installations, design shall be such that full tightening of nuts and bolts
should be possible with the use of double wrench.
The connectors shall be such as to avoid local corona, sound or visible discharge.
6. TEMPRATURE RISE
The temperature rise of connectors when carrying rated current shall not exceed 45˚ C above
reference design temperature of 50˚ C.
i) Acceptance Tests
(a) Tensile Test
(b) Temperature rise test
© Temperature rise test
ii) Routine Test
(a) Visual Inspection
(b) Dimensional Check

Type test reports from a recognized laboratory shall have to be submitted.
7. WEIGHTS
Weights of different materials uses in manufacture, such as aluminium, silicon, copper etc.
should be clearly indicated in the bid.
8. INTERCHANGE ABILITY
Corresponding parts of similar clamps and connectors shall be made to gauge or jig and shall
be interchangeable in every respect.
(B) TECHNICAL SPECIFICATION FOR ACSR BUS-BAR

1. SCOPE
The specification covers design, engineering, manufacture, testing at manufacturer‟s works, supply
and delivery of heavy duty ACSR bus-bar for use in 220 KV and 132 kV sub-station.
2. MATERIALS
The ACSR bus bar shall be drawn by using MOOSE/ZEBRA as per system requirement.
The strung ACSR bus-bar shall be of heavy duty type and design to operate within set temperature
limits and to withstand thermal and electromechanical forces developed due to short circuits.
3. MECHANICAL CHARACTERISTICS
The mechanical strength of the strung ACSR bus-bar shall be limited to be maximum allowable
tension for specific size of conductor as per ISS.
4. DIMENSIONAL TOLERANCE
Dimensional tolerances shall be as per relevant ISS.
5. CHEMICAL COMPOSITION
The chemical composition for ACSR conductors (MOOSE/ZEBRA) shall be holding good under all
operating condition.
6. ELECTRICAL & MECHANICAL CHARACTERISTICS AND CURRENT RATINGS
Electrical and mechanical characteristics and current ratings for ACSR bus-bar shall be same as
stipulated for MOOSE/ZEBRA ACSR conductors, the details of which has been specified.

SCHEDULE OF GUARANTEED TECHNICAL PARTICULARS
LINE HARDWARE AND ACCESSORIES FOR 132/220 KV & GROUND WIRE 7/3.15mm
A HARDWARES Suspension Tension

i Maker’s name and Address ERI-TECH LIMITED
ii Size and designation of ball and socket with 16mmB as per IS 2486 20mm as per IS 2486
standard specification to which conforming
iii Material
a Anchor shackle NA Forged steel Galvanised
b Chain Link NA Forged Steel galvanised
c Ball hook / Ball Link (HH) Forged Steel galvanized Forged Steel galvanised
d Socket Eye (HH) Forged Steel galvanized NA
e Ball Clevis Forged Steel galvanized Forged Steel galvanised
f Socket Clevis Forged Steel galvanized Forged Steel galvanised
g Yoke Plate Mild Steel Galvanised Mild Steel Galvanised
h Arcing Horn Mild Steel Galvanised Mild Steel Galvanised
i Clamp Suspension A.G.S. Clamp NA
j Dead End/Cross arm strap NA NA
k Dead end clamp(Compression) NA Ext. Al. Alloy
iv Standard specification to which the Hardwares
IS 2486, IS: 2004,IS:617, IS-2633, & IS-733
conform
v Standard specification to which conforming IS: 2486
vi Galvanising
a Ferrous parts Hot Dip Galvanised
b Spring washers Electro Galvanised
c Quality of zinc used 99.5%
d Number of dips which the clamp can withstand 4/ 1 minute dips
vii Standard to which conforming IS 2633
viii Reference to drawing No. Drg. Attached
ix Minimum failing load in kg For AAAC & For AAAC & ACSR For AAAC & ACSR
ACSR Panther Zebra (220 kv) Moose (220 kv/400
(132 kv) KV)
a For Single Tension Hardwire Fittings 120 kN 160 kN 160 kN
b For Double Tension Hardwire Fittings 120 kN 160 kN 160 kN
c For Single Suspension Hardwire Fittings 70 kN 70 kN 90/120 kN
d For Double Suspension Hardwire Fittings 70 kN 70 kN 120 kN
B. TENSION CLAMPS Suitable for Panther, Zebra & Moose (AAAC/ACSR)
i Type Compression type tension clamp
ii Material Ext. Al. Alloy/ Ext. Al.
iii Breaking Strength 95% of UTS of Conductor
iv Slipping strength 95% of UTS of Conductor
v Galvanising
vi Standard to which conforming IS 2633
vii Electrical Conductivity
a. Results of heating cycle test carried out T.C. Attached
b. Electrical resistance Not more than 75% of equivalent length of conductor
viii Reference to type tests and other tests reports
T.C. Attached
attached
ix Make of bolts and nuts used Local Make
Panther Zebra (AAAC/ACSR) Moose
C SUSPENSION CLAMPS (AAAC/ACSR)
(AAAC/ACSR)
i Type AGS Type
ii Type of material used for retaining rod for AGS Aluminium Alloy Aluminium Alloy 6061/ Aluminium Alloy
assembly giving reference of ISS 6061/ Equivalent 6061/ Equivalent
Equivalent
iii minimum tensile strength of retaining rod 35 kg/mm2 35 kg/mm2 35 kg/mm2
material
iv Chemical composition of retaining rod material As per IS:733 As per IS:733 As per IS:733
v Electrical conductivity of Armour Rod material Not less than Not less than 40% of Not less than 40%
(in percentage of the conductivity of IACS i.e. 40% of IACS IACS of IACS
International Annealed Copper Standard
vi Slipping strength of cushioned suspension 8% to 15% of 20 to 29 KN of UTS of 20 to 29 KN of
assembly UTS of Conductor UTS of Conductor
Conductor
vii Breaking strength of suspension Clamp 7000kgf 7000kgf 9000kgf
viii Physical properties of neoprene cushion
a Minimum Tensile Strength 2000 psi 2000 psi 2000 psi
b Minimum ultimate Elongation 300% 300% 300%
ix Ageing (guaranteed life of the assembly) 40 years 40 years 40 years
x Hardness 65 to 80 A 65 to 80 A 65 to 80 A
D Midspan compressions joints for Panther Zebra

AAAC ACSR AAAC ACSR
i Type Compression Type
ii Suitable for AAAC Panther ACSR AAAC Zebra ACSR
Panther Zebra
iii Materials
a Outer Sleeve Ex. Al. Alloy Ex. Al. Ex. Al. Alloy Ex. Al.
Galvanised Galvanise
b Inner Sleeve N.A. N.A.
Steel d Steel
iv Outer Sleeve
a Outer Dia. Before compression (mm) Ø 38 Ø 38 Ø 48 Ø 48
b Flat to Flat After compression (mm) 32 32 40 40
v Length of Outer Sleeve
a Before compression (mm) 610 610 711 711
b After compression (mm) 655 660 760 768
vi Inner Sleeve
a Outer Dia. Before compression (mm) N.A. Ø 18 N.A. Ø 19.2
b Flat to Flat After compression (mm) N.A. 15.1 N.A. 16.1
vii Length of Inner Sleeve
a Before compression (mm) N.A. 203 N.A. 241
b After compression (mm) N.A. 230 N.A. 273
viii Weight of Sleeve
a Aluminium (kg) 1.2 1.2 2.032 2.032
b Galvanised Steel (kg) N.A. 0.295 N.A. 0.410
ix Galvanising
b Spring washers Electro Galvanized
x Standard to which conforming IS 2633
Slipping strength of mid span joint expressed as
xi 95%
percentage of UTS of conductor

Breaking strength of mid span joint expressed
xii 95%
as percentage of UTS of conduct
Conductivity of Compression joint expressed as
xiii 100% of equivalent length of conductor
percentage of conductivity of cable
Resistance as percentage of measured
xiv Not more than 75% of equivalent length of conductor
resistance of equivalent length of conductor
AAAC & ACSR Panther AAAC & ACSR

E Repair Sleeve
Zebra
i Type Compression type
ii Suitable for AAAC ACSR AAAC ACSR Zebra
Panther Panther Zebra
iii Outside diameter or length of sleeve
a Before compression (mm) Ø 38 Ø 38 Ø 48 Ø 48
b After compression Flat to Flat (mm) 32 32 40 40
iv Length of Sleeve
a Before compression (mm) 241 241 279 279
b After compression (mm) 270 270 310 310
v Material Ex. Al.Alloy Ex. Al. Ex. Ex. Al.
Al.Allo
y
vi Weight of sleeve in (kg) 0.450 0.453 0.810 0.810
vii Breaking strength as percentage of UTS of
95%
conductor
viii Conductivity as percentage of conductivity of
100% of equivalent length of conductor
conductor
ix Resistance as percentage of measured
Not more than 75% of equivalent length of conductors
resistance of equivalent length of conductor
F Vibration Damper For AAAC & ACSR ZEBRA

i Total weight of the damper (Kg) 4.5 Approx
Left Right
ii Weigh of each damper mass (kgs.) 1.6 2.2
iii Resonance frequencies
1. First frequency (Hz) 12+ 1 18+ 2
2. Second frequency (Hz) 28+ 2 36+2
iv Dimensions of each damper mass 60 Φ x 195 55 Φ x 165
v Material of :
1. Damper mass Cast iron hot dip galvanised.
2. Messenger cable. High tensile galvanised steel wire.
vi Galvanising
vii Standard to which conforming IS 2486 and IS 2633
viii No of strands in messenger cable strands 19
ix Lay ratio of messenger cable strands 9 11
x Min tensile strength of messenger cable ( kg
135
/sq. mm)
xi Mass pull – off strength (KN) 5
xii Clamping torque (Kg.m) 7
xiii Slipping strength of the damper clamp
1.Before fatigue test (KN) 2.5
2. After fatigue test (KN) 2

xiv Magnetic power loss per vibration damper
1 watt at 500 amps
(Watts)
xv Min. corona extinction voltage under dry
154
conditions (KV)
xvi Radio interference voltage under conditions 1
Below 1000
MHZ, AT 154 KV (Microvolt)
xvii Percentage variation in reactance after fatigue
test in comparison with that before the fatigue 20
test (%)
G Midspan compression joint For 7/3.15mm

Galvanised Stranded Steel Wire
i Material Galvanized Steel
ii Size OD 20.2 x Length 230
iii Suitable for groundwire Yes (7/3.15)
iv Weight in kg 0.85
v Minimum failing load 50 KN
vi Galvanization
d Number of dips which the clamp can withstand 4 / 1 minute dip
vii Standard to which conforming IS 2633
H Suspension Clamps For 7/3.15mm Galvanised

Stranded Steel Wire
i Materials Malleable Cast Iron / Galvansied Steel
ii Size As per Drawing
iii Suitable for groundwire Yes (7/3.15)
iv Weight in kg
v Slip strength 12-17 KN
vi Minimum failing load 70 KN
vii Galvanising
c Quality of Zinc used 99.5%
d Number of dips which the clamp can withstand 4/1 minute dips
viii Standard to which conforming IS 2486 and IS 2633
I Compression type dead end assemblies For

7/3.15mm Galvanised Stranded Steel Wire
i Materials Forged steel
ii Size As per drawing
iii Suitable for ground wire Yes (7/3.15)
iv Weight in kg 3.69
v Minimum failing load 70 KN
vi Galvanising
b Spring washers Electro Galvanized
vii Standard to which conforming IS 2486 and IS 2633
J Flexible copper bond

i Drawings enclosed Yes

ii Stranding 37/7/0.417
iii Cross sectional area (Sq.mm) 75.6
iv Minimum copper equivalent area (Sq.mm) 34 (each individual wire)
vi Length of copper cable (mm) 500
vii Material lugs Tinned Copper
viii Bolt Size
(i) Diameter (mm) 16
(ii) Length (mm) 40
ix Resistance (Ohm) 0.0004 ( as per IS:2121)
x Total weight of flexible copper bond (kg) 0.45 (approx)

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ODISHA POWER TRANSMISSION CORPORATION LIMITED

TS-Vol-III E20-COND, E/W, INSULATORS- Page 1/69

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12.14 (v)Stress Strain Curves

TS-Vol-III E20-COND, E/W, INSULATORS- Page 8/69

1. Size of conductor: 54/7/3.53 mm 54/7/3.18 mm

0.7036 x 106 Kg x CM2

9. Co-efficient of linear expansion -------------19.3 x 10-6 -------------------

10. Standard area of Cross Section in 597.0 mm2 484.5 mm2

TS-Vol-III E20-COND, E/W, INSULATORS- Page 9/69

6. Minimum breaking load: 9.91 1.23 12.22 1.49

7. Zinc coating of steel

8. Maximum resistance at: 3.626 2.974 2.921 20°C of

9. Minim Purity of aluminum rod: ------------------------99.5 %-------------------

TS-Vol-III E20-COND, E/W, INSULATORS- Page 10/69

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1 Stranding and wire diameter 54Al /3.53 mm+7 Steel/3.53 mm

Minimum breaking load of strand before stranding 1.57 kN

Minimum breaking load of strand after stranding 1.49 kN

Maximum DC resistance of strand at 2O oC 2.921/km

Minimum breaking load of strand after stranding 12.22 kN

Diameter of steel strands Standard 3.53 mm

14b Steel Carbon 0.50 to 0.85 %

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1. Diameter Steel Aluminum

Standard 3.00 mm 3.00 mm

Maximum 3.06 mm 3.03 mm

Minimum 2.94 mm 2.97 mm

2. Cross Sectional Area

of nominal Diameter Wire 7.069 mm2 7.069 mm2

3. Weight 55.13 Kg/KM 19.11Kg/Km

4. Minimum tensile strength 134Kg/mm2 16.87Kg/mm2

5. Minimum breaking load 9.29 KN 1.17 KN

6. Minimum breaking load 8.83 KN 1.11 KN

7. Zinc coating of steel strands

No and duration of dips 3 (1 Min. dip)

Minimum Weight of As per IS 4826-1979

8. Maximum resistance at 4.079 Ohms/KM

20°C of Aluminum strands

9. Purity of aluminum rod 99.5%

TS-Vol-III E20-COND, E/W, INSULATORS- Page 15/69

1. Conductor Steel cored Aluminum

TS-Vol-III E20-COND, E/W, INSULATORS- Page 16/69

4. SIZE AND CONSTRUCTION

6. TESTS AND TEST CERTIFICATES

7. PACKING AND MARKING

8. SAG AND TENSION CHARTS AND SAG TEMPLATE

9. OVERHEAD EARTH CONDUCTORS

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(i) Material : Steel

(vii) Zinc coating :

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Table for Technical parameters for earth wires