Vol II Insulator PDF

BIDDING DOCUMENTS FOR INSULATOR PACKAGES C1 & C2 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.
VOLUMEII TechnicalSpecifications CONTENTS: SECTIONI :GENERALINFORMATIONANDSCOPE SECTIONIIA:TECHNICALSPECIFICATIONFORCOMPOSITE LONGRODINSULATOR SECTIONIIB:TECHNICALSPECIFICATIONFORANTIFOG DISC/LONGRODINSULATOR SECTIONIII:DRAWINGS
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 GuaranteedTechnicalParticulars 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. Linelength i) 400kVD/CTransmissionLineSugentoPirana 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 shall mean the stores established by the Contractor of the Owner alongtheTransmissionLines. 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 under this Specification are mentioned in the biddingdocuments. PackageC1: CompositeLongrodInsulator PackageC2: AntifogDisc/LongrodInsulator 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
TechnicalSpecifications: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 Supplier to rectify the drawings in good time shall not alter the Contract completiondate.
4.2.2
4.3 4.3.1
4.3.2
4.4 4.4.1
4.4.2
4.4.3
PAGE2
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 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. QualityAssurance
4.45
4.4.6
4.5
4.6 4.6.1
4.6.2 4.7 4.7.1
4.7.2
4.8
PAGE3
4.8.1
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) (e) (f) (g) (h) (i) (j) (k) (l) (m) (n) Hisorganisationstructureforthemanagementandimplementationofthe proposedQualityAssuranceProgramme. Documentationcontrolsystem. Qualificationdataforkeypersonnel; Theprocedureforpurchasesofmaterials.Parts/componentsandselection ofsubSuppliersservicesincludingvendoranalysis,sourceinspection, incomingrawmaterialinspection,verificationofmaterialpurchasesetc. Systemforshopmanufacturingincludingprocesscontrols. Controlofnonconformingitemsandsystemforcorrectiveaction. Controlofcalibrationandtestingofmeasuringandtestingequipments. Inspectionandtestprocedureformanufacture. Systemforindicationandappraisalofinspectionstatus. Systemforqualityaudits. SystemforauthorisingreleaseofmanufacturedproducttotheOwner. Systemformaintenanceofrecords. Systemforhandling,storageanddeliveryand AQualityPlandetailingoutthespecificqualitycontrolprocedureadopted forcontrollingthequalitycharacteristicsoftheproduct.
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. 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.
4.8.3
PAGE4
4.9 4.9.1
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) InterpretationofallthetermsandconditionsoftheseDocumentsand Specifications.
4.9.2
4.10 4.10.1
(b) ReviewandinterpretationofalltheSuppliersdrawings,engineeringdata etc. (c) Witnessorauthorisehisrepresentativetowitnesstestsatthemanufacturers worksoratsite,oratanyplacewhereworkisperformedundertheContract.
(d) Inspect,acceptorrejectanyequipment,materialandworkunderthe Contract,inaccordancewiththeSpecifications. (e) (f) Issuecertificateofacceptanceand/orprogressivepaymentandfinalpayment certificate. Reviewandsuggestmodificationandimprovementincompletionschedules fromtimetotime,and
(g) SupervisetheQualityAssuranceProgrammeimplementationatallstagesof 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 to have been made in the Inspectors presence and he shall forthwith forward to theInspectordulycertifiedcopiesoftestsintriplicate.
TechnicalSpecifications:SectionI(VOLUMEII) PAGE5
4.10.2
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 the 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 Composite Longrod and Antifog Disc / Longrod Insulator is specified in SectionIIA & IIB respectively, of this Technical Specifications. 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. 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.
4.10.4
4.10.5
4.10.6
5. 5.1
6. 6.1 6.1.1
6.1.2
TechnicalSpecifications:SectionI(VOLUMEII) PAGE6
6.1.3 6.1.4
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. GuaranteedTechnicalParticulars TheGuaranteedTechnicalParticularsofthevariousitemsshallbefurnishedbythe Bidders in one original and four (4) copies in the prescribed schedules of the Specifications. The Bidder shall also furnish any other schedule information as in their opinion is needed to give full description and details to judge the item(s) offeredbythem The data furnished inGuaranteed Technical Particulars should be theminimum or maximum value (as per the requirement of the specification) required. A Bidder may guarantee a value more stringent than the specification requirement. 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.
6.1.5 6.1.6
6.1.7 7. 7.1
7.2
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.
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SECTION-II A
TECHNICALSPECIFICATIONS SECTIONIIA 1.0 TechnicalDescriptionofCompositeLongRodInsulators 1.1 DetailsofCompositeLongRodInsulators 1.1.1 The insulators of the strings shall consist of composite long rod insulators for a three phase, 50 Hz, effectively earthed 400kV transmission system application in a very heavypollutedenvironment.Couplingsshallbeballandsockettype. 1.1.2 Bidder shall quote such composite insulators which have proven use under foggy/humid operational conditions in heavily polluted industrial environment combined with smoke and dust particles. The Bidder shall furnish evidence in the formofcertificationfromthepowerutilitiesthatthesimilartypeofproductsupplied to them had been performing satisfactory. TheBidder shall also submit certified test report for an accelerated ageing test of 5000 hours such as that described in AppendixCofIEC61109. 1.1.3 Insulators shall have sheds of the open aerodynamic profile without any under ribs with good selfcleaning properties.. Insulator shed profile, spacing projection etc.shallbestrictlyinaccordancewiththerecommendationofIEC60815. 1.1.4 Thesizeoflongrodinsulator,minimumcreepagedistance,thenumbertobeusedin different type of strings, their electromechanical strength and mechanical strength of insulatorstringalongwithhardwarefittingsshallbeasfollows:
S.No. *Sizeof Minimum No.of Electro Composite Creepage individual Mechanical Insulator Distance Unitsper Strengthof (Corediax String Insulator Nominal Unit length) (mm) (mm) (Nos.) (kN) FOR400kVACTRANSMISSIONLINESWITHTwinMOOSECONDUCTOR SingleI 1. Suspension 2024x3335 13020 1x1 120 SingleSuspension 2. Pilot 3. DoubleTension 24x3910 13020 2x1 160 TypeofString Mechanical Strengthof InsulatorString alongwith Hardware Fittings (kN)
120 2x160
Note: *The core dia of composite insulators mentioned at column No.3 is for indicative purpose. The bidder shall offer composite long rod insulators of suitable core dia to meet specified E&M strength requirements. However, the overall string length shall be within the limits specified in the drawing. ( Long rod insulator should be similar toporcelindiscInsulatorsoastohaveinterchangeability)
SECTION-II A(VOLUME-II)
PAGE 1
1.2 1.2.1
PinandCap Pinandcapshallbedesignedtotransmitthemechanicalstressanddevelopuniform mechanical strength in the insulator. The cap shall be circular with the inner and outer surfaces concentric of such design that it will not yield or distort under load conditions. Thedesignshallbesuchastopermiteasyremovalofreplacementofeitherinsulator unitsorfittingsunderthelivelineconditions. BallandSocketDesignation The dimensions of the Ball and Socket shall be of 20mm designation for 120 & 160 kN Insulators in accordance with the standard dimensions stated in IEC:120/IS:2486 (PartII) DimensionalToleranceofCompositeInsulators Thetolerancesonalldimensionse.g.diameter,lengthandcreepagedistanceshallbe allowedasfollows: (0.04d+1.5)mmwhend300mm. (0.025d+6)mmwhend>300mm. Where, d being the dimensions in millimeters for diameter, length or creepage distanceasthecasemaybe. However,nonegativetoleranceshallbeapplicabletocreepagedistance. Interchangeability The composite long rod insulators inclusive of the ball & socket connection shall be standard design suitable for use with the hardware fittings of any make conforming torelevantIECstandards. CoronaandR1Performance All surfaces shall be clean, smooth, without cuts, abrasions or projections. No part shallbesubjectedtoexcessivelocalizedpressure.Theinsulatorandmetalpartsshall besodesignedandmanufacturedthatitshallavoidlocalcoronaformationandshall not generate any radio interference beyond specified limit under the operating conditions. Maintenance The long rod insulators offered shall be suitable for employment of hot line maintenance technique so that usual hot line operation can be carried out with ease, speedandsafety.
1.2.2 1.3
1.4 1.5
1.6
1.7 1.7.1
PAGE 2
1.7.2
All insulators shall be designed to facilitate cleaning and insulators shall have the minimum practical number of sheds and grooves. All grooves shall be so proportioned that any dust deposit can be removed without difficulty either by wipingwithaclothorbyremotewashingunderlivelinecondition. Materials Core It shall be a glassfiber reinforced (FRP rod) epoxy resin rod of high strength. Glass fibers and resin shall be optimized. The rod shall be electrical grade corrosion resistant (ECR), boron free glass and shall exhibit both high electrical integrity and highresistancetoacidcorrosion. Housing&Weathersheds The FRP rod shall be covered by a seamless sheath of a silicone rubber compound of a thickness of minimum 3mm. The housing & weathersheds should have silicon content of minimum 30% by weight. It should protect the FRP rod against environmental influences, external pollution and humidity. It shall be extruded or directlymoldedonthecore.Theinterfacebetweenthehousingandthecoremustbe uniformandwithoutvoids.Thestrengthofthebondshallbegreaterthanthetearing strength of the polymer. The manufacturer shall follow nondestructive technique (N.D.T.) to check the quality of jointing of the housing interface with the core. The technique being followed with detailed procedure and sampling shall be furnished along with the bid. The details for this shall be finalized during detailed engineering andfinalizationofMQP.
1.8 1.8.1
1.8.2
The weathersheds of the insulators shall be of alternate shed profile. The weathershedsshallbevulcanizedtothesheath(extrusionprocess)ormoldedaspart of the sheath (injection moulding process) and free from imperfections. The vulcanization for extrusion process shall be at high temperature and for injection moulding shall be at high temperature & high pressure. Any seams / burrs protruding axially along the insulator, resulting from the injection moulding process shall be removed completely without causing any damage to the housing. The track resistance of housing and shed material shall be class 1A4.5 according to IEC60587. The strength of the weathershed to sheath interface shall be greater than the tearing strength of the polymer. The composite insulator shall be capable of high pressure washing. EndFittings End fittings transmit the mechanical load to the core. They shall be made of malleablecastiron/spheroidalgraphiteironorforgedsteel.Theyshallbeconnected to the rod by means of a controlled compression technique. The manufacturer shall haveinprocessAcousticemissionarrangementstoensurethatthereisnodamageto
1.8.3
PAGE 3
1.8.4
the core during crimping. This verification shall be inprocess and done on each insulator. The gap between fitting and sheath shall be sealed by a flexible silicone rubber compound. The system of attachment of end fitting to the rod shall provide superior sealing performance between housing and metal connection. The sealing mustbehumidityproofanddurablewithtime. GradingRings Grading rings shall be used at both ends of each composite insulator unit for reducing the voltage gradient on and within the insulator and to reduce radio and TV noise to acceptable levels. The size and placement of the metallic grading rings shall be designed to eliminate dry band arcing/corona cutting/ exceeding of permissible electrical stress of material. The bidder shall furnish calculations along with the proposed placement and design of corona ring in support of the above. Gradingringsshallbecapableofinstallationandremovalwithhotlinetoolswithout disassemblinganyotherpartoftheinsulatorassembly. Thesupplyofgradingringsshallbeinthescopeofthecompositeinsulatorsupplier.
1.8.5 1.8.6
Workmanship All the materials shall be of latest design and conform to the best modern practices adoptedintheextrahighvoltagefield.Biddersshallofferonlysuchinsulatorsasare guaranteedbyhimtobesatisfactoryandsuitablefortransmissionlinesspecifiedand willgivecontinuedgoodservice. The design, manufacturing process and material control at various stages shall be such as to give maximum working load, highest mobility, best resistance to corrosion,goodfinishandeliminationofsharpedgesandcornerstolimitcoronaand radiointerference. The design of the insulators shall be such that stresses due to expansion and contractioninanypartoftheinsulatorshallnotleadtodeterioration. The core shall be sound and free of cracks and voids that may adversely affect the insulators.
1.8.7
1.8.8 1.8.9
1.8.10 Weathersheds shall be uniform in quality. They shall be clean, sound, smooth and freefromgrossdefectsandexcessiveflashingatpartinglines. 1.8.11 Endfittingsshallbefreefromcracks,seams,shrinks,airholesandroughedges.End fittings should be effectively, sealed to prevent moisture ingress, effectiveness of sealing system must besupported by test documents. All surfaces of the metal parts shallbeperfectlysmoothwiththeprojectingpointsorirregularitieswhichmaycause corona.Allloadbearingsurfacesshallbesmoothanduniformsoastodistributethe loadingstressesuniformly.
PAGE 4
1.8.12 All ferrous parts shall be hot dip galvanized to give a minimum average coating of zinc equivalent to 600 gm/sq.m. and shall be in accordance with the requirement of ISO:1461 (E) and shall satisfy the tests mentioned in ISO:1460 (E). The zinc used for galvanizingshallbeofpurityof99.95%.Thezinccoatingshallbeuniform,adherent, smooth, reasonably bright continuous and free from imperfections such as flux, ash rust stains, bulky white deposits and blisters. The galvanized metal parts shall be guaranteed to withstand at least six successive dips each lasting for one (1) minute duration under the standard preece test. The galvanizing shall be carried out only afteranymachining. 2.0 EquipmentMarking 2.1 Each composite long rod unit shall be legibly and indelibly marked with the trade mark of the manufacturer, name of TPL and month & year of manufacture. The guaranteed combined mechanical and electrical strength shall be indicated in kilo Newton followed by the word kN to facilitate easy identification and to ensure properuse. BidDrawings TheBiddershallfurnishfulldescriptionandillustrationofthematerialoffered. The Bidder shall furnish along with the bid the outline drawing (6 copies) of each insulator unit including a cross sectional view of the long rod insulator unit. The drawingshallincludebutnotlimitedtothefollowinginformation: (a) (b) (c) (d) Longroddiameterandballtoballspacingwithmanufacturingtolerances MinimumCreepagedistancewithpositivetolerance Protectedcreepagedistance Eccentricityofthelongrodunit (i) (ii) (e) (f) (g) (h) 3.3 Axialrunout Radialrunout
3.0 3.1 3.2
Unitmechanicalandelectricalcharacteristics Sizeandweightofballandsocketparts Weightofporcelain/compositelongrodunits Materials (i) (ii) Identificationmark Manufacturerscataloguenumber
After placement of award, the Supplier shall submit full dimensioned insulator drawings containing all the details as given in Clause No. 3.2 above, in four (4) copies to Owner for approval. After getting approval from Owner and successful
PAGE 5
completion of all the type tests, theSupplier shall submit 20 more copies of the same drawingtotheOwnerforfurtherdistributionandfielduseatOwnersend. 3.4 3.5 After placement of award the Supplier shall also submit fully dimensioned insulator cratedrawingfordifferenttypeofinsulators. Afterplacementofaward,theSuppliershallsubmitfulldimensionedmanufacturing drawing of porcelain / composite long rod insulator unit in six (6) copies to the Ownerforreferenceandrecord.
4.0TestsandStandards 4.1TypeTests Thefollowingtypetestsshallbeconductedonlongrodunits,components,materials orcompletestrings: 4.1.1 OnthecompletecompositeLongRodInsulatorStringwithHardwareFittings (a) Power frequency voltage withstand test with corona control rings/grading ring and arcing horns under wet condition for AC transmission lines Switchingsurgevoltagewithstandtestunderwet condition Impulse voltage withstand test under dry condition CoronaandRIVtestunderdrycondition MechanicalStrengthtest Vibrationtest Saltfogpollutionwithstandtest : IEC:3831993/ AnnexureA : IEC:3831993 : IEC:3831993 : AnnexureA : AnnexureA : AnnexureA : AnnexureA
(b) (c) (d) (e) (f) (g) 4.1.2
OnCompositeInsulatorUnits (a) Tests on interfaces and connections of metal fittings (Tests to be performed on the same samplesinthesequencegivenbelow) i) Drypowerfrequencyvoltagetest ii) Suddenloadreleasetest iii) Thermalmechanicaltest iv) Waterimmersiontest v) Steepfrontimpulsevoltagetest vi) Drypowerfrequencyvoltagetest (b) Assembledcoreloadtimetest i) Determination of the average failing loadofthecoreoftheassembledunit ii) Control of the slope of the strength timecurveoftheinsulator
IEC:61109
IEC:61109
PAGE 6
(c) (d) (e)
Brittlefractureresistancetest Testofhousing,Trackinganderosiontest Testsforthecorematerial i) Dyepenetrationtest ii) Waterdiffusiontest Flammabilitytest RecoveryofHydrophobicitytest Mechanical Load Time test and test of tightness betweenendfiringsandinsulatorhousing Siliconecontenttest HighPressurewashingtest
AnnexureA IEC:61109 IEC:61109 IEC:61109 AnnexureA IEC:61109 AnnexureA AnnexureA
(f) (g) (h) (i) (j)
4.1.3 All the type test given in Clause No. 4.1.1 shall be conducted on Single I suspension & double tension string along with hardware fittings. All the type test given in Clause No. 4.1.1 (a) to (e) shall also be conducted on Single I Pilot suspensioninsulatorstringalongwithhardwarefittings. 4.2 AcceptanceTests: 4.2.1 ForCompositeLongRodInsulators (a) (b) (c) (d) Verificationofdimensions Galvanisingtest ) ) ) ) ) ) ) ) IEC:61109, IEC:60383 IEC:60383 IEC:61109 AnnexureA IEC:61109
Verificationoflockingsystem Verificationoftightness ofinterfacebetweenendfittingsand insulatorhousingandofspecified mechanicalload RecoveryofHydrophobicity
(d) (e)
Testsoninterfacesandconnectionsof ) metalfittings(Teststobeperformedon ) thesamesamplesinthesequencegivenbelow) i) Drypowerfrequencyvoltagetest ii) Suddenloadreleasetest iii) Thermalmechanicaltest iv) Waterimmersiontest v) Steepfrontimpulsevoltagetest vi) Drypowerfrequencyvoltagetest Siliconecontenttest
(f)
AnnexureA
PAGE 7
Thetest4.2.1.(e)&(f)shallbedoneagainsteachlotoragainstevery5000nos. of insulators whichever is less. In the event of failure of the sample to satisfy the acceptance test(s) specified in 4.2 above, the retest procedure shall be as IEC61109.
4.3
RoutineTests
4.3.1ForCompositeLongRodInsulatorUnits a) b) VisualInspection Mechanicalroutinetest) AsperIEC:61109 AsperIEC:61109
4.4
TestsDuringManufacture Onallcomponentsasapplicable a) b) Chemicalanalysisofzincusedforgalvanising Chemicalanalysis,mechanical,metallographictest andmagneticparticleinspectionformalleable castings. Chemicalanalysishardnesstestsandmagnetic particleinspectionforforgings Trackinganderosiontestoninsulatingmaterial AsperAnnexA AsperAnnexA AsperAnnexA IEC60587
c) d) 4.5 4.5.1 4.5.2
TestingExpenses Testing charges for the type test specified shall be indicated separately in the prescribedschedule. Bidder shall indicate unit type test charges for all type tests covered under Clause 4.1.1and4.1.2separately,intherelevantscheduleofPricesasapplicable.Chargesfor eachtypetestsshallbeseparatelyindicated. For Type Tests which involves the tests on the complete insulator string with hardwarefitting,standardhardwarefittingssimilartoexistinginsulatorstringsshall bearrangedandusedbytheinsulatorsupplier. In case of failure in any type test the contractor is either required to modify the design of the material & successfully carryout all the type tests as has been detailed out in this specifications or to repeat that particular type test at least three times successfullyathisownexpenses. Biddershallindicatethelaboratoriesinwhichtheyproposetoconductthetypetests. They shall ensure that adequate facilities are available in the laboratory and the tests can be completed in these laboratories within the time schedule guaranteed by them intheappropriateschedule.
4.5.3
4.5.4
4.5.5
PAGE 8
4.5.6
The entire cost of testing for acceptance and routine tests and tests during manufacturespecifiedhereinshallbetreatedasincludedinthequotedExworks/CIF Price. 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 deductedfromthecontractprice.AlsoifonreceiptoftheSuppliersnoticeoftesting, theOwnersrepresentativedoesnotfindthematerialortestsetup/equipmentstobe ready for testing, the expenses incurred by the Owner for redeputation shall be deductedfromcontractprice. The bidder shall intimate the Owner about carrying out of the type tests along with detailed testing programme at least 1 week in advance (in case of testing in India) and at least 2 weeks advance (in case of testing abroad) of the scheduled date of testing during which the Owner will arrange to depute his representative to be presentatthetimeofcarryingoutthetests. SampleBatchforTypeTesting The bidder shall offermaterial for sample selection for type testing only after getting Quality Assurance Programme approved by the Owner. The bidder shall offer at least three times the quantity of materials required for conducting all the type tests for sample selection. The sample for type testing will be manufactured strictly in accordancewiththeQualityAssuranceProgrammeapprovedbytheOwner. Before sample selection for type testing, the bidder shall be required to conduct all theacceptancetestssuccessfullyinpresenceofOwnersrepresentative. ScheduleofTesting TheBidderhastoindicatethescheduleoffollowingactivitiesintheirbids: a) b) c) d) Submissionofdrawingforapproval. SubmissionofQualityAssuranceProgrammeforapproval. Offeringofmaterialforsampleselectionfortypetests. Typetesting.
4.5.7
4.5.8
4.6 4.6.1
4.6.2 4.7 4.7.1 4.8 4.8.1
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 additiontotheaforesaidtype,acceptanceandroutineteststosatisfyhimselfthatthe materialcomplywiththeSpecifications. 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 premisesoratanyothertestcentre.Incaseofevidenceofnoncompliance,itshallbe binding on the part of the Supplier to prove the compliance of the items to the technical specifications by repeat tests or correction of deficiencies or replacement of defectiveitems,allwithoutanyextracosttotheOwner.
4.8.2
PAGE 9
4.9 4.10
Guarantee The Supplier of insulators shall guarantee overall satisfactory performance of the insulators. TestReports
4.10.1 Copies of type test reports shall be furnished in at least six (6) copies along with one original.OnecopyshallbereturneddulycertifiedbytheOwneronlyafterwhichthe commercialproductionoftheconcernedmaterialshallstart. 4.10.2 Copiesofacceptancetestreportsshallbefurnishedinatleastsix(6)copies.Onecopy shall be returned duly certified by the Owner, only after which the material shall be dispatched. 4.10.3 Record of routine test reports shall be maintained by the Supplier at his works for periodicinspectionbytheOwnersrepresentative. 4.10.4 Test certificates of test during manufacture shall be maintained by the Supplier. TheseshallbeproducedforverificationasandwhendesiredbytheOwner. 4.11 Inspection
4.11.1 The Owners representative shall at all times be entitled to have access to the works and all places of manufacture, where insulator, and its component parts shall be manufactured and the representatives shall have full facilities for unrestricted inspectionoftheSuppliersandsubSuppliers works,rawmaterials,manufacture of thematerialandforconductingnecessarytestasdetailedherein. 4.11..2 The material for final inspection shall be offered by the Supplier only under packed condition as detailed in clause No.4.13 of the specification. The Owner shall select samples at random from the packed lot for carrying out acceptance tests. The lot should be homogeneous and should contain insulators manufactured in 34 consecutiveweeks. 4.11.3 The Supplier shall keep the Owner informed in advance of the time of starting and the progress of manufacture of material in their various stages so that arrangements couldbemadeforinspection. 4.11..4 No material shall be dispatched from its point of manufacture before it has been satisfactorily inspected and tested unless the inspection is waived off by the Owner in writing. In the latter case also the material shall be dispatched only after satisfactorytestingforalltestsspecifiedhereinhavebeencompleted. 4.11.5 TheacceptanceofanyquantityofmaterialshallbenowayrelievetheSupplierofhis responsibility for meeting all the requirements of the specification and shall not preventsubsequentrejection,ifsuchmaterialarelaterfoundtobedefective. 4.12 PackingandMarking
4.12.1 All insulators shall be packed in suitable PVC/ plastic tubes/any other suitable packing along with temporary wrap on shields/shrouds for each insulator unit. The packing shall provide protection against rodent. The shields/shrouds shall be for protection during transport and for preventing bird pecking during erection.
PAGE 10
Further, the shields/shrouds shall be made of opaque, weather proof material of adequate strength and shall be colour coded. The shields/shrouds shall have smaller diameter than the insulator to stay in place against winds & weather and shall be designed so as to leave only the end fittings exposed for attachment of insulator to tower and line hardware until line construction is complete. The shield/shroud shall have suitable pull off loop for easy detachment just prior to charging of the line without causing any damage to the insulator. The bidder shall furnish detailed design of the packing and shield/shroud along with attachment and detachment procedureinthisregard.Formarinetransportation,cratesshallbepalleted. 4.12.2 The packing shall be of sufficient strength to withstand rough handling during transit,storageatsiteandsubsequenthandlinginthefield. 4.12.3 Suitable cushioning, protective padding, or dunnage or spacers shall be provided to preventdamageordeformationduringtransitandhandling. 4.12.4 All packing cases shall be marked legibly and correctly so as to ensure safe arrival at their destination and to avoid the possibility of goods being lost or wrongly dispatched on account of faulty packing and faulty or illegible markings. Each case/crateshallhaveallthemarkingsstenciledonitinindelibleink. 4.13 Standards The insulator strings and its components shall conform to the following Indian/ International Standards which shall mean latest revision, with amendments/ changes adopted and published, unless specifically stated otherwise in the Specification. 4.13.1 Intheeventofsupplyofinsulatorsconformingtostandardsotherthanspecified,the Bidder shall confirm in his bid that these standards are equivalent or better to those specified. In case of award, salient features of comparison between the standards proposedbytheBidderandthosespecifiedinthisdocumentwillbeprovidedbythe Suppliertoestablishequivalence.
Sl.No. 1. 2. 3. 4. Indian Standard IS:2091992 IS:4061991 IS:7311991 Title International Standard BS:3436 BS:3436 BS:137(I&II) IEC:60383 IEC:600601 BS:3288 IEC:60120 IEC:60372 ISO1461(E)
5.
6. 7.
Specificationforzinc MethodofChemicalAnalysisofSlabZinc PorcelaininsulatorsforoverheadPowerlines withanominalvoltagegreaterthan1000V IS:2071 Part MethodsofHighVoltageTesting (I) 1993 (Part(II) 1991 Part(III)1991 SpecificationforInsulatorfittingsforOverhead IS:2486 PowerLineswithanominalvoltagegreaterthan 1000V GeneralRequirementsandTests PartI1993 DimensionalRequirements PartII1989 LockingDevices PartIII1991 IS:26291990 RecommendedPracticeforHot,Dip Galvanisationforironandsteel IS:26331992 TestingofUniformityofCoatingofzinccoated
PAGE 11
Sl.No.
Indian Standard IS:31881988 IS:67451990 IS:82631990
Title articles DimensionsforDiscInsulators DeterminationofWeightofZincCoatingonZinc coatedironandsteelarticles MethodsofRITestofHVinsulators
International Standard IEC:60305 BS:4331969 ISO:14601973 IEC:60437 NEMAPubli cationNo.07/ 1964/CISPR IEC:60506 IEC:60575
8. 9. 10.
11. 12.
IS:82691990
13. 14.
15. 16.
17.
MethodsforSwitchingImpulsetestonHV insulators ThermalMechanicalPerformancetestand mechanicalperformancetestonstringinsulator units SaltFogPollutionVoltageWithstandTest CompositeinsulatorsforA.C.Overheadlines withnominalvoltagegreaterthan1000V Definitions,testmethodsandacceptancecriteria Guidefortheselectionofinsulatorsinrespectof pollutedconditions TestsoninsulatorsofCeramicmaterialorglass orglassforoverheadlineswithanominal voltagegreaterthan1000V Characteristicsofstringinsulatorunitsofthe longrodtype
IEC:60507 IEC61109
IEC:60815 IEC:60383 IEC:60433
Thestandardsmentionedaboveareavailablefrom:
ReferenceAbbreviation BS NameandAddress BritishStandards, BritishStandardsInstitution 101,PentonvileRoad, N19ND,UK InternationalElectrotechnicalCommission, BureauCentraldelaCommission, electroTechniqueinternational, 1Ruedeverembe, Geneva,SWITZERLAND BeureauOfIndianStandards. ManakBhavan, 9,BahadurShahZafarMarg, NewDelhi110001.INDIA InternationalOrganisationforStandardization. DanishBoardofStandardization DanishStandardizingSraat, Aurehoegvej12 DK2900,Heeleprup,DENMARK NationalElectricManufactureAssociation, 155,East44thStreet. NewYork,NY10017U.S.A. AmericanSocietyforTestingandMaterials, 1916RaceSt.Phelledelphia,PA19103USA
IEC/CISPR
BIS/IS
ISO
NEMA
ASTM
PAGE 12
1.A 1A.1 ANNEXUREA
Tests on Complete Strings with Hardware Fittings for 400kV AC transmissionlines CoronaExtinctionVoltageTest(Dry) Thesampleassemblywhensubjectedtopowerfrequencyvoltageshallhavea corona extinction voltage of not less than 320 kV (rms) line to ground under drycondition.Thereshallbenoevidenceofcoronaonanypartofthesample. The atmospheric condition during testing shall be recorded and the test results shall be accordingly corrected with suitable correction factor as stipulatedinIEC:383. RIVTest(Dry) Under the conditions as specified under (1.A.1) above, the insulator string along with complete hardware fittings shall have a radio interference voltage levelbelow1000microvoltsatoneMHzwhensubjectedto50HzACvoltage of 305 kV line to ground under dry condition. The test procedure shall be in accordancewithIS:8263/IEC:60437. MechanicalStrengthTest Thecompleteinsulatorstringalongwithitshardwarefittingexcludingarcing horn, corona control ring, grading ring and suspension assembly/dead end assembly shall be subjected to a load equal to 50% of the specified minimum ultimate tensile strength (UTS) which shall be increased at a steady rate to 67% of the minimum UTS specified. The load shall be held for five minutes and then removed. After removal of the load, the string componentsshall not show any visual deformation and it shall be possible to disassemble them by hand. Hand tools may be used to, remove cotter pins and loosen the nuts initially. The string shall then be reassembled and loaded to 50% of UTS and the load shall be further increased at a steady rate till the specified minimum UTS and held for one minute. No fracture should occur during this period. The applied load shall then be increased until the failing load is reached and thevaluerecorded. VibrationTest The suspension string shall be tested in suspension mode, and tension string intensionmodeitselfinlaboratoryspanofminimum30metres.Inthecaseof suspension string a load equal to 600 kg shall be applied along the axis of the suspension string by means of turn buckle. The insulator string along with hardware fittings and two/ triple/quad (as applicable) subconductors (each tensioned at 43 kN shall be secured with clamps. The system shall be suitable to maintain constant tension on each subconductors throughout the duration of the test. Vibration dampers shall not be used on the test span. Both the subconductors shall be vertically vibrated simultaneously at one of the resonance frequencies of the insulators string (more than 10 Hz) by means of vibration inducing equipment. The peak to peak displacement in mm of
1A.2
1A.3
1A.4
PAGE 13
vibration at the antinode point, nearest to the string, shall be measured and the same shall not be less than 1000/f1.8 where f is the frequency of vibration incycles/sec.Theinsulatorstringshallbevibratedfornot lessthan10million cycles without any failure. After the test the insulators shall be examined for looseness of pins and cap or any crack in the cement. The hardware shall be examined for looseness, fatigue failure and mechanical strength test. There shallbenodeteriorationofpropertiesofhardwarecomponentsandinsulators after the vibration test. The insulators shall be subjected Mechanical performance test followed by mechanical strength test as per relevant standards: Saltfogpollutionwithstandtest ThistestshallbecarriedoutinaccordancewithIEC:60507.Thesalinitylevel forcompositelongrodinsulatorsshallbe160Kg/m3NACL CompositeLongrodInsulatorUnits BrittleFractureResistanceTest Assembled core load time test with container that contains 1NHNO3 concentric acid that is applied at the naked rod. The rod should be held at 80%ofSMLforthedurationofthetest. Therodshouldnotfailwithinthe96hourtestduration 2.2 (1) RecoveryofHydrophobicityTest Thesurfaceofselectedsamplesshallbecleanedwithisopropylalcohol. Allowthesurfacetodryandspraywithwater.RecordtheHCclassification. Drythesamplesurface. Treatthesurfacewithcoronadischargestodestroythehydrophobicity.This canbedoneutilizingahighfrequencycoronatester,Holdingtheelectrode approximately3mmfromthesamplesurface,slowlymovetheelectrodeover anareaapproximately1x1.Continuetreatingthisareafor23minutes, operatingthetesteratmaximumoutput. Immediatelyafterthecoronatreatment,spraythesurfacewithwaterand recordtheHCclassification.Thesurfaceshouldbehydrophilic,withanHC valueof6or7.Ifnot,drythesurfaceandrepeatthecoronatreatmentfora longertimeuntilanHCof6or7isobtained.Drythesamplesurface. Allowthesampletorecoverandrepeatthehydrophobicitymeasurementat severaltimeintervals.SiliconerubbershouldrecovertoHC1HC2within 24to48hours,dependingonthematerialandtheintensityofthecorona treatment.
1A.5 2.0 2.1
(2)
(3)
(4)
PAGE 14
2.3
Siliconecontenttest Minimum content of silicone as guaranteed by supplier shall be verified through FTIR spectroscopy & TGA analysis or any other suitable method mutually agreed between Owner & Supplier in Quality Assurance Programme. HighPressurewashingtest The test is to be carried out at 3800kPa with nozzles of 6mm diameter at a distance of 3m from nozzles to the insulator, followed by a dry power frequencyvoltagetestasperIEC61109. TestsonAllcomponents(Asapplicable) ChemicalAnalysisofZincusedforGalvanizing Samples taken from the zinc ingot shall be chemically analysed as perIS:2091979.Thepurityofzincshallnotbelessthan99.95%. TestsforForgings The chemical analysis hardness tests and magnetic particle inspection for forgings, will be as per the internationally recognised 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 SupplierandOwnerinQualityAssuranceProgramme. TestsonCastings The chemical analysis, mechanical and metallographic tests and magnetic, particle inspection for castings will be as per the internationally recognised 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 Owner in Quality Assurance Programme.
2.4
3. 3.1 3.2
3.3
PAGE 15
SECTION-II B
TECHNICALSPECIFICATIONS SECTIONIIB 1. 1.1. 1.1.1. TechnicalDescriptionofDiscInsulators DetailsofDiscInsulators The Insulator strings shall consist of Antifog discs for a three phase, 50 Hz, effectively earthed 400 kV transmission system in a heavy polluted atmosphere.Thediscsshallbecapandpin,ballandsockettype. Supplier may quote for disc insulator, made of either electroporcelain or toughenedglass. Thesizeofdiscinsulator,minimumcreepagedistance,thenumbertobeused in different type of strings, their electromechanical strength and mechanical strengthofinsulatorstringalongwithhardwarefittingsshallbeasfollows:
1.1.2. 1.1.3.
Sl. No. Typeofstring Sizeofdisc insulators (mm) Minimum creepage distanceof eachdisc (mm) 1. 2. SingleI suspension SingleI suspension Pilot 3. 4. 5. Single Tension Double Tension DoubleV Suspension 280305 x145 305320 x170 305320 x170 475 2x2x24 160 320 475 2x23 160 320 460 1x24 120 120 280305 x145 280305 x145 460 1x23 120 120 460 1x23 No.ofdisc Electro mechnical strengthof insulator disc(KN) 120 Mechanical strengthof insulatorstring alongwith hardwarefittings (KN) 120
1.1.4.
PinandCap PinandCapshallbedesignedtotransmitthemechanicalstressestotheshell by compression and develop uniform mechanical strength in the insulator. The cap shall be circular with the inner and outer surfaces concentric, of such designthatitwillnotyieldordistortunderloadconditions. The pin ball shall move freely in the cap socket but without danger of accidental uncoupling during erection or in position. The design of the disc shouldbesuchthatstressesduetoexpansionorcontractioninanypartofthe insulatorshallnotleadtodeterioration.
1.1.5.
SECTION-II B (VOLUME-II) PAGE 1
1.2. 1.2.1. 1.2.2. 1.2.3.
ZincSleeve ThePinshallbeequippedwithzincsleevefusedtoitwithoutgap. The zinc sleeve shall have sufficient thickness and length and shall be adequatelyfusedtopinshanktocoverthecementlineoftheinsulator. To avoid ionic current through the gap between zinc sleeve and pin shank, the zinc sleeve shall have sufficient adhesion in area on the pin shank; the zinc sleeve shall have sufficient adhesion in area on the pin shank. The total fused area of the interface shall be more than 80% of the total area between zincsleeveandpinshank. The exposed part of the zinc sleeve shall have minimum dimensions of 5mm thickness, 10mm length. The total length of sleeve shall not be less than 20mm. Securityclip SecurityclipforusewithballandsocketcouplingshallbeofRshapedhump typewhichshallprovidepositivelockingofthecouplingasperIS:2486(Part Ill)/IEC : 372. The legs of the security clips shall be spread after installation to prevent complete withdrawal from the socket. The locking device should be resilient, corrosion resistant and of suitable mechanical strength. There shall be no risk of the locking device being displaced accidentally or being rotated when in position. Under no circumstances shall locking device allow separationofinsulatorunitsorfittings. The hole for the security clip shall be countersunk and the clip shall be of such design that the eye of clip may be engaged by a hot line clip puller to provide for disengagement under energised conditions. The force required to pull the security clip into its unlocked position shall not be less than 50N (5 kg)ormorethan500N(50kg). BallandSocketDesignation Thedimensionsoftheballsandsocketsshallbeof20mmdesignationfor120 KN and 160 KN disc insulator in accordance with the standard dimensions statedinIS:2486(PartII)/IEC:120. DimensionalToleranceofInsulatorDisc(Antifog) It shall be ensured that the dimensions of the disc insulators are within the limitsspecifiedbelow: a) DiameterofDisc(mm) Standard 120KNDisc 280305 160KNDisc 305320
1.2.4.
1.3. 1.3.1.
1.3.2.
1.4.
1.5.
Maximum 293318 318333
Minimum 267292 293307
Thenominaldiametershouldbeguaranteedbythebidderinappropriate scheduleinBidProposalSheet b) Balltoballspacingbetweendiscs Standard 120KNDisc 145 160KNDisc 170
Maximum 149 175
Minimum 141 165
1.6. Interchangeability Thediscinsulatorsinclusiveoftheballandsocketfittingsshallbeofstandard design suitable for use with the hardware fittings of any make conforming to relevantIndian/InternationalStandards. CoronaAndRIPerformance Allsurfacesmustbeclean,smooth,withoutcuts,abrasionsorprojections.No part shall be subjected to excessive localised pressure. The metal parts shall be so designed and manufactured that it shall not generate any Radio Interference beyond specified limit and not produce any noise generating coronaundertheoperatingconditions. Maintenance The disc insulators offered shall be suitable for employment of hot line maintenance techniques so that the usual hot line operations can be carried outwithease,speedandsafety. Biddersshallindicatethemethodsgenerallyusedintheroutinehotanddead line maintenance of EHV Lines for which similar disc insulators have been suppliedbythem.Biddersshallalsoindicatetherecommendedperiodicityof suchmaintenance. Materials Porcelain The porcelain used in the manufacture of shells shall be sound, free from defectsthoroughlyvitrifiedandsmoothlyglazed. Glaze The finished porcelain shall be glazed in brown colour. The glaze shall cover all exposed parts of the insulator and shall have a good lusture, smooth surface and good performance under the extreme weather conditions of a tropical climate. It shall not crack or chip by ageing under the normal service conditions. The glaze shall have the same coefficient of expansion as of the porcelainbodythroughouttheworkingtemperaturerange.
1.7.
1.8. 1.8.1.
1.8.2.
1.9. 1.9.1. 1.9.2.
1.9.3.
ToughenedGlass The glass used for the shells shall be sound, free from defects such as flaws. bubbles, inclusions etc. and be of uniform toughness over its entire surface. Allexposedglasssurfacesshallbesmooth. Cement Cement used in the manufacture of the insulator shall not cause fracture by expansion or loosening by contraction. The cement shall not give rise to chemical reaction with metal fittings and its thickness shall be as small and uniform as possible. Proper care shall be taken to correctly centre and locate individualpartsduringcementing. PinsandCaps Pins and Caps shall be made of drop forged steel and malleable cast iron/ spheriodal graphite iron/drop forges steel respectively, duly hot dip galvanised and shall not be made by jointing, welding, shrink fitting or any otherprocessfrommorethanonepieceofmaterial. SecurityClips Security clips shall be made of good quality stainless steel or phosphor bronzeasperIS:1385.2.5%extraSecurityclipshallbeprovided. Workmanship All the material shall be of the latest design and conform to the best modern practices adopted in the extra high voltage field. Suppliers shall offer only such insulators as are guaranteed by him to be satisfactory and suitable for 400kVTransmissionlinesandwillgivecontinuedgoodservice. The design, manufacturing process and material control at various stages shall be such as to give maximum working load, highest mobility, best resistance to corrosion, good finish and elimination of sharp edges and cornerstolimitcoronaandradiointerference. The design of the insulators shall be such that stresses due to expansion and contractioninanypartoftheinsulatorshallnotleadtodeterioration. Metal caps shall be free from cracks, seams, shrinks, air holes, burrs and roughedges.Allsurfacesofthemetalpartsshallbeperfectlysmoothwithno projecting points or irregularities which may cause corona. All load bearing surfaces shall be smooth and uniform so as to distribute the loading stresses uniformly. All ferrous parts shall be hot dip galvanised to give a minimum average coating of Zinc equivalent to 600 gm/sq.m. and shall be in accordance with the requirement of IS:2629 and shall satisfy the tests mentioned in IS:2633. The zinc used for galvanising shall be of 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 whitedepositsandblisters.Thegalvanisedmetalpartsshallbeguaranteedto
1.9.4.
1.9.5.
1.9.6. 1.10. 1.10.1.
1.10.2.
1.10.3. 1.10.4.
1.10.5.
withstand atleast six successive dips each lasting for one (1) minute duration underthestandardpreecetest. 1.10.6. Before ball fittings are galvanised, all die flashing on the shank surface of the ball shall be carefully removed without reducing the dimensions below the designrequirements. The design of the insulators shall be such that the shell shall not engage directly with hard metal. The design shall also be such that when units are coupled together there is no contact between the shell of one unit and metal of the next adjacent unit. The design of the shell ribs shall be such that the security clip of the insulator can be engaged and disengaged easily with hot stickwithoutdamagingtheshellribs. Insulatorunitsafterassemblyshallbeconcentricandcoaxialwithinlimitsas permittedbytherelevantIndianStandards. The manufacturer of the insulators shall guarantee an insulator failure rate not exceeding 1 (one) per 10000 (ten thousand) per year for disc insulator per year. In case the annual failure rate during the first ten years of service exceeds the above figure, under normal operating condition, as will be determined by check to be conducted as per mutually agreed procedure and conditions upto ten years, (as permitted by the operating situation), the Supplier shall supply to the Owner free of cost spare insulators equal to 10 timetheexcessfailure. The Supplier shall guarantee that there shall not be any decapping/breaking of insulators on line under normal operating conditions. In the event of any decapping/breaking and subsequent line drop, during the first ten years of service the Supplier shall have to pay Rs. 50,000/ (Rs. Fifty thousand only) per dropped string towards expenditure to be incurred by TPL ( Torrent Power)forthislinerepair. TechnicalDescriptionofPorcelainLongRodInsulators DetailsofLongRodInsulators The insulators of the stings shall consist of standard long rod insulators with normal sheds for a three phase, 50 Hz, effectively earthed 400 kV transmission system in a heavy polluted atmosphere. Insulators shall be long rodtypewithBallandsocketconnections. Insulators shell have normal sheds/alternate sheds with good selfcleaning properties. Insulator shed profile, spacing projection etc. shall be strictly in accordancewiththerecommendationofIEC815. Supplier quoting for long rod insulators made of electro porcelain shall also supply intermediate ball pins and intermediate arcing horns along with long rodinsulators. The price of these items shall be considered as including in the price of long rodinsulators.
1.10.7.
1.10.8. 1.10.9.
1.10.10.
2.0 2.1 2.1.1
2.1.2
2.1.3
2.1.4
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 alongwith hardware fittings shall be asfollows:
Sl. No. Typeof string Sizeoflong rod insulators (mm) Minimum creepage distanceof eachunit (mm) 1. 2. SingleI suspension SingleI suspension Pilot 3. 4. 5. Single Tension Double Tension DoubleV suspension 7585 3645 2x2x3 160 320 7585 3645 2x3 160 320 6075 3500 1x3 120 120 6075 3500 1x3 120 120 6075 3500 No.of individu alunits per string 1x3 Electro mechanical strengthof insulator disc(KN) 120 Mechanical strengthof insulator stringalong withhardware fittings(KN) 120
Note:(i)Biddersmayquotefortherelevantstrings. (ii) (iii) Lengthoflongrodinsulatorstringsshallbematchingwiththe correspondingdiscinsulatorstrings./PolymericInsulator ThecostofintermediateBallpinandintermediatearcinghorn shallbeconsideredasincludinginthepriceoflongrod insulators.
2.2 2.2.1
PinandCap 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, of such designthatitwillnotyieldordistortunderloadconditions. The pin ball shall move freely in the cap socket but without danger of accidental uncoupling during erection or in position. The design of the long rod should be such that stresses due to expansion or contraction in any part oftheinsulatorshallnotleadtodeterioration. BallandSocketDesignation The dimensions of the balls and socket shall be of 20 mm designation for 120 &160KNforlongrodinsulatorsinaccordancewiththestandarddimensions statedinIS2486(PartII)/IEC:120.
2.2.2
2.3
2.4 2.5 2.6 2.6.1
DimensionalTolerance The tolerance on all dimensions e.g. diameter, length and creepage distance shallbeallowedasfollows: (0.04d+1.5)mmwhend<300mm. (0.025d+6)mmwhend>300mm Wheredbeingthedimensionsinmillimetersfordiameter,lengthorcreepage distanceasthecasemaybe. However,nonegativetoleranceshallbeapplicabletocreepagedistance. IntermediateBallPinDesignation The dimensions of the intermediate ball pin shall be in accordance with the standarddimensionstatedinIEC:471. IntermediateArcingHorn For Insulator strings with long rod insulators besides the arcing horn on towersideofhardwarefittings,intermediatearcinghornsalongwithfixtures andfastenersasshowninthespecificationshallalsobeprovided. The total effective arcing distance shall be 3050 mm under nominal dimensionsofinsulator. The spark gap shall be so adjusted to ensure effective operation under actual fieldcoordination. InterChangeability The long rod insulators with ball and socket connection shall be of standard design suitable for use with the hardware fittings of any make conforming to relevantIECstandards. CoronaandRIPerformance All surfaces shall be clean, smooth,without cuts, abrasionsor projections. No part shall be subjected to excessive localised pressure. The insulator and metal parts shall be so designed and manufactured that it shall avoid local corona formation and not generate any radio interference beyond specified limitundertheoperatingconditions. Maintenance The long rod insulators offered shall be suitable for employment of hot line maintenance techniques so that usual hot line operations can be carried out withease,speedandsafety. Allinsulatorsshallbedesignedtofacilitatecleaningandinsulatorsshallhave the minimum practical number of sheds and grooves. All grooves shall be so proportioned that any dust deposit can be removed without difficulty either bywipingwithaclothorbyremotewashingunderlivelinecondition.
2.6.2 2.7
2.8
2.9 2.9.1
2.9.2
2.10 2.10.1
Materials Porcelain The porcelain used in the manufacture of long rods shall be alumina type. It shall be sound, free from defects and thoroughly vitrified and smoothly glazed. Glaze The finished porcelain shall be glazed in brown colour. The glaze shall cover all exposed parts of the insulator and shall have a good lusture, smooth surface and good performance under the extreme weather conditions of a tropicalclimate.Itshallnotbecrackedorchippedbyagingunderthenormal service conditions. The glaze shall have the same coefficient of expansion as oftheporcelainbodythroughouttheworkingtemperaturerange. InsulatorCap The caps of long rod insulator units shall be of malleable cast iron or other suitable material, duly hot dip galvanised and shall not be made by jointing, welding, shrink fitting or any other process from more than one piece of material. The design of the unit shall be such that stresses due to expansion andcontractionofanypartoftheinsulatorshallnotleadtodeterioration. IntermediateBallPin The intermediate ball pin shall be made of drop forged steel, duly hot dip galvanised and shall not be made by jointly welding, shrink filling or any otherprocessfrommorethanonepieceofmaterial. IntermediateArcinghorn IntermediateArcinghornshallbemildsteeltube. Cement Cement used in the manufacture of the insulator shall not cause fracture by expansion or loosening by contraction. The cement shall not give rise to chemical reaction with metal fittings and its thickness shall be as small and uniform as possible. Proper care shall be taken to correctly centre and locate individualpartsduringcementing. Workmanship All the materials shall be of latest design and conform to the best modern practicesadoptedintheextrahighvoltagefield.Biddersshallofferonlysuch insulators as are guaranteed by him to be satisfactory and suitable for 400 kV transmissionlinesandwillgivecontinuedgoodservice. The design, manufacturing process and material control at various stages shall be such as to give maximum working load, highest mobility, best resistance to corrosion, good finish and elimination of sharp edges and cornerstolimitcoronaandradiointerference.
2.10.2
2.10.3
2.10.4
2.10.5 2.10.6
2.11 2.11.1
2.11.2
2.11.3 2.11.4
The design of the insulators shall be such that stresses due to expansion and contractioninanypartoftheinsulatorshallnotleadtodeterioration. Metal caps shall be free from cracks, seams, shrinks, air holes and rough edges. All surfaces of the metal parts shall be perfectly smooth with the projecting points or irregularities which may cause corona. All load bearing surfaces shall be smooth and uniform so as to distribute the loading stresses uniformly. All ferrous parts shall be not dip galvanised to give a minimum average coating of zinc equivalent to 600 gm/sq. mm. and shall be in accordance with the requirement of IS: 2629 and shall satisfy the tests mentioned in IS : 2633. 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 galvanised metal parts shall be guaranteed to withstandat least six successive dips each lasting for one (1) minute duration underthestandardpreecetest.Thegalvanisingshallbecarriedoutonlyafter anymachining. The design of the insulators shall be such that the porcelain shall not engage withhardmetal. Insulatorunitsafterassemblyshallbeconcentricandcoaxialwithinlimitsas permittedbytherelevantinternationalstandard. The manufacturer of the insulators shall guarantee an insulator failure rate notexceedingoneper1500porcelainlongrodunits.Incasetheannualfailure rate during the first ten years of operation exceeds the above figure under normal operating conditions, as will be determined by check to be conducted as per mutually agreed procedure and conditions upto ten years (as permitted by the operating situation). The manufacturer shall supply to the owner free of cost spare insulators (Porcelain long rod) equal to 10 times the excessfailure. The manufacturer shall guarantee that there shall not be any decapping and breakage of insulators or line under normal operating conditions. In event of any decapping or breakage resulting in line drop during the first ten years of servicethemanufacturershallhavetopayRs.50,000/(Rs.fiftythousand)per dropped string towards expenditure to be incurred by TPGL (Torrent Power GridLtd)forthislinerepair. EquipmentMarking Each insulator disc/long rod unit shall be legibly and indelibly marked with the trade mark of the manufacturer, name of TPL and month & year of manufacture. The guaranteed combined mechanical and electrical strength shall be indicated in kilo Newton followed by the word kN to facilitate easy identificationandtoensureproperuse. For porcelain insulator, the marking shall be on porcelain. The marking shall be printed, not impressed and shall be applied before firing. For toughened glassinsulatorsthemarkingshallbeonthemetalparts.
2.11.5
2.11.6 2.11.7 2.11.8
2.11.9
3.0 3.1
3.2
3.3
One10mmthickringor20mmthickspotofsuitablequalityofpaintshallbe marked on the cap of each insulator porcelain disc/porcelain long rod of particular strength for easy identification of the type of insulator. The paint shall not have any deteriorating effect on the insulator performance. Followingcodesshallbeusedasidentificationmark: For For 120kNdisc/longrodunit 160kNdisc/longrodunit : : Yellow Green
4.0 4.1 4.2
BidDrawings The Bidder shall furnish full description and illustration of the material offered. The Bidder shall furnish along with the bid the outline drawing (6 copies) of each insulator unit including a cross sectional view of the insulator shell. The drawingshallincludebutnotlimitedtothefollowinginformation: (a) (b) (c) (d) Shelldiameterandballtoballspacingwithmanufacturingtolerances MinimumCreepagedistancewithpositivetolerance Protectedcreepagedistance Eccentricityofthedisc (i) (ii) (e) (f) (g) (h) (i) (j) Axialrunout Radialrunout
4.3
Unitmechanicalandelectricalcharacteristics Sizeandweightofballandsocketparts Weightofunitinsulatordisc/longrodunits Materials Identificationmark Manufacturerscataloguenumber
After placement of award, the Supplier shall submit full dimensioned insulator drawings containing all the details as given in Clause No. 4.11.2 above, in four (4) copies to Owner for approval. After getting approval from Owner and successful completion of all the type tests, the Supplier shall submit 20 more copies of the same drawing to the Owner for further distributionandfielduseatOwnersend. After placement of award the Supplier shall also submit fully dimensioned insulatorcratedrawingfordifferenttypeofinsulators. After placement of award, the Supplier shall submit full dimensioned manufacturing drawing of insulator cap, pin and insulator shell in six (6) copiestotheOwnerforreferenceandrecord.
4.4 4.5
5.0 5.1
TestsandStandards TypeTests The following type tests shall be conducted on a suitable number of individual standard disc insulators or long rod units, components, materials orcompletestrings: OnunitdiscInsulators a) b) c) Verificationofdimensions Thermalmechanicalperformancetest Power frequency voltage withstand and flashovertestunder(i)dry (ii)wetcondition Impulse voltage withstand and flashover test (dry) VisibleDischargetest(dry) RIVtest(dry) ResidualstrengthTest SteepwavefrontTest ImpactTest AsperIEC:60383 AsperAnnexA AsperIEC:60383 AsperAnnexA AsperIEC:60383 AsperIEC:60383 AsperIS:731,Cl. 10.2 AsperIEC:60437 AsperAnnexA AsperAnnexA AsperAnnexA
5.1.1
d) e) f) g) h) i) 5.1.2
OnPorcelainlongrodInsulatorunits a) b) c) Verificationofdimensions Thermalmechanicalperformancetest
d) e) f) 5.1.3
Power frequency voltage withstand and AsperIEC:60383 flashovertestunder(i)dry (ii)wetcondition Impulse voltage withstand and flashover test AsperIEC:60383 (dry) VisibleDischargetest(dry) AsperIS:731, Cl10.2 RIVtest(dry) AsperIEC:60437
OnthecompleteDiscInsulatorStringwithHardwareFittings a) Power frequency voltage withstand test with AsperIEC:60383 corona control rings/grading ring and arcing hornsunderwetcondition Switching surge voltage withstand test under AsperIEC:60383 wetcondition
b)
c) d) e) f) g) h) i) 5.1.4
Impulse voltage withstand test under dry AsperIEC:60383 condition Voltagedistributiontest AsperAnnexA CoronaandRIVtestunderdrycondition MechanicalStrengthtest Vibrationtest Saltfogpollutionwithstandtest PowerArcTest AsperAnnexA AsperAnnexA AsperAnnexA AsperAnnexA AsperAnnexA
OnthecompletePorcelainlongrodInsulatorstringwithHardwareFittings a) Power frequency voltage withstand test with corona control rings/grading ring and arcing hornsunderwetcondition Switching surge voltage withstand test under wetcondition Impulse voltage withstand test under dry condition CoronaandRIVtestunderdrycondition MechanicalStrengthtest Vibrationtest Saltfogpollutionwithstandtest PowerArcTest AsperIEC:60383 AsperIEC:60383 AsperIEC:60383 AsperAnnexA AsperAnnexA AsperAnnexA AsperAnnexA AsperAnnexA
b) c) d) e) f) g) h)
5.1.5
5.1.6
All the type test given in Clause No. 5.1.3 for disc insulator string or Clause No. 5.1.4 for long rod porcelain insulator string shall be conducted on Single I suspension and Double tension insulator string along with hardware fittings. All the type tests given under Clause No. 5.1.3 (a) to (f) for disc insulator string or 5.1.4 (a) to (e) for porcelain long rod insulator string shall also be conducted on Single Suspension Pilot , Single Tension Strings and Double V SuspensionString. TypetestsspecifiedunderClause5.1.3(a)to(c)orunderClause5.1.4(a)to(c) shallnotberequiredtobecarriedoutifavalidtestcertificateisavailablefora similar design, i.e., tests conducted earlier should have either been conducted in accredited laboratory (accredited based on ISO/IEC vide 25/17025 or EN 45001 by the National accreditation body of the country where laboratory is located) or witnessed by the representative(s) of DTL or utility. The test reports submitted shall be for the tests conducted within last 5 (five) years priortodateofbidopening. In case the test have been conducted earlier than the above stipulated period or in the event of any discrepancy in the test report (i.e., any test not applicable due to any design/manufacturing change including substitution of
5.1.7
components or due to noncompliance with the requirement stipulated in the Technical Specifications), the tests shall be conducted by the Supplier at no extracosttotheOwner. 5.2 5.2.1 AcceptanceTests ForDiscInsulators(Bothporcelainandglass) a) b) c) d) e) f) g) h) Visualexamination Verificationofdimensions Temperaturecycletest Galvanisingtest Mechanicalperformancetest Testonlockingdeviceforballandsocket coupling Eccentricitytest ResidualStrengthTest AsperIEC:60383 AsperIEC:60383 AsperIEC:60383 AsperIEC:60383 AsperIEC:60575Cl4.0 AsperIEC:60372 AsperIEC:60383 AsperIEC:797 Clause4.4&4.5 AsperAnnexA AsperAnnexA AsperAnnexA AsperAnnexA AsperAnnexA AsperAnnexA
i) j) k) l)
MetallurgicalTest(Formetalfittingsonlyin blackcondition) i) Grainsize ii) Inclusionrating iii) Chemicalanalysis iv) Microstructure ChemicalanalysisofZincSleeve IRMeasurement ImpactTest
m) SteepWavefronttest n) 5.2.2 ThermalMechanicalperformancetest
Note:TestsspecifiedunderClause5.2.1(m)&(n)aboveshallbeperformed asacceptancetestsonceforeverysupplyof25,000nos.ofaparticularrating. ForPorcelaindiscInsulatorsOnly a) b) c) Electromechanicalstrengthtest Porositytest Puncturetest AsperAnnexA AsperIEC:60383 AsperIEC:60383
5.2.3
ForGlassInsulatorsOnly a) b) c) Thermalshocktest Steepwavefronttest/Puncturetest MechanicalfailingloadTest AsperIEC:60383 AsperAnnexA AsperAnnexA
5.3
ForPorcelainLongrodInsulators a) b) c) d) e) Visualexamination Verificationofdimensions Temperaturecycletest Galvanisingtest Mechanicalperformancetest AsperIEC:60383 AsperIEC:60383 AsperIEC:60383 AsperIEC:60383
AsperIEC:60575 Clause4.0 f) Test on locking device for ball and socket AsperIEC:60372 coupling g) Eccentricitytest AsperIEC:60383 1 h) Mechanicalfailingloadtest AsperIEC:60383 1 i) Porositytest AsperIEC:60383 j) MetallurgicalTest(Formetalfittingsonlyin AsperAnnexA blackcondition) i) Grainsize ii) Inclusionrating iii) Chemicalanalysis iv) Microstructure k) ThermalMechanicalperformancetest AsperAnnexA Note:Thetestspecifiedunder5.3(k)aboveshallbeperformedasacceptance testonceforeverysupplyof3260nos.longrodinsulatorunitsofaparticular rating. RoutineTests ForDiscInsulators
a) b) c) d) e) VisualInspection Mechanicalroutinetest AsperIS:731,Cl.10.13 AsperIS:731Cl.10.14
5.4 5.4.1
Electrical routine test (for porcelain disc insulator AsperIS:731Cl.10.15 only) Thermal shock routine test (for glass insulator AsperIEC:60383 only) Polarised Light Inspection (for glass insulator AsperAnnexureA only)
5.4.2
ForPorcelainLongRodInsulatorUnits a) VisualInspection b) Mechanicalroutinetest)
AsperIEC:60383 AsperIEC:60383
5.5 TestsDuringManufacture Onallcomponentsasapplicable a) b) Chemicalanalysisofzincusedforgalvanising Chemicalanalysis,mechanical,metallographic testandmagneticparticleinspectionfor malleablecastings. Chemicalanalysishardnesstestsandmagnetic particleinspectionforforgings AsperAnnexA AsperAnnexA
c) d)
AsperAnnexA AsperAnnexA AsperAnnexA
5.6 5.6.1 5.6.2
HydraulicInternalPressuretestsondisc insulatorshells e) AutoclaveTestonCement TestingExpenses
Testing charges for the type test specified shall be indicated separately in the prescribedschedule. Bidder shall indicate unit type test charges for all type tests covered under Clause 5.1.1/5.1.2 and 5.1.3 (d) to (i)/5.1.4 (d) to (h) separately, in the relevant schedule of Prices as applicable. Charges for each type tests shall be separatelyindicated. For Type Tests which involves the tests on the complete insulator string with hardware fitting the Contractor of hardware fittings shall supply the necessary number of sets of hardware fittings at the place of testing free of cost. Incaseoffailureinanytypetestthebidderwhosematerialhasfailediseither required to modify the design of the material & successfully carryout all the typetestsashasbeendetailedoutinClause5.1.3or5.1.4ofthisspecifications or to repeat that particular type test at least three times successfully at his own expenses. Incase of failure of the complete string in any type test, the manufacturerwhoseproducthasfailedintheuseshallgetthetestrepeatedat his cost. The Supplier whose material has not failed in the test shall be required to supply the requisite quantity of material (that is insulator or hardware fittings as the case may be) required for repeat testing at the place of testing and the cost of supply shall be borne by the Supplier whose materialhasfailedintesting. Supplier shall indicate the laboratories in which they propose to conduct the type tests. They shall ensure that adequate facilities are available in the
5.6.3
5.6.4
5.6.5
laboratoryandthetestscanbecompletedintheselaboratorieswithinthetime scheduleguaranteedbythemintheappropriateschedule. 5.6.6 The entire cost of testing for acceptance and routine tests and tests during manufacture specified herein shall be treated as included in the quoted Ex works/CIFPrice. 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 redeputationshallbedeductedfromcontractprice. The Supplier shall intimate the Owner about carrying out of the type tests alongwith detailed testing programme at least 3 weeks in advance (in case of Domestic Supplier) and at least 6 weeks advance (in case of foreign Supplier) of the scheduled date of testing during which the Owner will arrange to deputehisrepresentativetobepresentatthetimeofcarryingoutthetests. SampleBatchforTypeTesting The Supplier shall offer material for sample selection for type testing only after getting Quality Assurance Programme approved by the Owner. The Supplier shall offer at least three times the quantity of materials required for conducting all the type tests for sample selection. The sample for type testing will be manufactured strictly in accordance with the Quality Assurance ProgrammeapprovedbytheOwner. Before sample selection for type testing, the Supplier shall be required to conduct all the acceptance tests successfully in presence of Owners representative. ScheduleofTesting The Bidder has to indicate the schedule of following activities in their bids: a) b) c) d) Submissionofdrawingforapproval. SubmissionofQualityAssuranceProgrammeforapproval. Offeringofmaterialforsampleselectionfortypetests. Typetesting.
5.6.7
5.6.8
5.7 5.7.1
5.7.2
5.8 5.8.1 5.9 5.9.1
RepeatE&MStrengthTest E&Mteston20nos.fordiscinsulatoror3nos.forPorcelainlongrodinsulator of samples for every lot of 10,000 nos. or 1500 nos. for Porcelain longrod received at site shall be conducted. Testing expenses have to be borne by the Supplier and shall be included in quoted Exworks/CIF price. Incase of failure, it will be repeated on double no. of samples and if it again fails, the whole lot should be rejected and shall be replaced by the Supplier. The
samples have to be taken at random after segregating insulators damaged in transportationorotherwise. 5.9.2 The Owner reserves the right of having at his own expenses any other test(s) ofreasonablenaturecarriedoutatSupplierspremises,atsite,orinanyother place in addition to the aforesaid type, acceptance and routine tests to satisfy himselfthatthematerialcomplywiththeSpecifications. 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 compliance, it shall be binding on the part of the 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. CoordinationforTesting The Supplier shall have to coordinate testing of insulators with hardware fittings to be supplied by other Supplier and shall have to guarantee overall satisfactoryperformanceoftheinsulatorswiththehardwarefittings. Guarantee The Supplier of insulators shall guarantee overall satisfactory performance of theinsulatorswiththehardwarefittings. TestReports Copies of type test reports shall be furnished in at least six (6) copies along with one original. One copy shall be returned duly certified by the Owner only after which the commercial production of the concerned material shall start. Copies of acceptance test reports shall be furnished in at least six (6) copies. One copy shall be returned duly certified by the Owner, only after which the materialshallbedispatched. RecordofroutinetestreportsshallbemaintainedbytheSupplierathisworks forperiodicinspectionbytheOwnersrepresentative. Test certificates of test 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 insulator, and its component parts shall be manufactured and the representatives shall have full facilities for unrestricted inspection of the Suppliers and subSuppliers works, raw materials, manufacture of the material and for conducting necessary test as detailedherein.
5.9.3
5.10
5.11 5.12 5.12.1
5.12.2
5.12.3 5.12.4
5.13 5.13.1
5.13.2
The material for final inspection shall be offered by the Supplier only under packed condition as detailed in clause No.5.14 of the specification. The Owner shall select samples at random from the packed lot for carrying out acceptancetests.Insulatorsshallnormallybeofferedforinspectioninlotsnot exceeding10,000nos.fordisc/650unitsforlongrodinsulator.Thelotshould be homogeneous and should contain insulators manufactured in 34 consecutiveweeks. TheSuppliershallkeeptheOwnerinformedinadvanceofthetimeofstarting and the progress of manufacture of material in their various stages so that arrangementscouldbemadeforinspection. No material shall be dispatched from its point of manufacture before it has been satisfactorily inspected and tested unless the inspection is waived off by the Owner in writing. In the latter case also the material shall be dispatched only after satisfactory testing for all tests specified herein have been completed. The acceptance of any quantity of material shall be no way relieve the Supplier of his responsibility for meeting all the requirements of the specification and shall not prevent subsequent rejection, if such material are laterfoundtobedefective. PackingandMarking All insulators shall be packed in strong seasoned wooden crates. The gross weight of the crates along with the material shall not normally exceed 200 Kg to avoid handling problem. For marine transportation crates shall be palleted. The packing shall be of sufficient strength to withstand rough handling duringtransit,storageatsiteandsubsequenthandlinginthefield. Suitablecushioning,protectivepadding,ordunnageorspacersshallbe providedtopreventdamageordeformationduringtransitandhandling. All packing cases shall be marked legibly and correctly so as to ensure safe arrival at their destination and to avoid the possibility of goods being lost or wrongly dispatched on account of faulty packing and faulty or illegible markings. Each wooden case/crate shall have all the markings stencilled on it inindeliableink. Standards The insulator strings and its components shall conform to the following lndian/ International Standards which shall mean latest revision, with amendments/ changes adopted and published, unless specifically stated otherwise in the Specification. In the event of supply of insulators conforming to standards other than specified, the Bidder shall confirm in his bid that these standards are
5.13.3
5.13.4
5.13.5
5.14 5.14.1
5.14.2 5.14.3 5.14.4
5.15
5.15.1
equivalent to those specified. In case of award, salient features of comparison between the standards proposed by the Bidder and those specified in this documentwillbeprovidedbytheSuppliertoestablishequivalence.
Sl. No. 1. 2. 3. Indian Standard IS:2091992 IS:4061991 IS:7311991 Title Specificationforzinc MethodofChemicalAnalysisofSlabZinc PorcelaininsulatorsforoverheadPower lineswithanominalvoltagegreaterthan 1000V MethodsofHighVoltageTesting International Standard BS:3436 BS:3436 BS:137(I&II) IEC:60383 IEC:600601 BS:3288 IEC:60120 IEC:60372 ISO1461(E) IEC:60305 BS:4331969 ISO:14601973 IEC:60437 NEMAPubli cationNo.07/ 1964/CISPR IEC:60506 IEC:60575
4.
5.
6. 7. 8. 9. 10.
IS:2071 Part(I)1993 (Part(II)1991 Part(III)1991 IS:2486 PartI1993 PartII1989 PartIII1991 IS:26291990 IS:26331992 IS:31881988 IS:67451990 IS:82631990
SpecificationforInsulatorfittingsfor OverheadPowerLineswithanominal voltagegreaterthan1000V GeneralRequirementsandTests DimensionalRequirements LockingDevices RecommendedPracticeforHot,Dip Galvanisation forironandsteel TestingofUniformityofCoatingofzinc coated articles DimensionsforDiscInsulators DeterminationofWeightofZincCoatingon Zinccoatedironandsteelarticles MethodsofRITestofHVinsulators
11. 12.
IS:82691990
13. 14.
15. 16.
17.
MethodsforSwitchingImpulsetestonHV insulators ThermalMechanicalPerformancetestand mechanicalperformancetestonstring insulatorunits SaltFogPollutionVoltage WithstandTest ResidualStrengthofString InsulatorUnits ofGlassor CeramicMaterialforOverhead LinesafterMechanical Damageofthe Dielectric Guidefortheselectionofinsulatorsin respect ofpollutedconditions TestsoninsulatorsofCeramicmaterialor glassorglassforoverheadlineswitha nominalvoltagegreaterthan1000V Characteristicsofstringinsulatorunitsof thelong rodtype
IEC:60507 IEC:60797
IEC:60815 IEC:60383 IEC:60433
18. 19.
StandardTestMethodforAutoclave ExpansionofPortlandCement AmericanNationalStandardforInsulators wetprocessporcelainandtoughenedglass suspensiontype
ASTMC15193 a ANSIC292 1992
Thestandardsmentionedaboveareavailablefrom:
ReferenceAbbreviation BS NameandAddress BritishStandards, BritishStandardsInstitution 101,PentonvileRoad, N19ND UK InternationalElectrotechnicalCommission, BureauCentraldelaCommission, electroTechniqueinternational, 1Ruedeverembe, Geneva SWITZERLAND BeureauOfIndianStandards. ManakBhavan, 9,BahadurShahZafarMarg, NewDelhi110001. INDIA InternationalOrganisationforStandardization. DanishBoardofStandardization DanishStandardizingSraat, Aurehoegvej12 DK2900,Heeleprup, DENMARK. NationalElectricManufactureAssociation, 155,East44thStreet. NewYork,NY10017 U.S.A. AmericanSocietyfor TestingandMaterials, 1916RaceSt.Phelledelphia,PA19103USA
IEC/CISPR
BIS/IS
ISO
NEMA
ASTM
ANNEXUREA 1. 1.1 TestsonCompleteStringswithHardwareFittings VoltageDistributionTest(ForDiscInsulatorsonly) The voltage across each insulator unit shall be measured by sphere gap method. The result obtained shall be converted into percentage. The voltage across any disc shall not exceed 9% for suspension insulator strings and 10% fortensioninsulatorstrings. CoronaExtinctionVoltageTest(Dry) Thesampleassemblywhensubjectedtopowerfrequencyvoltageshallhavea corona extinction voltage of not less than 320 kV (rms) line to ground under drycondition.Thereshallbenoevidenceofcoronaonanypartofthesample. The atmospheric condition during testing shall be recorded and the test results shall be accordingly corrected with suitable correction factor as stipulatedinIEC:383. RIVTest(Dry) Undertheconditionsasspecifiedunder(1.2)above,theinsulatorstringalong with complete hardware fittings shall have a radio interference voltage level below 1000 micro volts at one MHz when subjected to 50 Hz AC voltage of 305 kV line to ground under dry condition. The test procedure shall be in accordancewithIS:8263/IEC:437. MechanicalStrengthTest Thecompleteinsulatorstringalongwithitshardwarefittingexcludingarcing horn, corona control ring, grading ring and suspension assembly/dead end assembly shall be subjected to a load equal to 50% of the specified minimum ultimate tensile strength (UTS) which shall be increased at a steady rate to 67% of the minimum UTS specified. The load shall be held for five minutes and then removed. After removal of the load, the string componentsshall not show any visual deformation and it shall be possible to disassemble them by hand. Hand tools may be used to, remove cotter pins and loosen the nuts initially. The string shall then be reassembled and loaded to 50% of UTS and the load shall be further increased at a steady rate till the specified minimum UTS and held for one minute. No fracture should occur during this period. The applied load shall then be increased until the failing load is reached and thevaluerecorded. VibrationTest The suspension string shall be tested in suspension mode, and tension string intensionmodeitselfinlaboratoryspanofminimum30metres.Inthecaseof suspension string a load equal to 600 kg shall be applied along the axis of the suspension string by means of turn buckle. The insulator string along with hardware fittings and two subconductors (each tensioned at 43 kN shall be secured with clamps. The system shall be suitable to maintain constant tension on each subconductors throughout the duration of the test. Vibration
1.2
1.3
1.4
1.5
dampers shall not be used on the test span. Both the subconductors shall be vertically vibrated simultaneously at one of the resonance frequencies of the insulators string (more than 10 Hz) by means of vibration inducing equipment.Thepeaktopeakdisplacementinmmofvibrationattheantinode point, nearest to the string, shall be measured and the same shall not be less than1000/f1.8wherefisthefrequencyofvibrationincycles/sec.Theinsulator string shall be vibrated for not less than 10 million cycles without any failure. Afterthetesttheinsulatorsshallbeexaminedforloosenessofpinsandcapor any crack in the cement. The hardware shall be examined for looseness, fatiguefailureandmechanicalstrengthtest.Thereshallbenodeteriorationof properties of hardware components and insulators after the vibration test. The insulators shall be subjected to the following tests as per relevant standards: Percentageofunitstobetested TestsPercentageof Discinsulators a) b) 1.6 PowerArcTest This test shall be performed on the complete string in accordance with IEC TechnicalReportIEC:614671997withthefollowingtestseries: Testcircuit Shortcircuitcurrent Numberanddurationoftest B In=Isys=40KA Twooftn=0.2sandoneoftn=0.5s Theacceptancecriteriaafterthecompletionoftestseriesshallbefollowing. a) Insulatorseparationnotpermitted. b) c) Burning/melting of metal components, breakage of insulator sheds, glazeremovalarepermitted. The complete insulator string alongwith its hardware fitting excluding arching horn, corona control ring/grading ring shall withstand80%ofUTS. Temperaturecycletest followed bymechanical performancetest Puncture test/steep wave front test 60 40 Longrod insulators 100
1.7 2. 2.1
Saltfogpollutionvoltagewithstandtest This test shall be carried out in accordance with IEC507 with salinity label of 40kg/m3ofNACLandmaximumwithstandsalinitymayalsoberecorded. OnDiscInsulatorUnits/Porcelainlongrodunits(asapplicable) SteepWaveFrontTest(ForDiscInsulatoronly)
Test following test shall be performed on 10 insulator units in case of disc insulators selected at random from the lot offered for selection of sample for typetest. a) Each insulator unit shall be subjected to five successive positive and negative impulse flashovers with a wave having minimum effective rateofriseof2500kVpermicroseconds. Each unit shall then be subjected to three dry power frequency voltageflashovers.
b)
AcceptanceCriteria An insulator shall be deemed to have met the requirement of this test if, having been successfully subjected to the ten impulse flashovers, the arithmetic mean of the three subsequent dry/power frequency voltage flashover values equals or exceeds 95% of the rated dry power frequency flashovervoltage. An insulator shall be deemed to have failed to meet the requirement of above testingif, (a) It has not flash over when the oscillogram or peak voltage indicator showsamarkedreductioninvoltage. or
2.2
(b)
Any one of the subsequent three dry power frequency voltage flashovervalueislessthan80%ofthevaluespecified.
Failure of any one unit either in the steep wave front or subsequent low frequencyvoltagetestshallcausefortestingondoublenumberofunits. PolarisedLightInspection(onlyforGlassDiscInsulator) The disc insulator shall be held over a polarised light source and the stress lines viewed thereon. There shall be no uneven stress distribution in the toughenedglassinsulators.Thisshallbecarriedouton100%glassshells. HydraulicInternalPressureTestonShells(onlyforDiscInsulator) The test shall be carried out on 100% shells before assembly. The details regarding test will be as discussed and mutually agreed to by the Supplier andOwnerinQualityAssuranceProgramme. ThermalMechanicalPerformanceTest Thermal Mechanical Performance Test shall be performed in accordance with IEC603831Clause20withthefollowingmodifications: (1) (2) The applied mechanical load during this test shall be 70% of the rated electromechanicalormechanicalvalue. Theacceptancecriteriashallbe (a) XgreaterthanorequaltoR+3S. Where
2.3
2.4
(b) (c)
X=Meanvalueoftheindividualmechanicalfailingload. R=Ratedelectromechanical/mechanicalfailingload. S=Standarddeviation. The minimum sample size shall be taken as 20 for disc insulatorunitsand5unitsforlongrodunits. The individual electromechanical failing load shall be at least equal to the rated value. Also puncture shall not occur before theultimatefracture.
2.5
Electromechanical/MechanicalFailingLoadTest This test shall be performed in accordance with clause 18 and 19 of IEC 383 withthefollowingacceptance (i) (ii) XgreaterthanorequaltoR+3S Where X=Meanvalueoftheelectromechanical/mechanical/failingload. R=Ratedelectromechanical/mechanicalfailingload. S=Standarddeviation. Theminimumsamplesizeshallbetakenas20fordiscinsulatorsunits and 5 for long rod units. However, for larger lot size, IEC 591 shall be applicable. The individual electromechanical/mechanical failing load shall be at least equal to the rated value. Also electrical puncture shall not occur beforetheultimatefracture.
(iii)
2.6
ResidualStrengthTest(ForDiscInsulatorsonly) The above test shall be performed as per clause 4.4 and 4.5 of IEC 797 preceded by the temperature cycle test, on both glass and porcelain disc insulators. The Sample size shall be 25 and the evaluation of the results and acceptancecriteriashallbeasperclauseNo.4.6ofIEC:797. ChemicalAnalysisofZincSleeve The purity of the zinc used in zinc sleeve shall be tested as per IS:209. The purityofzincshallnotbelessthan99.8%. IRMeasurements IR measurement shall be carried out by the instrument operating at 1 kV DC. IR value when measured under fair weather condition, shall not be less than 50Mohm. ImpactTest The Impact Test shall be carried out in accordance with ANSIC29.2 Clause 8.2.8withthefollowingmodification.
2.7 2.8
2.9
The breaking point of the pendulum shall be so adjusted that, when released thecoppernosewillstriketheouterrimoftheshellorthemostprotudedrim of the shell squarely in a direction parallel to the axis of the unit and towards thecap. The test specimen shall receive an impact of 7 Nm for 120 kN Disc & 10Nm for160kNDiscbyreleasingthependulum. TestsonAllcomponents(Asapplicable) ChemicalAnalysisofZincusedforGalvanizing Samples taken from the zinc ingot shall be chemically analysed as perIS:2091979.Thepurityofzincshallnotbelessthan99.95%. TestsforForgings The chemical analysis hardness tests and magnetic particle inspection for forgings, will be as per the internationally recognised 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 SupplierandOwnerinQualityAssuranceProgramme. TestsonCastings The chemical analysis, mechanical and metallographic tests and magnetic, particle inspection for castings will be as per the internationally recognised 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 Owner in Quality Assurance Programme.
3. 3.1 3.2
3.3
3.4
AutoclaveTest For cement used in the assembly of the insulators six samples from different batches shall be tested in accordance with ASTM C151. The cement shall haveanexpansionlessthan0.12%.
SECTIONIII DRAWINGS
SECTIONIII DRAWINGS S.No. Description DrawingNo.

1. 2. 3. 4. 5. 6. 7. SingleSuspensionString(DiscInsulator) TL/400KV/TWIN/DISC/018 TL/400KV/TWIN/LR/019 TL/400KV/TWIN/DISC/014 TL/400KV/TWIN/LR/015 400KV/016 TL/400KV/TWIN/LR/021 400kV/TWIN/DISC/DVS
SingleSuspensionString(LongrodInsulator) DoubleTensionString(DiscInsulator)
DoubleTensionString(LongrodInsulator) SingleTensionString(DiscInsulator) SingleTensionString(Longrod) DoubleVSuspensionString

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BIDDING DOCUMENTS FOR INSULATOR PACKAGES C1 & C2 OF 400 KV D/C SUGEN-PIRANA TRANSMISSION LINE ASSOCIATED WITH 1147.

Volume - II Technical Specifications

4.6.2 4.7 4.7.1

(b) ReviewandinterpretationofalltheSuppliersdrawings,engineeringdata etc. (c) Witnessorauthorisehisrepresentativetowitnesstestsatthemanufacturers worksoratsite,oratanyplacewhereworkisperformedundertheContract.

(d) Inspect,acceptorrejectanyequipment,materialandworkunderthe Contract,inaccordancewiththeSpecifications. (e) (f) Issuecertificateofacceptanceand/orprogressivepaymentandfinalpayment certificate. Reviewandsuggestmodificationandimprovementincompletionschedules fromtimetotime,and

3.0 3.1 3.2

Unitmechanicalandelectricalcharacteristics Sizeandweightofballandsocketparts Weightofporcelain/compositelongrodunits Materials (i) (ii) Identificationmark Manufacturerscataloguenumber

(b) (c) (d) (e) (f) (g) 4.1.2

(c) (d) (e)

AnnexureA IEC:61109 IEC:61109 IEC:61109 AnnexureA IEC:61109 AnnexureA AnnexureA

(f) (g) (h) (i) (j)

Verificationoflockingsystem Verificationoftightness ofinterfacebetweenendfittingsand insulatorhousingandofspecified mechanicalload RecoveryofHydrophobicity

4.3.1ForCompositeLongRodInsulatorUnits a) b) VisualInspection Mechanicalroutinetest) AsperIEC:61109 AsperIEC:61109

c) d) 4.5 4.5.1 4.5.2

4.6.2 4.7 4.7.1 4.8 4.8.1

Indian Standard IS:31881988 IS:67451990 IS:82631990

Title articles DimensionsforDiscInsulators DeterminationofWeightofZincCoatingonZinc coatedironandsteelarticles MethodsofRITestofHVinsulators

IEC:60815 IEC:60383 IEC:60433

1.A 1A.1 ANNEXUREA

1A.5 2.0 2.1

SECTION-II B (VOLUME-II) PAGE 1

1.2. 1.2.1. 1.2.2. 1.2.3.

Maximum 293318 318333

Minimum 267292 293307

SECTION-II B (VOLUME-II) PAGE 2

Thenominaldiametershouldbeguaranteedbythebidderinappropriate scheduleinBidProposalSheet b) Balltoballspacingbetweendiscs Standard 120KNDisc 145 160KNDisc 170

Maximum 149 175

Minimum 141 165

1.9. 1.9.1. 1.9.2.

SECTION-II B (VOLUME-II) PAGE 3

1.9.6. 1.10. 1.10.1.

SECTION-II B (VOLUME-II) PAGE 4

2.0 2.1 2.1.1

SECTION-II B (VOLUME-II) PAGE 5

Note:(i)Biddersmayquotefortherelevantstrings. (ii) (iii) Lengthoflongrodinsulatorstringsshallbematchingwiththe correspondingdiscinsulatorstrings./PolymericInsulator ThecostofintermediateBallpinandintermediatearcinghorn shallbeconsideredasincludinginthepriceoflongrod insulators.

SECTION-II B (VOLUME-II) PAGE 6

2.4 2.5 2.6 2.6.1

SECTION-II B (VOLUME-II) PAGE 7

SECTION-II B (VOLUME-II) PAGE 8

2.11.6 2.11.7 2.11.8

SECTION-II B (VOLUME-II) PAGE 9

4.0 4.1 4.2

Unitmechanicalandelectricalcharacteristics Sizeandweightofballandsocketparts Weightofunitinsulatordisc/longrodunits Materials Identificationmark Manufacturerscataloguenumber

SECTION-II B (VOLUME-II) PAGE 10

OnPorcelainlongrodInsulatorunits a) b) c) Verificationofdimensions Thermalmechanicalperformancetest

SECTION-II B (VOLUME-II) PAGE 11

SECTION-II B (VOLUME-II) PAGE 12

m) SteepWavefronttest n) 5.2.2 ThermalMechanicalperformancetest

Note:TestsspecifiedunderClause5.2.1(m)&(n)aboveshallbeperformed asacceptancetestsonceforeverysupplyof25,000nos.ofaparticularrating. ForPorcelaindiscInsulatorsOnly a) b) c) Electromechanicalstrengthtest Porositytest Puncturetest AsperAnnexA AsperIEC:60383 AsperIEC:60383

SECTION-II B (VOLUME-II) PAGE 13

ForGlassInsulatorsOnly a) b) c) Thermalshocktest Steepwavefronttest/Puncturetest MechanicalfailingloadTest AsperIEC:60383 AsperAnnexA AsperAnnexA

SECTION-II B (VOLUME-II) PAGE 14

ForPorcelainLongRodInsulatorUnits a) VisualInspection b) Mechanicalroutinetest)

AsperAnnexA AsperAnnexA AsperAnnexA

5.6 5.6.1 5.6.2

HydraulicInternalPressuretestsondisc insulatorshells e) AutoclaveTestonCement TestingExpenses

SECTION-II B (VOLUME-II) PAGE 15

5.8 5.8.1 5.9 5.9.1

SECTION-II B (VOLUME-II) PAGE 16

5.11 5.12 5.12.1

SECTION-II B (VOLUME-II) PAGE 17

5.14.2 5.14.3 5.14.4

SECTION-II B (VOLUME-II) PAGE 18