BIDDING DOCUMENTS FOR CONDUCTOR PACKAGE OF 400 KV D/C SUGEN-PIRANA TRANSMISSION LINE ASSOCIATED WITH 1147.

5 MW SUGEN CCPP

Volume - II Technical Specifications

Document Code: DC-TPGL-SPTL-05

This document is meant for the exclusive purpose of bidding against this specification and shall not be transferred, reproduced or otherwise used for purpose other than that for which it is specifically issued.

VOLUME - II

CONTENTS :

SECTIONI SECTIONII

GENERALINFORMATIONANDSCOPE TECHNICALSPECIFICATIONFORACSRMOOSE CONDUCTOR

SECTION-I

ClauseNo. 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0

TECHNICALSPECIFICATIONS SECTIONI CONTENTS Description GeneralInformation Scope WeightsandMeasures GeneralTechnicalConditions TechnicalDescription TestandStandards TechnicalParticulars TechnicalInformation ServiceCondition

PageNo. 1 1 1 1 6 6 7 8 8

1. 1.1

TECHNICALSPECIFICATIONS SECTIONI GeneralInformation The material covered in this specification shall be used in following Transmission Line. Package Linelength i) 400kVD/CTransmissionLine SugentoPirana B:ACSRMOOSE Conductor 210km(approx.)

2. 2.1

Scope The material to be supplied on final destination at site basis as covered in this volume shall be designed, manufactured and tested as per the requirements specified. Final Destination shallmean the stores established by theContractor of theOwneralongtheTransmissionLines. The materials covered here under this specification shall be supplied complete in all respects, including all components, fittings and accessories which are necessary or are usual for their efficient performance and satisfactory maintenance under the various operating and atmospheric conditions. Such parts shall be deemed to be within the scope of the Contract, whether specifically included or not in the SpecificationorintheContractSchedules.TheSuppliershallnotbeeligibleforany extrachargesforsuchfittings,etc. The details of the materials required for the Conductor package under this Specification are mentioned in the bidding documents. WeightsandMeasures All weights and measures shall be in System International (S.I.) units. All fasteners shallbeofMetricsizeonly. GeneralTechnicalConditions The following provisions shall supplement all the detailed technical specifications and requirements brought out in the accompanying Technical Specifications. The Bidders proposal shall be based on the use of equipment and materials complying fullywiththerequirements,specifiedherein. TheBiddershallfurnishclausebyclausecommentary(withdetailedtechnicaldata as required) on the Technical Specifications demonstrating the goods substantial responsiveness to the specifications or deviations and exceptions to the provisions oftheTechnicalSpecification. EquipmentPerformanceGuarantee

2.2

3. 4. 4.1

4.2

SECTIONI(VOLUMEII)

PAGE1

4.2.1

The performance requirements of the items are detailed separately in this Specification. These guarantees shall supplement the general performance guarantee provisions covered under General Terms and Conditions of Contract in clauseentitledGuarantee. Liquidated damages for not meeting specified performance shall be assessed and recovered from the Supplier. Such liquidated damages shall be without any limitation whatsoever and shall be in addition to damages, if any payable under anyotherclauseofConditionsofContract. EngineeringData The furnishing of engineering data by the Supplier shall be in accordance with the appropriate Schedule appended to this document. The review of these data by the Owner will cover only general conformance of the data to the specifications and drawings. This review by the Owner may not indicate a thorough review of all dimensions, quantities and details of the equipment, materials, any devices or items indicated or the accuracy of the information submitted. This review and/or approval by the Owner shall not be considered by the Supplier, as limiting any of his responsibilities and liabilities for mistakes and deviations from the requirements,specifiedundertheseSpecificationsanddocuments. AllengineeringdatasubmittedbytheSupplierafterfinalprocessincludingreview and approval by the Owner shall form part of the Contract Document and the entire works performed under these Specifications shall be performed in strict conformity,unlessotherwiseexpresslyrequestedbytheOwnerinwriting. Drawings All drawings submitted by the Supplier including those submitted at the time of bid shall be in sufficient detail to indicate the type, size, arrangement, dimensions, material description, Bill of Materials, weight of each component, breakup for packing and shipment, fixing arrangement required, the dimensions required for installationandanyotherinformationspecificallyrequestedintheSpecifications. Each drawing submitted by the Supplier shall be clearly marked with the name of the Owner, the unit designation, the Specification title, the Specification number and the name of the Project. All titles, noting, markings and in writings on the drawingshallbeinEnglish.Allthedimensionsshouldbetothescaleandinmetric units. The drawings submitted by the Supplier shall be reviewed by the Owner as far as practicable within four (4) weeks and shall be modified by the Supplier if any modifications and/or corrections are required by the Owner in compliance with Specifications.TheSuppliershallincorporatesuchmodificationsandorcorrections andsubmitthefinaldrawingsforapproval.Anydelaysarisingoutoffailurebythe

4.2.2

4.3 4.3.1

4.3.2

4.4 4.4.1

4.4.2

4.4.3

SECTIONI(VOLUMEII)

PAGE2

Supplier to rectify the drawings in good time shall not alter the Contract completiondate. 4.4.4 The drawings submitted for approval to the Owner shall be in quadruplicate. One print of such drawings shall be returned to the Supplier by the Owner marked approved/approved with corrections. The Supplier shall there upon furnish the Owner additional print as stipulated in Technical Specification along with one reproducibleinoriginalofthedrawingsafterincorporatingallcorrections. Further work by the Supplier shall be strictly in accordance with these drawings and no deviation shall be permitted without the written approval of the Owner, if sorequired. All manufacturing and fabrication work in connection with the equipment/ material prior to the approval of the drawings shall be at the Suppliers risk. The Supplier may make any changes in the design which are necessary to make the equipment conform to the provisions and intent of the Contract and such changes will again be subject to approval by the Owner.Approval of Suppliers drawing or work by the Owner shall not relieve the Supplier of any of his responsibilities and liabilitiesundertheContract. ManufacturingSchedule The Supplier shall submit to the Owner his manufacturing, testing and delivery schedules of various items within thirty (30) days from the date of the Letter of Award in accordance with the delivery requirements stipulated. Schedules shall alsoincludethematerialsanditemspurchasedfromoutsideSuppliers,ifany. ReferenceStandards The Codes and/or Standards referred to in Specifications shall govern, in all cases wherever such references are made. In case of a conflict between such Codes and/or Standards and the specifications, latter shall govern. Such Codes and/or Standards, referred to shall mean the latest revisions, amendments/changes adoptedandpublishedbytherelevantagencies. Other Internationally acceptable Standards which ensure equivalent or better performancethanthosespecifiedshallalsobeaccepted. DesignImprovements The Owner or the Supplier may propose changes in the Specification of the equipment or quality thereof and if the parties agree upon any such changes, the Specificationshallbemodifiedaccordingly. If any such agreed upon change is such that it affects the price and schedule of completion, the parties shall agree in writing as to the extent of any change in the
SECTIONI(VOLUMEII) PAGE3

4.45

4.4.6

4.5

46 4.6.1

4.6.2 4.7 4.7.1

4.7.2

price and/or schedule of completion before the Supplier proceeds with the change. Following such agreement, the provision thereof, shall be deemed to have been amendedaccordingly. 4.8 4.8.1 QualityAssurance To ensure that the equipment under the scope of this Contract whether manufactured within the Suppliers Works or at his SubSuppliers premises is in accordance with the specifications, the Supplier shall adopt suitable Quality AssuranceProgrammetocontrolsuchactivitiesatallpointsnecessary. Such programme shall be outlined by the Supplier and shall be finally accepted by the Owner after discussions before the award of Contract. A Quality Assurance ProgrammeoftheSuppliershallgenerallycoverbutnotlimitedtothefollowing: (a) (b) (c) (d) His organisation structure for the management and implementation of the proposedQualityAssuranceProgramme. Documentationcontrolsystem. Qualificationdataforkeypersonnel; The procedure for purchases of materials. Parts/components and selection of subSuppliers services including vendor analysis, source inspection, incomingrawmaterialinspection,verificationofmaterialpurchasesetc. Systemforshopmanufacturingincludingprocesscontrols. Controlofnonconformingitemsandsystemforcorrectiveaction. Controlofcalibrationandtestingofmeasuringandtestingequipments. Inspectionandtestprocedureformanufacture. Systemforindicationandappraisalofinspectionstatus. Systemforqualityaudits. SystemforauthorisingreleaseofmanufacturedproducttotheOwner. Systemformaintenanceofrecords. Systemforhandling,storageanddeliveryand A Quality Plan detailing out the specific quality control procedure adopted forcontrollingthequalitycharacteristicsoftheproduct.

(e) (f) (g) (h) (i) (j) (k) (I) (m) (n)

4.8.2 The Quality Plan shall be mutually discussed and approved by the Owner after incorporatingnecessarycorrectionsbytheSupplierasmayberequired. QualityAssuranceDocuments The Supplier shall be required to submit all the Quality Assurance Documents as stipulated in the Quality Plan at the time of Owners inspection of equipment/material.

SECTIONI(VOLUMEII)

PAGE4

 4.8.3

The Owner or his duly authorised representatives reserves the right to carry out Quality Audit and quality surveillance of the systems and procedures of the Suppliers/hisvendorsQualityManagementandControlActivities. OwnersSupervision To eliminate delays and avoid disputes and litigation it is agreed between the parties to the Contract that all matters and questions shall be resolved in accordancewiththeprovisionsofthisdocument. The manufacturing of the product shall be carried out in accordance with the specifications. The scope of the duties of the Owner, pursuant to the contract, will includebutnotbelimitedtothefollowing: (a) Interpretation of all the terms and conditions of these Documents and Specifications. (b) ReviewandinterpretationofalltheSuppliersdrawings,engineeringdataetc (c) Witness or authorise his representative to witness tests at the manufacturers worksoratsite,oratanyplacewhereworkisperformedundertheContract. (d) Inspect, accept or reject any equipment, material and work under the Contract,inaccordancewiththeSpecifications. (e) Issue certificate of acceptance and/or progressive payment and final payment certificate. (f) Review and suggest modification and improvement in completion schedules fromtimetotime,and (g) Supervise the Quality Assurance Programme implementation at all stages of theworks. Inspection,Testing&InspectionCertificate The Owner, his duly authorised representative and/or outside inspection agency acting on behalf of the Owner shall have at all reasonable times access to the Suppliers premises and works and shall have the power at all reasonable times to inspect and examine the materials and workmanship of the product during its manufacture and if part of the product is being manufacture or assembled at other premises or works, the Supplier shall obtain from the Owner and /or his duly authorisedrepresentativepermissiontoinspectasiftheequipment/materialswere manufacturedorassembledontheSuppliersownpremisesorworks. The Supplier shall give the Owner Inspector fifteen (15) days written notice of any materialbeingreadyfortesting.SuchtestsshallbetotheSuppliersaccountexcept for the expenses of the Inspector. The Owner/inspector, unless witnessing of the tests is waived, will attend such tests within fifteen (15) days of the date of which theequipmentisnotifiedasbeingreadyfortest/inspectionoronamutuallyagreed date, failing which the Supplier may proceed with the test which shall be deemed

4.9 4.9.1

4.9.2

4.10 4.10.1

4.10.2

SECTIONI(VOLUMEII)

PAGE5

to have been made in the Inspectors presence and he shall forthwith forward to theInspectordulycertifiedcopiesoftestsintriplicate. 4.10.3 The Owner/Inspector shall, within fifteen (15) days from the date of inspection as defined herein give notice in writing to the Supplier, of any objection to any drawings and all or any equipment and workmanship which in his opinion is not in accordance with the Contract. The Supplier shall give due consideration to such objectionsandshallmakethemodificationsthatmaybenecessarytomeetthesaid objections. When the factory tests have been completed at the Suppliers or SubSuppliers works, the Owner inspector shall issue a certificate to this effect within fifteen (15) days after completion of tests but if the tests are not witnessed by the Owner/inspector,thecertificateshallbeissuedwithinfifteen(15)daysofreceiptof he Suppliers Test Certificate by the Owner/ Inspector. The completion of these testsortheissueofthecertificateshallnotbindtheOwnertoaccepttheequipment shouldit,onfurthertestsaftererection,befoundnottocomplywiththeContract. In all cases where the Contract provides for test whether at the premises or works of, the Supplier or of any SubSupplier, the Supplier except where otherwise specified shall provide free of charge such item as labour , materials, electricity, fuel, water, stores, apparatus and instruments as may be reasonably demanded by the Owner inspector or his authorised representative to carry out effectively such tests of the equipment in accordance with the Contract and shall give facilities to theOwner/Inspectorortohisauthorisedrepresentativetoaccomplishtesting. The inspection by Owner and issue of Inspection Certificate thereon shall in no way limit the liabilities and responsibilities of the Supplier in respect of the agreed QualityAssuranceProgrammeformingapartoftheContract. TechnicalDescription The technical description of the conductor shall be as specified in SectionII of this TechnicalSpecifications. TestsandStandards Tests The following type, acceptance and routine tests and tests during manufacture shallbecarriedoutonthematerial.Forthepurposeofthisclause: Type Tests shall mean those tests which are to be carried out to prove the process of manufacture and general conformity of the material to this Specification. These tests shall be carried out on samples prior to commencement of commercial production against the order. The Bidder shall indicate his schedule for carrying outthesetests.
SECTIONI(VOLUMEII) PAGE6

4.10.4

4.10.5

4.10.6

5. 5.1 6. 6.1 6.1.1

 6.1.2

Acceptance Tests shall mean those tests which are to be carried out on samples taken from each lot offered for predispatch inspection, for the purposes of acceptanceofthatlot. Routine Tests shall mean those tests, which are to be carried out on the material to checkrequirementswhicharelikelytovaryduringproduction. Tests During Manufacture shall mean those tests, which are to be carried out during the process of manufacture and end inspection by the Supplier toensurethedesiredqualityoftheendproducttobesuppliedbyhim. The norms and procedure of sampling for these tests will be as per the Quality AssuranceProgrammetobemutuallyagreedtobytheSupplierandtheOwner. The standards and norms to which these tests will be carried out are listed against them. Where a particular test is a specific requirement of this Specification, the normsandprocedureofthetestshallbeasspecifiedinAnnexureAorasmutually agreed to between the Supplier and the Owner in the Quality Assurance Programme. Foralltypeandacceptancetests,theacceptancevaluesshallbethevaluesspecified inthisSpecificationorguaranteedbytheBidder,asapplicable. TechnicalParticulars The Standard Technical Particulars of the various items which the bidder has to guarantee(itemasapplicable)arespecifiedinSectionIIofthisvolume.TheBidder shall furnish any other information as in their opinion is needed to give full descriptionanddetailstojudgetheitem(s)offeredbythem ABiddermayguaranteeavaluemorestringentthanthespecificationrequirement. However,fortestingpurposeorfromperformancepointofview,thematerialshall be considered performed successfully if it achieves the minimum/maximum value required as per the technical specification. No preference what so ever shall be giventothebidderofferingbetter/morestringentvaluesthanthoserequiredasper specification.

6.1.3 6.1.4

6.1.5 6.1.6

6.1.7 7. 7.1

7.2

SECTIONI(VOLUMEII)

PAGE7

8.0 8.1

TechnicalInformation ElectricalSystemData SL. No. a. b. c. d. e. f. Parameter NominalVoltage Maximumsystemvoltage BIL(Impulse) Powerfrequencywithstandvoltage (Wet) Switchingsurgewithstandvoltage (Wet) MinimumCoronaextinctionvoltage at50HzACsystemunderdry condition RadiointerferencevoltageatoneMHz forphasetoearthvoltageof305kV (for400kVlineunderdrycondition.) kV kV kV(Peak) kV(rms) kV(peak) KV(rms) Phaseto earth. Microvolts 400kVline 400 420 1550 680 1050 320

g.

1000(max)

9.0

ServiceCondition. Equipment/material to be supplied against this specification shall be suitable for satisfactorycontinuousoperationunderconditionsasspecifiedbelow: Maximumambienttemperature(DegreeCelsius) Minimumambienttemperature(DegreeCelsius) Relativehumidity(%range) Maximumannualrainfall&snowfall(Cm) Windzone(asperIS:875) Maximumwindvelocity(m/sec.) Maximumaltitudeabovemeansealevel(Metres) Isokerauniclevel(days/years) : : : : : : : : 50 4 10100 asperpublishedMeteorological/ climatologicaldata 3 44m/sec.forWZ3 (asperIS:875) Upto1000m 50

Climatevariesfrommoderatelyhotandhumidtropicalclimatetocoldclimate.

SECTIONI(VOLUMEII)

PAGE8

SECTION-II

ClauseNo. 1.0 2.0

TECHNICALSPECIFICATIONS SECTIONII CONTENTS Description TechnicalDescriptionofACSRConductor TestsandStandards AnnexureA :TestsonConductor AnnexureB:StandardTechnicalParticulars DrumDrawing

PageNo. 1 4 13 16 18

TECHNICALSPECIFICATIONS SECTIONII TechnicalDescriptionofACSRConductor DetailsofConductor The ACSR Conductor shall generally conform to IEC: 1089/ IS: 398 except whereotherwisespecifiedherein. ThesalientparametersoftheACSRConductorareindicatedbelow. a) b) c) d) e) 1.1.3 1.1.3.1 ACSRMOOSEConductor

1. 1.1 1.1.1 1.1.2

Strandingandwirediameter 54/3.53mmAl+7/3.53mmsteel NumberofStrands Steelcore 1ststeellayer 2ndsteellayer 1stAluminiumlayer 2ndAluminiumlayer 3rdAluminiumlayer SectionalareaofAluminium Totalsectionalarea Overalldiameter(mm) 1 6 12 18 24 528.5 597.0 31.77

StandardTechnicalParticulars TheStandardTechnical Particulars(STP)ofthe ACSRconductorareenclosed at AnnexureB of this section. The values indicated in the STP are the minimumand/ormaximumvaluesrequiredtobemetbytheSupplier. Workmanship All the Aluminium and steel strands shall be smooth, uniform and free from all imperfections, such as spills and splits, die marks, scratches, abrasions, etc.,afterdrawingandalsoafterstranding. The finished conductor shall be smooth, compact, uniform and free from all imperfections including kinks (protusion of wires), wire cross over, over riding, looseness (wire being dislocated by finger/hand pressure and/or unusual bangle noise on tapping), material inclusions, white rust, powder formation or black spot (on account of reaction with trapped rain water etc.), dirt,gritetc.

1.2 1.2.1

1.2.2

SECTION-II (VOLUME-II)

PAGE 1

 1.2.3

The steel strands shall be hot dip galvanised and shall have a minimum zinc coating as indicated in the STP. The zinc coating shall be smooth, continuous, of uniform thickness, free from imperfections and shall withstand number of dipsinstandardPreecetestasindicatedinSTP.Thesteelwirerodsshallbeof such quality and purity that, when drawn to the size of the strands specified andcoatedwithzinc,thefinishedstrandsandtheindividualwiresshallbeof uniform quality and have the same properties and characteristics as prescribedinIEC:888. The steel strands shall be preformed and post formed in order to prevent spreadingofstrandsintheeventofcuttingofcompositecorewire.Careshall be taken to avoid, damages to galvanisation during preforming and post formingoperation. JointsinWires AluminiumWires During stranding, no aluminium wire welds shall be made for the purpose of achievingtherequiredconductorlength. No joints shall be permitted in the individual wires in the outer most layer of the finished conductor. However joints are permitted in the inner layer of the conductor unavoidably broken during stranding, provided such breaks are not associated with either inherently defective wire or with the use of short lengths of aluminium wires. Such joints shall not be more than four (4) per conductorlengthandshallnotbecloserthan15metersfromjointinthesame wireorinanyotheraluminiumwireofthecompletedconductor. Joints shall be made by cold pressure butt welding and shall withstand a stressofnotlessthanthebreakingstrengthofindividualstrandguaranteed. SteelWires There shall be no joint of any kind in the finished wire entering into the manufacture of the strand. There shall also be no strand joints or strand splicesinanylengthofthecompletedstrandedsteelcoreoftheconductor. Tolerances The manufacturing tolerances to the extent indicated in the STP shall be permitted in the diameter of individual aluminium and steel strands and lay ratiooftheconductor

1.2.4

1.3 1.3.1 1.3.1.1 1.3.1.2

1.3.1.3 1.3.2

1.4

SECTION-II (VOLUME-II)

PAGE 2

1.5 1.5.1

Materials Aluminium Thealuminiumstrandsshallbeharddrawnfromelectrolyticaluminiumrods having purity not less than 99.5% and a copper content not exceeding 0.04%. They shall have the same properties and characteristics as prescribed in IEC: 889. Steel The steel wire strands shall be drawn from high carbon steel wire rods produced by either the acid or the basic openhearth process, the electric furnace process, or the basic oxygen process and shall conform to the chemicalcompositionindicatedintheSTP. The Steel wire strands shall have the same properties and characteristics as prescribedforregularstrengthsteelwireinIEC:888. Zinc The zinc used for galvanizing shall be electrolytic High Grade Zinc of 99.95% purity as per IS209. It shall conform to and satisfy all the requirements of IS:209. StandardLength The standard length of the conductor shall be as indicated in the STP. All lengthsoutsidethislimitoftoleranceshallbetreatedasrandomlengths. Random lengths will be accepted provided no length is less than 70% of the standard length and the total quantity of such random lengths shall not be more than 10% of the total quantity ordered. When one number random length has been manufactured at any time, five (5) more individual lengths each equivalent to the above random length with a tolerance of +/ 5% shall also be manufactured and all the above six random lengths shall be despatched in the same shipment. At no point, the cumulative quantity supplied of such random lengths shall not be more than 12.5% of the total cumulative quantity supplied including such random lengths. However, the last 20% of the quantity ordered shall be supplied only in standard lengths as specified. The Owner reserves the right to place orders for the lengths above the standardlengthonthesametermsandconditionsapplicableforthestandard lengthsduringthependencyoftheContract.

1.5.2 1.5.3

1.5.4

1.6 1.6.1 1.6.2

1.6.3

SECTION-II (VOLUME-II)

PAGE 3

 2.0 2.1

TestsandStandards TypeTests Thefollowingtestsshallbeconductedonceonasample/samplesofconductor forevery1500Kms.ofproductionfromeachmanufacturingfacility: a) DCresistancetestonstrandedconductor AsperAnnexureA b) UTStestonstrandedconductor c) d) Radiointerferencevoltagetest(dry) Coronaextinctionvoltagetest(dry)

2.2

AcceptanceTests a) b) c) d) e) f) g) h) i) j) Visualanddimensionalcheckondrum Visual check for joints scratches etc. and length measurementofconductorbyrewinding Dimensional check on steel and aluminium strands Checkforlayratiosofvariouslayers Galvanizingtestonsteelstrands TorsionandElongationtestsonsteelstrands Breaking load test on steel and Aluminium strands Wraptestonsteel&Aluminiumstrands DCresistancetestonAluminiumstrands IEC:888&889 IEC:889

AsperAnnexureA

2.3

k) Note : All the above tests except (j) shall be carried out on Aluminium and steelstrandsafterstrandingonly. RoutineTest a) b) c) d) ChecktoensurethatthejointsareasperSpecification Checkthattherearenocuts,finsetc.,onthestrands. CheckthatdrumsareasperSpecification All acceptance test as mentioned above to be carried out on each coil/ drum(asapplicable)

Procedure qualification test on welded joint of AnnexureA Aluminiumstrands BarrelBattenstrengthtest AnnexureA

SECTION-II (VOLUME-II)

PAGE 4

2.4

TestsDuringManufacture a) b) Chemicalanalysisofzincusedforgalvanizing ChemicalanalysisofAluminiumusedfor makingAluminiumstrands Chemicalanalysisofsteelusedformaking steelstrands

AsperAnnexureA

c) 2.5 2.5.1 2.5.2

TestingExpenses The breakup of the testing charges for the type tests specified shall be indicatedseparately. Bidder shall indicate the laboratories in which they propose to conduct the type tests. They shall ensure that adequate facilities are available in the laboratories and the tests can be completed in these laboratories within the timescheduleguaranteedbythem. In case of failure in any type test the Supplier is either required to manufacture fresh sample lot and repeat all the test successfully once or repeatthatparticulartypetestthreetimessuccessfullyonthesampleselected from the already manufactured lot at his own expenses. In case a fresh lot is manufacturedfortestingthenthelotalreadymanufacturedshallberejected. TheentirecostoftestingfortheacceptanceandroutinetestsandTestsduring manufacture specified herein shall be treated as included in the quoted unit price of conductor, except for the expenses of the inspector/Owners representative. In case of failure in any type test, if repeat type tests are required to be conducted, then all the expenses for deputation of Inspector/Owners representative shall be deducted from the contract price. Also if on receipt of the Suppliers notice of testing, the Owners representative does not find plant to be ready for testing the expenses incurred by the Owner for re deputationshallbedeductedfromcontractprice. AdditionalTests The Owner reserves the right of having at his own expenses any other test(s) of reasonable nature carried out at Suppliers premises, at site or in any other place in addition to the aforesaid type, acceptance and routine tests to satisfy himselfthatthematerialscomplywiththeSpecifications. The Owner also reserves the right to conduct all the tests mentioned in this specification at his own expense on the samples drawn from the site at Suppliers premises or at any other test centre. In case of evidence of non

2.5.3

2.5.4

2.5.5

2.6 2.6.1

2.6.2

SECTION-II (VOLUME-II)

PAGE 5

compliance, it shall be binding on the part of Supplier to prove the compliance of the items to the technical specifications by repeat tests, or correction of deficiencies, or replacement of defective items all without any extracosttotheOwner. 2.7 2.7.1 SampleBatchForTypeTesting The Supplier shall offer material for selection of samples for type testing only after getting Quality Assurance Plan approved from Owners Quality Assurance Deptt. The sample shall be manufactured strictly in accordance withtheQualityAssurancePlanapprovedbyOwner. The Supplier shall offer at least three drums for selection of sample required forconductingallthetypetest. The Supplier is required to carry out all the acceptance tests successfully in presenceofOwnersrepresentativebeforesampleselection. TestReports Copies of type test reports shall be furnished in at least six copies alongwith oneoriginal.OnecopywillbereturneddulycertifiedbytheOwneronlyafter whichthecommercialproductionofthematerialshallstart. RecordofroutinetestreportsshallbemaintainedbytheSupplierathisworks forperiodicinspectionbytheOwnersrepresentative. Test Certificates of tests during manufacture shall be maintained by the Supplier. These shall beproduced for verification as and when desired by the Owner. Inspection The Owners representative shall at all times be entitled to have access to the works and all places of manufacture, where conductor shall be manufactured and representative shall have full facilities for unrestricted inspection of the Suppliers works, raw materials and process of manufacture for conducting necessarytestsasdetailedherein. TheSuppliershallkeeptheOwnerinformedinadvanceofthetimeofstarting and of the progress of manufacture of conductor in its various stages so that arrangementscanbemadeforinspection. No material shall be dispatched from its point of manufacture before it has beensatisfactorilyinspectedandtested,unlesstheinspectioniswaivedoffby theOwnerinwriting.Inthelattercasealsotheconductorshallbedispatched

2.7.2 2.7.3 2.8 2.8.1

2.8.2 2.8.3

2.9 2.9.1

2.9.2

2.9.3

SECTION-II (VOLUME-II)

PAGE 6

only after satisfactory testing for all tests specified herein have been completed. 2.9.4 The acceptance of any quantity of material shall in no way relieve the Supplier of any of his responsibilities for meeting all requirements of the Specification, and shall not prevent subsequent rejection it such material is laterfoundtobedefective. TestFacilities The following additional test facilities shall be available at the Suppliers works: a) Calibration of various testing and measuring equipment including tensile testing machine, resistance measurement facilities, burette, thermometer, barometer,digitalohmmetreetc. b) Standardresistanceforcalibrationofresistancebridges. c) Finished conductor shall be checked for length verification and surface finish on separate rewinding machine at reduced speed (variable from 8 to 16 meters per minute). The rewinding facilities shall have appropriate clutch system and free of vibrations, jerks etc. with traverse laying facilities. Packing The conductor shall be supplied in nonreturnable, strong, wooden drums provided with lagging of adequate strength, constructed to protect the conductor against all damage and displacement during transit, storage and subsequent handling and stringing operations in the field. The Supplier shall be responsible for any loss or damage during transportation handling and storage due to improper packing. The drums shall generally conform to IS:1778,exceptasotherwisespecifiedhereinafter. The drums shall be suitable for wheel mounting and for letting off the conductorunderaminimumcontrolledtensionoftheorderof5KN. The general outline of the drum for conductor shall be as in the annexed drawings. The Bidder should submit their proposed drum drawings along withthebid. Forconductor,onestandardlengthshallbewoundoneachdrum. All wooden components shall be manufactured out of seasoned soft wood free from defects that may materially weaken the component parts of the

2.10 2.10.1

2.11 2.11.1

2.11.2 2.11.3

2.11.4 2.11.5

SECTION-II (VOLUME-II)

PAGE 7

drums. Preservative treatment shall be applied to the entire drum with preservativesofaqualitywhichisnotharmfultotheconductor. 2.11.6 The flanges shall be of two ply construction with each ply at right angles to the adjacent ply and nailed together. The nails shall be driven from theinside face flange, punched and then clenched on the outer face. The thickness of each ply shall not vary by more than 3mm from that indicated in the figure. There shall be at least 3 nails per plank of ply with maximum nail spacing of 75mm. Where a slot is cut in the flange to receive the inner end of the conductortheentranceshallbeinlinewiththeperipheryofthebarrel. The wooden battens used for making the barrel of the conductor shall be of segmental type. These shall be nailed to the barrel supports with at least two nails. The battens shall be closely butted and shall provide a round barrel with smooth external surface. The edges of the battens shall be rounded or chamferedtoavoiddamagetotheconductor. Barrel studs shall be used for the construction of drums. The flanges shall be holed and the barrel supports slotted to receive them. The barrel studs shall be threaded over a length on either end, sufficient to accommodate washers, spindleplatesandnutsforfixingflangesattherequiredspacing. Normally, the nuts on the studs shall stand protruded of the flanges. All the nails used on the inner surface of the flanges and the drum barrel shall be countersunk.Theendsofbarrelshallgenerallybeflushedwiththetopofthe nuts. Theinnercheekoftheflangesanddrumbarrelsurfaceshallbepaintedwitha bitumenbasedpaint. Before reeling, card board or double corrugated or thick bituminised water proof bamboo paper shall be secured to the drum barrel and inside of flanges of the drum by means of a suitable commercial adhesive material. After reeling the conductor, the exposed surface of the outer layer of conductor shall be wrapped with water proof thick bituminised bamboo paper to preserve the conductor from dirt, grit and damage during transport and handling. A minimum space of 75 mm for conductor shall be provided between the inner surface of the external protective tagging and outer layer of the conductor. Each batten shall be securely nailed across grains as far as possible to the flange, edges with at least 2 nails per end. The length of the nails shall not be lessthantwicethethicknessofthebattens.Thenailsshallnotprotrudeabove the general surface and shall not have exposed sharp, edges or allow the battenstobereleasedduetocorrosion.

2.11.7

2.11.8

2.11.9

2.11.10 2.11.11

2.11.12

2.11.13

SECTION-II (VOLUME-II)

PAGE 8

 2.11.14 2.11.15

The nuts on the barrel studs shall be tack welded on the one side in order to fullysecurethem.Onthesecondend,aspringwashershallbeused. A steel collar shall be used to secure all barrel studs. This collar shall be located between the washers and the steal drum and secured to the central steelplatebywelding. Outside the protective lagging, there shall be minimum of two binder consisting of hoop iron/galvanised steel wire. Each protective lagging shall havetworecessestoaccommodatethebinders. Theconductorendsshallbeproperlysealedandsecuredonthesideofoneof the flanges to avoid loosening of the conductor layers during transit and handling. As an alternative to wooden drum Bidder may also supply the conductors in nonreturnable painted steel drums. After preparation of steel surface according to IS:9954, synthetic enamel paint shall be applied after application ofonecoatofprimer.Wooden/Steeldrumwillbetreatedatparforevaluation purposeandaccordinglytheBiddershouldquoteinthepackage. Marking Each drum shall have the following information stenciled on it in indelible inkalongwithotheressentialdata: (a) (b) (c) (d) (e) (f) (g) (h) (i) (k) (l) (m) (n) Contract/Awardletternumber. Nameandaddressofconsignee. Manufacturersnameandaddress. Drumnumber Sizeofconductor Lengthofconductorinmeters Arrowmarkingforunwinding Positionoftheconductorends DistancebetweenoutermostLayerofconductorandtheinner surfaceoflagging. Barreldiameteratthreelocations&anarrowmarkingatthelocation ofthemeasurement. Numberofturnsintheoutermostlayer. Grossweightofdrumafterputtinglagging. Tearweightofthedrumwithoutlagging.

2.11.16

2.11.17

2.11.18

2.12

SECTION-II (VOLUME-II)

PAGE 9

 (o) (p) 2.13

Netweightoftheconductorinthedrum. CIP/MICCNo.

Theaboveshouldbeindicatedinthepackinglistalso. VerificationofConductorLength TheOwnerreservestherighttoveritythelengthofconductorafterunreeling. The quantity for verification shall be between a minimum of five percent (5%) to a maximum of ten percent (10%)of the drums in a lot offered for inspection. The actual quantity will be discussed and mutually agreed to by the Supplier & OwnerintheQualityAssuranceProgramme. Standards The conductor shall conform to the following Indian/International Standards, which shall mean latest revisions, with amendments/changes adopted and published,unlessspecificallystatedotherwiseintheSpecification. In the event of the supply of conductor conforming to standards other than specified, the Bidder shall confirm in his bid that these standards are equivalent to those specified. In case of award, salient features of comparison between the standards proposed by the Supplier and those specified in this documentwillbeprovidedbytheSuppliertoestablishtheirequivalence.

2.14 2.14.1

2.14.2

SECTION-II (VOLUME-II)

PAGE 10


Sl. IndianStandard No. 1. IS:2091992 2. IS:398PartI 1996 IS:398PartII 1996 IS:398PartV 1992 IS:17781980 IS:15211991 IS:26291990 IS:26331992 IS:48261992 IS:67451990 Title Specificationforzinc SpecificationforAluminiumConductors forOverheadTransmissionPurposes AluminumConductorGalvanisedSteel Reinforced AluminumConductorGalvanisedSteel ReinforcedForExtraHighVoltage(400 KV)andabove ReelsandDrumsforBareConductors MethodofTensileTestingofSteelWire RecommendedPracticeforHotDip GalvanisingofIronandSteel MethodofTestingUniformityofCoating onZincCoatedArticles GalvanisedCoatingonRoundSteel Wires MethodsofDeterminationofWeightof ZincCoatingofZincCoatedIron and SteelArticles MethodofRadioInterferenceTestson HighVoltageInsulators ZincCoatedsteelwiresforstranded Conductors HarddrawnAluminiumwirefor overheadlineconductors International Standard BS:34361986 IEC:10891991 BS:2151970 BS;2151970 IEC:10891991 IEC:10891991 BS:2151970 BS:15591949 ISO68921984 IEC:8881987 BS:4431969 BS:4331969 ISO14601973 IEC:4371973 NEMA:1071964 CISPR IEC:8881987 IEC:8891987

3. 4.

5. 6. 7. 8. 9. 10.

11.

IS:82631990

12. 13.

SECTION-II (VOLUME-II)

PAGE 11

Thestandardsmentionedaboveareavailablefrom: ReferenceAbbreviation NameandAddress BS BritishStandards, BritishStandardsInstitution 101,PentonvileRoad, N19ND UK IEC/CISPR InternationalElectrotechnicalCommission, BureauCentraldelaCommission, electroTechniqueinternational, 1Ruedeverembe, Geneva SWITZERLAND BeureauOfIndianStandards. ManakBhavan, 9,BahadurShahZafarMarg, NewDelhi110001. INDIA InternationalOrganisationfor Standardization. DanishBoardofStandardization DanishStandardizingSraat, Aurehoegvej12 DK2900,Heeleprup, DENMARK. NationalElectricManufactureAssociation, 155,East44thStreet. NewYork,NY10017 U.S.A.

BIS/IS

ISO

NEMA

SECTION-II (VOLUME-II)

PAGE 12

ANNEXUREA 1. 1.1 TestsonConductor UTSTestonStrandedConductor Circles perpendicular to the axis of the conductor shall be marked at two places on a sample of conductor of minimum 5 m length between fixing arrangement suitably fixed on a tensile testing machine. The load shall be increased at a steady rate upto 50% of minimum specified UTS and held for one minute. The circles drawn shall not be distorted due to relative movement of strands. Thereafter the load shall be increased at steady rate to 100% of the UTS of conductor and held for one minute. The Conductor sample shall not fail during this period. The applied load shall then be increaseduntilthefailingloadisreachedandthisvalueshallberecorded. CoronaExtinctionVoltageTest Thesampleassemblywitheachconductorof5mlengthshallbestrungasper theconfigurationshownintheTablebelow. LineConfiguration No of conductor Spacing Maximum Height of the conductor samples per (mm) aboveground(m) Bundle 400kV with twin Two 450 8.84 ACSRMOOSE 400kV with Quad Four 457 8.84 ACSRMOOSE Thesampleassemblywhensubjectedtopowerfrequencyvoltageshallhavea corona extinction voltage of not less than that indicated in the STP. There shall be no evidence of corona on any part of the samples. The test should be conducted without corona control rings. However, small corona control rings may be used to prevent corona in the end fittings. The voltage should be correctedforstandardatmosphericconditions. RadioInterferenceVoltageTest Under the conditions as specified under (1.2) above, the conductor samples shall have radio interference voltage as indicated in the standard technical particulars enclosed at AnnexureB of this section. This test may carried out with corona control rings and arcing horns. The test procedure shall be in accordancewithIEC437 D.C.ResistanceTestonStrandedConductor On a conductor sample of minimum 5m length two contactclamps shall be fixedwithapredeterminedbolttorque.Theresistanceshallbemeasuredbya

1.2

1.3

1.4

SECTION-II (VOLUME-II)

PAGE 13

Kelvin double bridge or digital ohmmetre of sufficient accuracy by placing the clamps initially zero metre and subsequently one metre apart. The test shall be repeated at least five times and the average value recorded. The value obtained shall be corrected to the value at 200C as per IS:398. The resistancecorrectedat200Cshallconformtotherequirementsindicatedinthe STP. 1.4 ChemicalAnalysisofAluminiumandSteel Samples taken from the Aluminium and steel ingots/coils/strands shall be chemically/spectrographically analysed. The same shall be in conformity to therequirementsstatedinthisSpecification.
VisualandDimensionalCheckonDrums The drums shall be visually and dimensionally checked to ensure that they conformtotherequirementsofthisSpecification. VisualCheckforJoints,Scratchesetc. Conductor drums shall be rewound in the presence of the Owner. The Owner shall visually check for scratches, joints etc. and that the conductor generally conformtotherequirementsofthisSpecification.Fivepercent(5%)totenpercent (10%) drums from each lot shall be rewound in the presence of the Owners representative. The actual quantity will be discussed and mutually agreed to by theSupplier&OwnerintheQualityAssuranceProgramme. DimensionalCheckonSteelandAluminiumStrands The individual strands shall be dimensionally checked to ensure that they conformtotherequirementofthisSpecification. CheckforLayratiosofVariousLayers The layratios of various layers shall be checked to ensure that they conform to therequirementsofthisSpecification. ProcedureQualificationtestonweldedAluminiumstrands TwoAluminiumwireshallbeweldedaspertheapprovedqualityplanandshall be subjected to tensile load. The breaking strength of the welded joint of the wire shallnotbelessthanthebreakingstrengthofindividualstrands. ChemicalAnalysisofZinc Samples taken from the zinc ingots shall be chemically/ spectrographically analyzed. The same shall be in conformity to the requirements stated in the Specification.

1.5
1.6

1.7 1.8 1.9

1.10

SECTION-II (VOLUME-II)

PAGE 14

1.11

GalvanizingTest ThetestprocedureshallbeasspecifiedinIEC:888.Thematerialshallconformto the requirements of this Specification. The adherence of zinc shall be checked by wrappingaroundamandrelfourtimesthediameterofsteelwire. TorsionandElongationTestsonSteelStrands ThetestproceduresshallbeasperclauseNo.10.3ofIEC:888.Intorsiontest,the number of complete twists before fracture shall not be less than that indicated in the STP. In case test sample length is less or more than 100 times the stranded diameter of the strand, the minimum number of twists will be proportioned to the length and if number comes in the fraction then it will be rounded off to next higher whole number. In elongation test, the elongation of the strand shallnot be lessthan4%foragaugelengthof250mm. CheckonBarrelBattenstrengthofDrums Thedetailsregardingbarrelbattenstrengthtestwillbediscussedandmutually agreedtobytheSupplier&OwnerintheQualityAssuranceProgramme.

1.12

1.13

SECTION-II (VOLUME-II)

PAGE 15

AnnexureB STANDARDTECHNICALPARTICULARSOFACSRMOOSECONDUCTOR

Sl. Description Unit GuaranteedValues

1.0 1.1 1.1

RawMaterials SteelWire/Rods Aluminium

% % % % % % % .% mm mm mm KN KN Ohm mm mm mm KN KN

99.50 0.04 0.50to0.85 0.50to1.10 Notmorethan0.035 Notmorethan0.045 0.10to0.35(Max.) 99.95 3.53 3.55 3.51 1.57 1.49 0.002921 3.53 3.59 3.47 12.63 11.99

a) MinimumpurityofAluminium b) Maximumcoppercontent 1.2 Steelwires/rods

a) Carbon b) Manganese c) Phosphorous d) Sulphur e) Silicon 1.3 Zinc

a) MinimumpurityofZinc 2.0 2.1 Aluminumstrandsafterstranding Diameter

a) Nominal b) Maximum c) Minimum 2.2 Minimumbreakingloadofstrand

a) Beforestranding b) Afterstranding 2.3 Maximumresistanceof1mlengthof strandat20deg.C 3.0 Steelstrandafterstranding 2.1 Diameter

a) Nominal b) Maximum c) Minimum 3.2 Minimumbreakingloadofstrand

a) Beforestranding b) Afterstranding

SECTION-II (VOLUME-II)

PAGE 16

STANDARDTECHNICALPARTICULARSOFACSRMOOSECONDUCTOR
Sl. Description Unit GuaranteedValues

3.3

Galvanising

gm Nos.

250 2dipsofone minute&1dipof halfminute 16

a) Minimumweightofzinccoatingper sq.m. b) Minimumnumberofdipsthatthe galvanisedstrandcanwithstandin thestandardpreecetest c) Min.No.oftwistsinguagelength equal100timesthedia.ofwirewhich thestrandcanwithstandinthetorsion test(afterstranding) 4. StrandedConductor 4.1 4.2 UTSoftheconductor Laylengthofoutersteellayer

Nos

kN mm mm mm mm mm ohm/km kV (rms) Micto Volts m % kg/km kg/km kg/km

161.20(Min.) Max 18 14 13 12 0.05552 320 Below1000 1800 (+/)5 RightHand 2004 1969 2040 Min 16 12 11 10

a) OuterSteellayer b) 12wireAluminiumlayer c) 18wireAluminiumlayer d) 4.3 4.4 4.5 4.6 4.7 4.8 4.9 24wireAlumimiumLayer DCresistanceoftheconductorat 20C MinimumcoronaExtinctionVoltage (linetophase)underDrycondition RIVat1Mhzat305Amp(lineto phase)underDrycondition Standardlengthoftheconductor ToleranceonStandardlength Directionoflayofouterlayer Linearmassoftheconductor

a) Standard b) Minimum c) Maximum

SECTION-II (VOLUME-II)

PAGE 17

SECTION-II (VOLUME-II)

PAGE 18