Ts Compliance
Ts Compliance
Complied
STANDARD SPECIFICATION OF TRANSMISSON LINE (SECTION-
HARDWARE FITTINGS & ACCESSORIES FOR CONDUCTOR & EARTHWIRE)
SECTION-VI A
Complied
STANDARD SPECIFICATION OF TRANSMISSON LINE (SECTION-
HARDWARE FITTINGS & ACCESSORIES FOR CONDUCTOR & EARTHWIRE)
TECHNICAL SPECIFICATIONS
SECTION-VI A
Complied
STANDARD SPECIFICATION OF TRANSMISSON LINE (SECTION-
HARDWARE FITTINGS & ACCESSORIES FOR CONDUCTOR & EARTHWIRE)
TECHNICAL SPECIFICATIONS
SECTION-VI A
CONTENTS
Complied
STANDARD SPECIFICATION OF TRANSMISSON LINE (SECTION-
HARDWARE FITTINGS & ACCESSORIES FOR CONDUCTOR & EARTHWIRE)
TECHNICAL SPECIFICATIONS
SECTION- VI A
HARDWARE FITTINGS &
ACCESSORIES FOR CONDUCTOR & EARTHWIRE
1.0 Technical Description of Hardware Fittings
1.1 Details of Hardware Fittings
1.1.1 The hardware fittings shall be suitable for use with disc insulators, porcelain
longrod insulators and composite long rod insulators having ball and socket
fittings. The hardware fittings shall be as per the specification drawings
enclosed with the section of drawings of the specification.
Standard lengths of insulators have been considered in the above specification
drawings for indicative purpose only. The actual length of insulator string shall
be based on the insulators being supplied for the package.
For hardware fittings for transmission line upto 765kV voltage level (except
765kV S/C, +500 kV HVDC, +800 kV HVDC), the suppliers shall be required to
develop hardware components in line with the standard drawings enclosed
with the section of drawings of the specification (which are based on
component level interchangeability amongst various suppliers) and submit
their drawing for approval of POWERGRID prior to testing and manufacturing.
Employer may accept hardware components having better performance such
as higher mechanical strength at no extra cost to POWERGRID, provided
component level interchangeability is retained.
1.1.2 Each hardware fitting shall be supplied complete in all respects and shall
include the following hardware parts:
1.1.2.1 Suitable arcing horn as specified in clause 1.8 hereinafter.
1.1.2.2 Suitable yoke plates complying with the specifications given hereinafter.
1.1.2.3 Corona control rings/ grading ring with fittings for attachment to line side yoke
plate.
1.1.2.4 Sag adjustment plate for double/ triple/ quad tension hardware fittings and
turn buckle for single tension hardware fittings.
1.1.2.5 Suspension and dead-end assembly to suit conductor type and size as covered
in the scope.
1.1.2.6 Provisions for attaching balancing weights on the line side yoke plate of single
suspension pilot hardware fittings.
1.1.2.7 Other necessary fittings viz D-shackles, eye links, extension links, ball clevis,
socket clevis, clevis eye, U clevis and chain link etc. to make the hardware
fittings complete.
1.1.3 For owner supplied fittings 2.5% extra fasteners (excluding factory fitted
fasteners) & retaining rods shall be provided to the Contractor to take care of
losses during erection. No payment shall be admissible for these extra supplies.
For fittings included in the scope of the Contractor, the contractor is permitted
to get inspected and supply upto 2.5% extra fasteners & retaining rods to take
care of losses during erection. No payment shall be admissible for these extra
supplies.
1.2 Dimensions of Insulator String Along with Hardware Fitting
The various limiting dimensions of the insulator strings along with hardware
fittings shall be as per the specification drawings enclosed at section of
drawings of this specification.
1.2.1 For every set of tension hardware fitting for quad/ hexa bundle conductor
configuration one no. 250 mm rigid spacer suitable for twin conductor shall
also be provided to ensure that there is no fouling of conductors or any
component of the fittings while bringing down top two conductors through
bottom two conductors of quad/ hexa bundle, at the jumper location.
1.3 Interchangeability
1.3.1 The hardware for insulator strings with disc insulators/ porcelain long rod/
composite long rod insulators together with ball and socket fittings shall be of
standard design, so that this hardware is inter-changeable with each other and
suitable for use with insulators of any make conforming to relevant Standard.
1.4 Corona and RI Performance
Sharp edges and scratches on all the hardware fittings shall be avoided. All
surfaces must be clean, smooth, without cuts and abrasions or projections. The
Contractor must give suitable assurance about the satisfactory corona and
radio interference performance of the materials offered by him.
1.5 Maintenance
1.5.1 The hardware fittings offered shall be suitable for employment of hot line
maintenance technique so that usual hot line operations can be carried out
with ease, speed and safety. The technique adopted for hot line maintenance
shall be generally bare hand method & hot stick method. The Bidder should
clearly establish in the bid, the suitability of his fittings for hot line
maintenance.
1.5.2 The line side yoke plate shall have a notch & a working hole of suitable size.
The design of corona control rings/ grading ring shall be such that it can be
easily replaced by employing hot line maintenance technique.
1.6 Designation
1.6.1 Ball and Socket Designation
The dimensions of the ball and socket are furnished in the Standard Technical
Particulars enclosed with this section of the specification. The designation
should be in accordance with the standard dimensions stated in IS 2486 (Part-
II). The dimensions shall be checked by the appropriate gauge after galvanising
only.
1.7 Security Clips and Split Pins
1.7.1 Security clips for use with ball and socket coupling shall be R-shaped, hump
type which provides positive locking of the coupling as per IS 2486 (Part-III).
The legs of the security clips shall be spread after assembly in the works 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 the locking devices allow
separation of fittings
1.7.2 The hole for the security clip shall be countersunk and the clip should 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 50 N (5 kg)
or more than 500 N (50 kg).
1.7.3 Split pins shall be used with bolts & nuts.
1.8 Arcing Horn/Intermediate Arcing Horn
1.8.1 The arcing horn/ Intermediate Arcing Horn shall be either ball ended rod type
or tubular type, based on the drawings enclosed with the specifications.
1.8.2 The arcing horn shall be provided as shown in the drawing of the hardware
fittings, enclosed in this specification.
1.8.3 The air gap shall be so adjusted to ensure effective operation under actual field
conditions.
1.9 Yoke Plates
The strength of yoke plates shall be adequate to withstand the minimum
ultimate tensile strength as specified in the bid drawings.
The plates shall be either triangular or rectangular in shape as may be
necessary. The design of yoke plate shall take into account the most
1.11.2 The maximum length of the sag adjustment plate from the connecting part of
the rest of the hardware fittings shall be 330 mm. The details of the minimum
and maximum adjustment possible and the steps of adjustment shall be clearly
indicated in the drawing. An adjustment of 150 mm minimum at the interval
of 6 mm shall be possible with the sag adjustment plate.
1.11.3 Design calculations for deciding the dimensions of sag adjustment plate shall
be furnished by Contractor. The hole provided for bolts should satisfy shear
edge condition as per Clause No. 10.2.4.2 of IS 800.
1.12 Turn Buckle
1.12.1 The turn buckle is to be provided with single tension hardware fitting. The
threads shall be of sufficient strength to remain unaffected under the specified
tensile load.
1.12.2 The maximum length of the turn buckle from the connecting part of the rest of
the hardware fittings shall be 520 mm. The details of the minimum and
maximum adjustment possible shall be clearly indicated in the drawing. An
adjustment of 150 mm minimum shall be possible with turn buckle.
1.13 Suspension Assembly
1.13.1 The suspension assembly shall be suitable for the specific Conductor type and
size as covered in the scope.
1.13.2 The suspension assembly shall include free center type suspension clamp along
with standard preformed armour rods or armour grip suspension clamp;
except for Pilot insulator string for which only suitable Envelope type
suspension clamp shall be used.
1.13.3 The suspension clamp along with standard preformed armour rods set shall be
designed to have maximum mobility in any direction and minimum moment of
inertia so as to have minimum stress on the conductor in the case of oscillation
of the same.
1.13.4 The suspension clamp along with standard preformed armour rods/ armour
grip suspension clamp set shall have the slip strength not less than that
specified in the Standard Technical Particulars.
1.13.5 The suspension assembly shall be designed, manufactured and finished to give
it a suitable shape, so as to avoid any possibility of hammering between
suspension assembly and conductor due to vibration. The suspension assembly
shall be smooth without any cuts, grooves, abrasions, projections, ridges or
excrescence, which might damage the conductor.
1.13.6 The suspension assembly/ clamp shall be designed so that it shall minimise the
static & dynamic stress developed in the conductor under various loading
The dimensional tolerances of the cross section of aluminium and steel dead
end; for dead end assembly for the specific conductor shall be as stipulated in
the Standard Technical Particulars.
1.15.4 The assembly shall not permit slipping of, damage to, or failure of the complete
conductor or any part thereof at a load less than 95% of the ultimate tensile
strength of the conductor.
1.16 Balancing Weights
For holding the single suspension pilot insulator string used for jumper
connections at transposition towers or when used with Composite Insulators,
from excessive deflection, suitable balancing weights, weighing 200 kg (25x8)
for 400kV and above voltage lines and 100 kg (25kg x 4) for 220kVshall be
provided.
1.17 Fasteners: Bolts, Nuts and Washers
1.17.1 All bolts and nuts shall conform to IS 6639. All bolts and nuts shall be galvanised
as per IS 1367 (Part 13)/ IS 2629. All bolts and nuts shall have hexagonal heads,
the heads being forged out of solid truly concentric, and square with the shank,
which must be perfectly straight.
1.17.2 Bolts up to M16 and having length up to 10 times the diameter of the bolt
should be manufactured by cold forging and thread rolling process to obtain
good and reliable mechanical properties and effective dimensional control. The
shear strength of bolt for 5.6 grade should be 310 MPa minimum as per IS
12427. Bolts should be provided with washer face in accordance with IS 1363
(Part 1) to ensure proper bearing.
1.17.3 Nuts should be double chamfered as per the requirement of IS 1363 (Part-III).
It should be ensured by the manufacturer that nuts should not be over tapped
beyond 0.4 mm oversize on effective diameter for size up to M16.
1.17.4 Fully threaded bolts shall not be used for parts/ components requiring shear/
tensile strength. The length of the bolt shall be such that the threaded portion
shall not extend into the place of contact of the component parts. Bolts & Nuts
for these parts/ components shall be of minimum 5.6 grade conforming to IS
1367 or equivalent International standards.
1.17.4.1 For parts/ components requiring grip strength viz. arcing horn, corona rings &
dead-end jumper assembly, fully threaded bolts can be used as an alternative.
Bolts & nuts for these parts/ components shall be of minimum 4.6 grade
conforming to IS 6639 or equivalent International standards
1.17.4.2 In case of fasteners of other materials viz. stainless steel, aluminium alloy, etc.
are proposed to be used by the supplier, these shall conform to relevant
Indian/ International standards and complete details shall be submitted by the
supplier for review & approval by the Employer.
1.17.5 All bolts shall be threaded to take the full depth of the nuts and threaded
enough to permit the firm gripping of the component parts but no further. It
shall be ensured that the threaded portion of the bolt protrudes not less than
3 mm and not more than 8 mm when fully tightened. All nuts shall fit and tight
to the point where shank of the bolt connects to the head.
1.17.6 Flat washers and spring washers shall be provided wherever necessary and
shall be of positive lock type. Spring washers shall be electro-galvanised. The
thickness of washers shall conform to IS 2016.
1.17.7 The Supplier shall indicate the size & length of various bolts in the drawings,
based on thickness of components connected, the nut and the washer, the
length of shank, the threaded portion of bolts, etc. To obviate bending stress
in bolt, it shall not connect aggregate thickness more than three time its
diameter.
1.17.8 Bolts at the joints shall be so staggered that nuts may be tightened with
spanners without fouling.
1.17.9 To ensure effective in-process Quality control it is essential that the
manufacturer should have all the testing facilities for tests like weight of zinc
coating, shear strength, other testing facilities etc., in-house. The manufacturer
should also have proper Quality Assurance system, which should be in line with
the requirement of this specification and ISO 9001 services Quality System
standard.
1.17.10 Fasteners of grade higher than 8.8 are not to be used.
1.18 Materials
The materials of the various components shall be as specified hereunder. The
Contractor shall indicate the material proposed to be used for each and every
component of hardware fitting stating clearly the class, grade or alloy
designation of the material, manufacturing process & heat treatment details
and the reference standards.
1.18.1 The details of materials for different component are listed as in Table-I
TABLE-1 (Details of Materials)
1.19 Workmanship
1.19.1 All the equipment shall be of the latest design and conform to the best
modern practices adopted in the High Voltage field. The Contractor shall offer
only such equipment as guaranteed by him to be satisfactory and suitable for
the rated transmission lines and will give continued good performance.
1.19.2 The design, manufacturing process and quality control of all the materials shall
be such as to give the specified mechanical rating, highest mobility, elimination
of sharp edges and corners to limit corona and radio-interference, best
resistance to corrosion and a good finish.
1.19.3 All ferrous parts including fasteners shall be hot dip galvanised, after all
machining has been completed. Nuts may, however, be tapped (threaded)
after galvanising and the threads oiled. Spring washers shall be electro
galvanised. The bolt threads shall be undercut to take care of the increase in
diameter due to galvanising. Galvanising shall be done in accordance with IS
2629/ IS 1367 (Part 13) and shall satisfy the tests mentioned in IS 2633.
1.19.4 Before ball fittings are galvanized, all die flashing on the shank and on the
bearing surface of the ball shall be carefully removed without reducing the
dimensions below the design requirements.
1.19.5 The zinc coating shall be perfectly adherent, of uniform thickness, smooth,
reasonably bright, continuous and free from imperfections such as flux, ash
rust, stains, bulky white deposits and blisters. The zinc used for galvanising shall
be as per STP.
1.19.6 Ball ends shall be checked with the applicable “GO” gauges in at least two
directions, one of which shall be across the line of die flashing, and the other
90o to this line. "NO GO" gauges shall not pass in any direction.
1.19.7 Socket ends, before galvanising, shall be of uniform contour. The bearing
surface of socket ends shall be uniform about the entire circumference without
depressions of high spots. The internal contours of socket ends shall be
concentric with the axis of the fittings as per IS 2486.
The axis of the bearing surfaces of socket ends shall be coaxial with the axis of
the fittings. There shall be no noticeable tilting of the bearing surfaces with
the axis of the fittings.
1.19.8 In case of casting, the same shall be free from all internal defects like shrinkage,
inclusion, blow holes, cracks etc. Pressure die casting shall not be used for
casting of components with thickness more than 5 mm.
1.19.9 All current carrying parts shall be so designed and manufactured that contact
resistance is reduced to minimum.
1.19.10 No equipment shall have sharp ends or edges, abrasions or projections and
cause any damage to the conductor in any way during erection or during
continuous operation which would produce high electrical and mechanical
stresses in normal working. The design of adjacent metal parts and mating
surfaces shall be such as to prevent corrosion of the contact surface and to
maintain good electrical contact under service conditions.
1.19.10 All the holes shall be cylindrical, clean cut and perpendicular to the plane of
the material. The periphery of the holes shall be free from burrs.
1.19.11 All fasteners shall have suitable corona free locking arrangement to guard
against vibration loosening.
1.19.12 Welding of aluminum shall be by inert gas shielded tungsten arc or inert gas
shielded metal arc process. Welds shall be clean, sound, smooth, uniform
without overlaps, properly fused and completely sealed. There shall be no
cracks, voids incomplete penetration, incomplete fusion, under-cutting or
inclusions. Porosity shall be minimised so that mechanical properties of the
aluminum alloys are not affected. All welds shall be properly finished as per
good engineering practices.
1.20 Drawings & Approvals
1.20.1 Drawings:
1.20.2 After placement of award, the Contractor shall submit fully dimensioned
drawing including all the components, as described below, to the Employer for
approval. After submission of valid type test reports or successful completion
of type tests and getting approval from the Employer, the Contractor shall
submit the same drawings to the Employer for further distribution and field
use at Employer 's end.
1.20.3 Fully dimensioned drawings of the complete insulator string hardware and
their component parts showing clearly the following shall be submitted for
approval. Weight, material and fabrication details of all the components should
be included in the drawings.
(i) Attachment of the hanger or strain plate.
(ii) Suspension or dead-end assembly.
(iii) Arcing horn attachment to the string as specified in clause 1.8 of this
technical Specification.
(iv) Yoke plates
(v) Hardware fittings of ball and socket type for inter connecting units to
the top and bottom Yoke plates.
(vi) Corona control rings/ grading ring attachment to conductor and other
small accessories.
(vii) Links with suitable fittings.
(viii) Details of balancing weights and arrangements for their attachment in
the single suspension pilot insulator string.
1.20.4 All drawings shall be identified by a drawing number and contract number and
be neatly arranged. All drafting & lettering shall be legible. The minimum size
of lettering shall be 3 mm. All dimensions & dimensional tolerances shall be
mentioned in mm.
The drawings shall include:
(i) Dimensions and dimensional tolerance.
(ii) Material, fabrication details including any weld details & any specified
finishes & coatings. Regarding material designation & reference of
standards are to be indicated.
(iv) Marking
(v) Weight of assembly
(vi) Installation instructions, if any.
(vii) Design installation torque for the bolt or cap screw.
(ix) The compression die number with recommended compression
pressure.
(x) All other relevant terminal details.
2.5.14 The damper placement chart for spans ranging from 100 m to 1100 m shall be
submitted by the contractor/ supplier. Placement charts should be duly
supported with relevant technical documents and sample calculations.
2.5.15 The damper placement charts shall include the following
(1) Location of the dampers for various combinations of spans and line
tensions clearly indicating the number of dampers to be installed per
conductor per span.
(2) Placement distances clearly identifying the extremities between which
the distances are to be measured.
(3) Placement recommendation depending upon type of suspension
clamps (viz Free center type/ Armour grip type etc.)
(4) The influence of mid span compression joints, repair sleeves and
armour rods (standard and AGS) in the placement of dampers.
2.6 Bundle Spacer (for twin Bundle Conductors)
2.6.1 Armour grip bundle spacers shall be used to maintain the spacing of 450 mm
between the two sub-conductors of each bundle under all normal working
conditions.
2.6.2 Spacers offering equivalent or better performance shall also be accepted
provided offer meets the qualifying requirements stipulated in the
Specification.
2.6.3 The offer shall include placement charts recommending the number of spacers
per phase per span and the sub span lengths to be maintained between the
spacers while installing on the twin bundle conductors.
2.6.3.1 The placement of spacers shall be in such a way that adjacent sub spans are
sufficiently detuned and the critical wind velocity of each sub span shall be kept
more than 30 km/hr and to avoid clashing of sub conductors. The placement
shall ensure bundle stability under all operating conditions.
2.6.3.2 The placement chart shall be provided for spans ranging from 100 m to 1100m.
The number of spacers recommended for a ruling design span of 400m shall
however be seven with no sub-span greater than 70m and no end sub-span
longer than 40m. In case more spacers are recommended by the supplier, the
payment shall be restricted to the number of spacers indicated above.
2.6.4 The spacer offered by the Bidder shall satisfy the following requirements: -
2.6.4.1 Spacer shall restore normal spacing of the sub conductors after displacement
by wind, electromagnetic and the electrostatic forces under all operating
conditions including the specified short circuit level without permanent
deformation damage either to conductor or to the assembly itself. They shall
have uniform grip on the conductor
2.6.4.2 For spacer requiring retaining rods, the retaining rods shall be designed for the
specified conductor size. The preformed rods shall be made of high strength,
special aluminium alloy of type 65032 or equivalent aluminium alloy and shall
have minimum tensile strength of 35 kg/sq.mm. The ends of retaining rods
should be ball ended. The rods shall be heat-treated to achieve specified
mechanical properties and give proper resilience and retain the same during
service.
2.6.4.3 Four number of rods shall be applied on each clamp to hold the clamp in
position. The length and diameter of preformed retaining rod shall be decided
by suppliers as per design of the Bundle spacer. However, diameter and length
of the rods shall be as per the STP.
2.6.4.4 Where elastomer surfaced clamp grooves are used, the elastomer shall be
firmly fixed to the clamp. The insert should be forged from aluminium alloy of
type 65032. The insert shall be duly heat treated and aged to retain its
consistent characteristics during service.
2.6.4.5 The clamp grooves shall be in uniform contact with the conductor over the
entire surface, except for rounded edges. The groove of the clamp body and
clamp cap shall be smooth and free of projections, grit or other material, which
cause damage to the conductor when the clamp is installed.
2.6.4.6 The clamp when installed on the conductor shall not cause excessive stress
concentration on the conductor leading to permanent deformation of the
conductor strands and premature fatigue failure in operation.
2.6.4.7 No rubbing, other than that of the conductor clamp hinges, shall take place
between any parts of the spacer. Joint incorporating a flexible medium shall be
such that there is no relative slip between them.
2.6.4.8 The spacer shall be suitably designed to avoid distortion or damage to the
conductor or to themselves during service.
2.6.4.9 The spacer shall not damage or chafe the conductor in any way which might
affect its mechanical and fatigue strength or corona performance.
2.6.4.10 The clamping system shall be designed to compensate for any reduction in
diameter of conductor due to creep.
2.6.4.11 The spacer assembly shall not have any projections, cuts, abrasions etc. or
chattering parts which might cause corona or RIV.
2.6.4.12 The spacer tube shall be made of aluminium alloy of type 65032 or 63400.
2.6.4.13 Elastomer, if used, shall be resistant to the effects of temperature up to 95 0C,
ultraviolet radiation and other atmospheric contaminants likely to be
encountered in service. It shall have good fatigue characteristics. The physical
properties of the elastomer shall be of approved standard.
2.6.4.14 The spacer assembly shall have electrical continuity. The electrical resistance
between the sub-conductor across the assembly in case of spacer having
elastomer clamp grooves shall be suitably selected by the manufacturers to
ensure satisfactory electrical performance and to avoid deterioration of
elastomer under all service conditions.
2.6.4.15 The spacer assembly shall have complete ease of installation and shall be
capable of removal/ reinstallation without any damage.
2.6.4.16 The spacer assembly shall be capable of being installed and removed from the
energised line by means of hot line technique.
2.5 Spacer Damper
2.5.1 Suitable spacer dampers for bundle conductor configuration for line
(stipulated in relevant clause of section–I) shall be offered. The spacer damper
covered by this specification shall be designed to maintain the bundle spacing
of 457 mm under all normal operating conditions and to effectively control
Aeolian vibrations as well as sub span oscillation and to restore conductor
spacing after release of any external extraordinary load. The nominal sub
conductor spacing shall be maintained within ±5 mm.
2.5.2 The spacer damper shall restore the normal sub-conductor spacing due to
displacement by wind, electromagnetic and electrostatic forces including the
specified short circuit level without permanent deformation or damage either
to bundle conductors or to spacer damper itself.
2.5.3 The design offered shall be presented as a system consisting of spacer dampers
and their staggering scheme for spans ranging from 100 m to 1100 m. A
vibration performance test shall be carried out on an experimental test line.
The test line selected for the performance evaluation shall have been designed
for that purpose, be adequately exposed to wind and properly instrumented.
2.5.4 Under the operating conditions specified, the spacer damper system shall
adequately control Aeolian vibrations throughout the life of the transmission
line with wind velocity ranging from 0 to 30 km per hour in order to prevent
damage to conductor at suspension clamps, dead end clamps and spacer
damper clamps.
2.5.5 The spacer damper system shall also control the sub-span oscillations in order
to prevent conductor damage due to chaffing and severe bending stresses at
the spacer damper clamps as well as suspension and dead-end clamps and to
avoid wear to spacer damper components.
2.5.6 The spacer damper shall consist of a rigid central body called the frame linked
to the conductor by articulated arms. terminated by elastomer lined or
elastomer covered clamps and securely held by preformed retaining helical,
factory-formed rods. The articulation shall be designed to provide elastic and
damping forces under angular movement of the arms. The dynamic
characteristics of the articulations shall be maintained for the whole life of the
transmission line.
2.5.7 The clamping system shall be designed to provide firm but gentle and
permanent grip while protecting the conductor against local static or dynamic
stresses expected during normal operating conditions. The clamping system
shall be designed to compensate for any reduction of conductor diameter due
to creep.
2.5.8 Where elastomer surfaced clamps are used, the elastomer elements shall be
firmly fixed to the clamp.
2.5.9 Four number of rods shall be applied on each clamp to hold the clamp in
position. The retaining rods shall be designed for specific conductor size. They
shall be made of high strength aluminium alloy of type 65032 or equivalent
aluminium alloy having a minimum tensile strength of 35 kg/sq.mm. The end
of armour rod shall be parrot billed. The rods shall be heat treated and aged to
achieve specified mechanical properties and to retain the same during service.
Each rod shall be marked in the middle with paint for easy application on the
line. The length and diameter of preformed retaining rod shall be decided by
suppliers as per design of the Spacer Damper. However, diameter and length
of the rods shall be as per the STP.
2.5.10 The spacer damper body and clamps shall be cast/ forged from suitable high
strength corrosion resistant aluminum alloy. The aluminium alloy shall be
chosen in relation with the process used.
2.5.11 The rubber components involved in the design such as damping elements shall
be made with rubber compound selected specifically for that particular
application. The Bidder shall submit a complete list of physical and mechanical
properties of the elastomer used.
2.5.12 The rubber components used shall have good resistance to the effects of
temperature indicated in the Standard Technical Particulars and to ultraviolet
radiation, ozone and other atmospheric contaminants. The rubber shall have
good wear and fatigue resistance and shall be electrically semi conductive.
2.5.13 The spacer damper assembly shall have electrical continuity. The electrical
resistance between the sub-conductors across the assembly in case of spacer
damper involving elastomer surfaced clamps shall be suitably selected by the
manufacturer to ensure satisfactory electrical performance and avoid
deterioration of elastomer under service conditions.
2.5.14 The spacer damper assembly shall have complete ease of installation and shall
be capable of removal/reinstallation without any damage.
2.5.15 The spacer damper assembly shall be capable of being installed and removed
from the energized line by means of hot line techniques. The Supplier shall
submit complete description of the installation, removal and reinstallation
procedure.
2.5.16 A typical placement chart of spacer dampers for spans ranging from 100m to
1100m is indicated in table at Annexure-D. Sub span spacing indicated in
Annexure-D may be varied as per the manufacturer requirement, provided
total no. of Spacer Damper in sub-span shall not be less than indicated in table
at Annexure-D. In case of tension towers, one additional Spacer Damper shall
be placed within 10m of dead-end clamp.
In case more Spacer dampers are recommended by the supplier, the payment
shall be restricted to the number of Spacer dampers indicated in table at
Annexure-D for different spans and one additional in case of tension towers.
2.5.17 The staggering scheme shall be such that no sub span shall be greater than 65
m and no end sub span shall be longer than 40 m and that the spacer dampers
be unequally distributed along the span to achieve sufficient detuning of
adjacent sub spans for oscillations of sub span mode and to ensure bundle
stability for wind speeds up to 60 km/hr.
2.6 Rigid Spacer
2.6.1 Jumpers at tension points shall also be fitted with Rigid spacers so as to limit
the length of free conductor to 3.65 m and to maintain the sub conductor
spacing of 450mm for twin conductor line and 457 mm for Triple/ Quad/ Hexa
bundle lines. Supplier shall quote for rigid spacer for jumper. It shall meet all
the requirements of spacer used in line except for its vibration performance.
Rigid spacers requiring retaining rods shall not be quoted for jumpers.
2.6.2 The spacer offered by the Bidder shall satisfy the following requirement: -
2.6.2.1 Rigid spacer shall restore normal spacing of the sub conductors after
displacement by wind, electromagnetic and the electrostatic forces under all
operating conditions including the specified short circuit level without
permanent deformation damage either to conductor or to the assembly itself.
They shall have uniform grip on the conductor
2.6.2.2 Any nut used shall be locked in an approved manner to prevent vibration
loosening. The ends of bolts and nuts shall be properly rounded for specified
corona performance or suitably shielded.
2.6.2.3 Clamp with cap shall be designed to prevent its cap from slipping out of
position when being tightened.
2.6.2.4 The clamp grooves shall be in uniform contact with the conductor over the
entire surface, except for rounded edges. The groove of the clamp body and
clamp cap shall be smooth and free of projections, grit or other material. which
cause damage to the conductor when the clamp is installed.
2.6.3 For the rigid spacer involving bolted clamps, the manufacturer must indicate
the clamp bolt tightening torque to ensure that the slip strength of the clamp
is maintained between 2.5 kN and 5 kN. The clamp when installed on the
conductor shall not cause excessive stress concentration on the conductor
leading to permanent deformation of the conductor strands and premature
fatigue failure in operation.
2.6.4 Universal type bolted clamps, covering a range of conductor sizes, will not be
permitted.
2.6.5 No rubbing, other than that of the conductor clamp hinges or clamp swing
bolts, shall take place between any parts of the spacer. Joint incorporating a
flexible medium shall be such that there is no relative slip between them.
2.6.6 The spacer shall be suitably designed to avoid distortion or damage to the
conductor or to themselves during service.
2.6.7 Rigid spacers shall be acceptable only for jumpers.
2.6.8 The Rigid spacer shall not damage or chafe the conductor in any way which
might affect its mechanical and fatigue strength or corona performance.
2.6.9 The clamping system shall be designed to compensate for any reduction in
diameter of conductor due to creep.
2.6.10 The Rigid spacer assembly shall not have any projections, cuts, abrasions etc.
or chattering parts which might cause corona or RIV.
2.6.11 The spacer tube shall be made of extruded aluminium alloy of type 65032 or
63400. If fasteners of ferrous material are used, they shall conform to and be
galvanised conforming to relevant Indian Standards. The spacer involving
ferrous fasteners shall not have magnetic power loss more than that stipulated
in the Standard Technical Particulars.
2.6.12 Elastomer, if used, shall be resistant to the effects of temperature up to 95 0C,
ultraviolet radiation and other atmospheric contaminants likely to be
encountered in service. It shall have good fatigue characteristics. The physical
properties of the elastomer shall be of approved standard.
2.6.13 The spacer assembly shall have electrical continuity. The electrical resistance
between the sub-conductor across the assembly in case of spacer having
elastomer clamp grooves shall be suitably selected by the manufacturers to
ensure satisfactory electrical performance and to avoid deterioration of
elastomer under all service conditions.
2.6.14 The spacer assembly shall have complete ease of installation and shall be
capable of removal/reinstallation without any damage.
2.6.15 The spacer assembly shall be capable of being installed and removed from the
energised line by means of hot line technique.
2.7 Material and Workmanship
2.7.1 All the equipment shall be of the latest proven design and conform to the best
modern practice adopted in the extra high voltage field. The Bidder shall offer
only such equipment as guaranteed by him to be satisfactory and suitable for
transmission line applications of the rated voltage with bundle conductors and
will give continued good performance.
2.7.2 The design, manufacturing process and quality control of all the materials shall
be such as to achieve requisite factor of safety for maximum working load,
highest mobility, elimination of sharp edges and corners, best resistance to
corrosion and a good finish.
2.7.3 All ferrous parts shall be hot dip galvanised, after all machining has been
completed. Nuts may, however, be tapped (threaded) after galvanising and the
threads oiled. Spring washers shall be electro galvanised as per grade 4 of IS
1573. The bolt threads shall be undercut to take care of increase in diameter
due to galvanising. Galvanising shall be done in accordance with IS 2629/ IS
1367 (Part-13) and satisfy the tests mentioned in IS 2633. Fasteners shall
withstand four dips while spring washers shall withstand three dips. Other
galvanised materials shall have a minimum overall coating of Zinc equivalent
to 610 gm/sqm and shall be guaranteed to withstand at least six dips each
lasting one minute under the standard Preece test for galvanising unless
otherwise specified.
2.7.4 The zinc coating shall be perfectly adherent, of uniform thickness, smooth,
reasonably bright, continuous and free from imperfections such as flux, ash,
rust stains, bulky white deposits and blisters. The zinc used for galvanising shall
be as per STP.
2.7.5 In case of castings, the same shall be free from all internal defects like
shrinkage, inclusion, blow holes cracks etc.
2.7.6 All current carrying parts shall be so designed and manufactured that contact
resistance is reduced to minimum and localised heating phenomenon is
averted.
2.7.7 No equipment shall have sharp ends or edges, abrasions or projections and
shall not cause any damage to the conductor in any way during erection or
during continuous operation which would produce high electrical and
mechanical stresses in normal working. The design of adjacent metal parts and
mating surfaces shall be such as to prevent corrosion of the contact surface
and to maintain good electrical contact under all service conditions.
2.7.8 Particular care shall be taken during manufacture and subsequent handling to
ensure smooth surface free from abrasion or cuts.
2.7.9 The fasteners shall conform to the requirements of IS 6639. All fasteners and
clamps shall have corona free locking arrangement to guard against vibration
loosening.
2.8 Compression Markings
2.8.1 Die compression areas shall be clearly marked on each equipment designed for
continuous die compressions and shall bear the words ‘COMPRESS FIRST’
‘suitably inscribed on each equipment where the compression begins. If the
losses during erection. No payment shall be admissible for these extra supplies.
For accessories included in the scope of the Contractor, supplier is permitted
to get inspected and supply upto 2.5% extra fasteners to take care of lossess
during erection. No payment shall be admissible for these extra supplies.
3.2 Mid Span Compression Joint
3.2.1 Mid Span Compression Joint shall be used for joining two lengths of earth wire.
The joint shall be made of mild steel with aluminium encasing. The steel sleeve
should not crack or fail during compression. The Brinnel Hardness of steel
should not exceed the value as stipulated in the Standard Technical Particulars.
The steel sleeve shall be hot dip galvanised. The aluminium sleeve shall have
aluminium of purity not less than that stipulated in the Standard Technical
Particulars. Filler aluminium sleeve shall also be provided at the both ends. The
joints shall not permit slipping off, damage to or failure of the complete earth
wire or any part thereof at a load not less than 95% of the ultimate tensile
strength of the earth wire. The joint shall have resistance less than 75% of
resistance of equivalent length of earth wire. The dimensions and the
dimensional tolerances of the joint shall be as stipulated in the Standard
Technical Particulars.
3.3 Vibration Damper
3.3.1 Vibration dampers of 4R-Stockbridge type with four (4) different frequencies
spread within the specified aeolian frequency band-width corresponding to
wind speed of 1m/s to 7 m/s shall be used for suspension and tension points
on each earth wire in each span to damp out aeolian vibrations as mentioned
herein after.
3.3.2 Alternate damping systems or “Dogbone” dampers offering equivalent or
better performance also shall be acceptable provided the manufacturer meets
the qualifying requirements stipulated in the Specifications. Relevant technical
documents to establish the technical suitability of alternate systems shall be
furnished by the Supplier along with the bid.
3.3.3 One damper minimum on each side per earth wire at suspension points and
two dampers on each side per earth wire at tension points shall be used for
ruling design span as given is relevant clause of Section-I.
3.3.4 Incase more number of dampers per ruling design span are recommended by
the supplier, the payment shall be restricted to the number of dampers
specified in clause 3.3.3.
3.3.5 The clamp of the vibration damper shall be made of aluminium alloy. It shall
be capable of supporting the damper during installation and prevent damage
or chaffing of the earth wire during erection or continued operation. The
clamp shall have smooth and permanent grip to keep the damper in position
on the earth wire without damaging the strands or causing premature fatigue
failure of the earth wire under the clamp. The clamp groove shall be in uniform
contact with the earth wire over the entire clamping surface except for the
rounded edges. The groove of the clamp body and clamp cap shall be smooth,
free from projections, grit or materials which could cause damage to the earth
wire when the clamp is installed. Clamping bolts shall be provided with self
locking nuts designed to prevent corrosion of the threads or loosening during
service.
3.3.6 The messenger cable shall be made of high strength galvanised steel/stainless
steel with a minimum strength of 135 Kg/sq.mm. It shall be of preformed and
post formed quality in order to prevent subsequent drop of weights and to
maintain consistent flexural stiffness of the cable in service. The number of
strands in the messenger cable shall be 19. The messenger cable ends shall be
suitably and effectively sealed to prevent corrosion.
3.3.7 The damper mass shall be made of hot dip galvanised mild steel/cast iron or a
permanent mould cast zinc alloy. All castings shall be free from defects such as
cracks, shrinkages, inclusions and blow holes etc. The inside and outside
surfaces of the damper masses shall be smooth.
3.3.8 The vibration analysis of the system, with and without damper, dynamic
characteristic of the damper as detailed under Annexure-A, shall have to be
submitted by the Bidder along with his bid. The technical particulars for
vibration analysis and damping design of the system are as follows: -
Sl. No. Description Technical particulars
1. Span length in meters
i) Ruling design span As given in section-I
ii) Maximum span 1100 meters
iii) Minimum span 100 meters
2. Configuration As per Section-I of this
Specification
3. Tension of earthwire 25% of UTS of earthwire
4. Armour rods used Standard preformed armour
rods/ AGS
5. Maximum permissible +/- 150 micro strains
dynamic strain
3.3.9 The damper placement chart for spans ranging from 100 m to 1100 m shall be
submitted by the Bidder. All the placement charts should be duly supported by
relevant technical documents.
3.3.10 The damper placement charts shall include the following:
(1) Location of the dampers for various combinations of spans and line
tensions clearly indicating number of dampers to be installed per earth
wire per span.
shall be such that the direction of run of the earth wire shall be same as that
of the conductor.
3.5.6 The complete assembly shall be guaranteed for slip and breaking strength of
values indicated in the Standard Technical Particulars.
3.6 Tension Clamp
3.6.1 At all tension towers suitable compression type tension clamps shall be used
to hold the required galvanised steel earth wire. Anchor shackle shall be
supplied which shall be suitable for attaching the tension clamp to strain
plates.
3.6.2 The clamps shall have adequate area of bearing surface to ensure positive
electrical and mechanical contact and shall not permit any slip to the earth wire
under working tension and vibration conditions. The angle of jumper terminal
to be mounted should be 30 deg. with respect to the vertical line.
3.6.3 The clamps shall be made of mild steel with aluminium encasing. The steel
should not crack or fail during compression. The Brinnel hardness of steel
sleeve shall not exceed 200. The steel sleeve shall be hot dip galvanised. The
aluminium encasing shall have aluminium of purity not less than 99.5%. Filler
aluminium sleeve shall also be provided at the end.
3.6.4 The complete assembly shall be so designed as to avoid undue bending in any
part of the clamp and shall not produce any hindrance to the movements of
the clamps in horizontal or vertical directions.
3.6.5 The slip strength of the assembly shall not be less than 95% of the ultimate
strength of the earth wire.
3.6.6 The clamps shall be complete with all the components including anchor
shackle, bolts, nuts, washers, split pin, jumper arrangement etc.
3.7 Material and Workmanship
Same as Clause 2.7 of this section
3.8 Compression Marking
Same as Clause 2.8 of this section
3.9 Drawings
Same as Clause 2.9 of this section
4.0 Tests and Standards
4.1 Type Tests
4.1.1 On the complete Insulator String with Hardware Fittings
i)Double ‘I’ suspension All type test as per clause no. 4.1.1
ii)Quadruple tension
iii)Single ‘I’ suspension pilot All type test as per clause no.
iv) Single tension 4.1.1(a) to (g)
v) Double ‘I’ suspension (River Type test as per clause no. 4.1.1
Crossing) (g)
vi) Quadruple Tension (River
Crossing)
i) Double ‘I’ suspension All type test as per clause no. 4.1.1
ii) Single ‘V’ suspension
iii) Double ‘V’ suspension
iv) Quadruple tension
v) Single ‘I’ suspension pilot
vi) Single ‘V’ suspension pilot All type test as per clause no.
vii) Single tension 4.1.1(a) to (g)
viiI) Double ‘I’ suspension (River Type test as per clause no. 4.1.1
Crossing) (g)
ix) Quadruple Tension (River
Crossing)
i)Double ‘I’ suspension All type test as per clause no. 4.1.1
ii)Quadruple tension
iii)Single ‘I’ suspension pilot All type test as per clause no.
iv) Single tension 4.1.1(a) to (g)
v) Double ‘I’ suspension (River Type test as per clause no. 4.1.1
Crossing) (g)
vi) Quadruple Tension (River
Crossing)
i) Double ‘I’ suspension All type test as per clause no. 4.1.1
ii) Double tension
iii) Single ‘I’ suspension pilot All type test as per clause no.
iv) Single tension 4.1.1(a) to (g)
i)Single ‘I’ suspension All type test as per clause no. 4.1.1
ii)Double tension
iii)Single ‘I’ suspension pilot All type test as per clause no.
iv) Single tension 4.1.1(a) to (g)
v) Double ‘V’ suspension (River Type test as per clause no. 4.1.1
Crossing) (g)
vi) Triple Tension (River Crossing)
i) Single ‘I’ suspension All type test as per clause no. 4.1.1
ii) Single tension except c) & f)
iii) Single ‘I’ suspension pilot All type test as per clause no.
iv) Double ‘I’ suspension 4.1.1(a) to (g) except c) & f)
v) Double tension
i) Single ‘I’ suspension All type test as per clause no. 4.1.1
ii) Double tension except c) & f)
iii) Single ‘I’ suspension pilot All type test as per clause no.
iv) Double ‘I’ suspension 4.1.1(a) to (g) except c) & f)
i) Single ‘I’ suspension All type test as per clause no. 4.1.1
ii) Single tension except c) & f)
iii) Single ‘I’ suspension pilot All type test as per clause no.
iv) Double ‘I’ suspension 4.1.1(a) to (g) except c) & f)
v) Double tension
i) Single ‘V’ suspension All type test as per clause no. 4.1.1
ii) Quadruple tension
iii) Double ‘V’ suspension All type test as per clause no.
4.1.1(a) to (g)
i) Single ‘Y’ suspension All type test as per clause no. 4.1.1
ii) Triple tension
iii) Single ‘I’ suspension Pilot All type test as per clause no.
4.1.1(a) to (g)
i) Single ‘I’ suspension All type test as per clause no. 4.1.1
ii) Double tension except c) & f)
4.1.4 Mid Span Compression Joint for Conductor and Earth wire
a) Visual Examination IS 2121(Part-II)
b) Dimensional Verification IS 2121(Part-II)
c) Chemical Analysis of Materials Annexure-A
d) Electrical resistance test IS 2121(Part-II)
e) Heating cycle test IS2121 (Part-II)
f) Failing load test Annexure-A
g) Corona extinction voltage test (dry) Annexure - A
(for 400 kV & above voltage level line
only)
h) Radio interference voltage test (dry) Annexure – A
(for 400 kV & above voltage level line
only)
i) Galvanising test Annexure-A
Note: ‘Heating cycle’, ‘Corona extinction voltage’, ‘Radio interference
voltage’ tests are not applicable to Mid span compression joint for
Earthwire
(a) Visual examination & verification of IEC 61854; Clause 7.1 &
dimension, materials and mass 7.2
(b) Clamp slip test Annexure-A
(c) Clamp bolt tightening test (if applicable) IEC 61854; Clause 7.5.3
d) Vibration test Annexure-A
i) Vertical Vibration
ii) Longitudinal Vibration
iii) Sub span oscillation
(e) Magnetic power loss test (if applicable) Annexure-A
(f) Compression & Tension test Annexure-A
(g) Corona extinction voltage test (dry) (for Annexure-A
400 kV & above voltage level line only)
(h) Radio interference voltage test (dry) (for Annexure-A
400 kV & above voltage level line only)
(i) Ozone test IEC 61854; Clause 7.6.3
NOTE: ‘Vibration Test’ & ‘Ozone Test’ are not applicable to Rigid Spacers.
4.1.13 Type tests specified under Clause 4.1.1 to 4.1.12 shall not be required to be
carried out if the same has been carried out if a valid test certificate is available
for a similar design.
The test certificate shall be considered valid if,
i) Tests conducted earlier is either conducted in accredited laboratory
(accredited based on ISO/IEC guide 25/17025 or EN 45001 by the
National Accreditation body of the country where laboratory is located)
or witnessed by the representative (s) of POWERGRID or Utility and
ii) Type test reports contain valid Calibration reports of the relevant testing
equipment and information pertaining to ratings, the relevant drawings,
model number, test circuit, calculations (if any), photos, acceptance
criteria/values specified in Technical Specification/relevant standards
(IS/ IEC) and compliance to the same and
iii) Tests should have been conducted on the samples manufactured from
same manufacturing works within last 7 (seven) years as on the date of
NOA.
Further, test certificates of samples manufactured from same manufacturing
works shall also be considered valid, if the same has already been approved/
accepted by POWERGRID & tests have been conducted within the above-
mentioned validity period.
Also, in case, hardware components of previously type tested hardware
fittings are modified as per the attached standardized drawing, the suppliers
shall be required to carry out Mechanical strength test of the entire string
(without insulators) as per Clause 4.1.2 & 4.1.3 at no extra cost to the Employer
In case the tests have been conducted earlier than the above stipulated period
or carried out on samples manufactured from any other manufacturing works
or in case of revision/ amendment in the provisions/ test procedure of the IS/
IEC as referred in the TS or in the event of any discrepancy in the test report
(i.e., due to non-inclusion of valid calibration certificate, desired information
etc. or any test not applicable due to any design/ material/ manufacturing
process change including substitution of components or due to non-
compliance with the requirement stipulated in the Technical Specifications),
the tests shall be conducted by the supplier at no extra cost to the Purchaser.
Further, in-case of non–availability of valid type test reports for ‘Performance
test’ on Spacer Dampers, the type test shall not be required to be carried out
if the spacer damper design offered under the package has been in successful
operation for at least 3 years as on date of NOA on a transmission line having
same conductor bundle configuration. Documentary evidence including supply
record, performance certificate, etc. from respective utilities shall be
submitted by the supplier in this regard.
*The performance tests conducted on Spacer Dampers as well as operational
experience (in lieu of performance test) stipulated above with same Central
Frame and damping system but with different clamping system shall also be
considered valid.
4.2 Acceptance Tests
4.2.1 On Both Suspension and Tension Hardware Fittings
a) Visual Examination IS 2486 (Part-I)
4.2.4 Mid Span Compression Joint for Conductor and Earth wire
(a) Visual examination & verification of IEC 61854; Clause 7.1 &
dimension, materials and mass 7.2
(b) Galvanising test Annexure–A
(c) Movement test (except for spacers for Annexure–A
jumpers)
(d) Clamp slip test Annexure–A
(e) Clamp bolt tightening test (if applicable) IEC 61854; Clause 7.5.3
(f) Compression and tension test Annexure–A
Contractor) of the scheduled date of testing during which the Employer will
arrange to depute his representative to be present at the time of carrying out
the tests.
4.6 Sample Batch for Type Testing
4.6.1 The Contractor shall offer material for sample selection for type testing only
after getting Quality Assurance Programme approved by the Employer. The
Contractor 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
Programme approved by the Employer.
4.6.2 Before sample selection for type testing the Contractor shall be required to
conduct all the acceptance tests successfully in presence of Employer's
representative. However, those acceptance tests, which are also required to
be carried out afresh as the type test, shall not be required to be carried out.
4.7 Schedule of Testing and Additional Tests
4.7.1 The Bidder has to indicate the schedule of following activities in their bids
(a) Submission of drawing for approval.
(b) Submission of Quality Assurance programme for approval.
(c) Offering of material for sample selection for type tests.
(d) Type testing.
4.7.2 The Employer reserves the right of having at his own expense any other test(s)
of reasonable nature carried out at Contractor’s premises, at site, or in any
other place in addition to the aforesaid type, acceptance and routine tests to
satisfy himself that the material complies with the specifications.
4.7.3 The Employer 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
Contractor’s premises or at any other test center. In case of evidence of non-
compliance, it shall be binding on the part of Contractor 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
extra cost to the Employer.
4.8 Test Reports
4.8.1 Copies of type test reports shall be furnished in at least six copies along with
one original. One copy shall be returned duly certified by the Employer, only
after which the commercial production of the concerned material shall start.
4.8.2 Copies of acceptance test report shall be furnished in at least six copies. One
copy shall be returned, duly certified by the Employer, only after which the
materials will be dispatched.
4.8.3 Record of routine test report shall be maintained by the Contractor at his works
for periodic inspection by the Employer's representative.
4.8.4 Test certificates of tests during manufacture shall be maintained by the
Contractor. These shall be produced for verification as and when desired by
the Employer.
4.9 Inspection
4.9.1 The Employer 's representative shall at all times be entitled to have access to
the works and all places of manufacture, where the material and/or its
component parts shall be manufactured and the representatives shall have full
facilities for unrestricted inspection of the Contractor’s, sub-Contractor’s
works raw materials. manufacturers of all the material and for conducting
necessary tests as detailed herein.
4.9.2 The material for final inspection shall be offered by the Contractor only under
packed condition as detailed in clause 4.10 of this part of the Specification. The
engineer shall select samples at random from the packed lot for carrying out
acceptance tests.
4.9.3 The Contractor shall keep the Employer informed in advance of the time of
starting and of the progress of manufacture of material in its various stages so
that arrangements could be made for inspection.
4.9.4 Material shall not be dispatched from its point of manufacture before it has
been satisfactorily inspected and tested unless the inspection is waived off by
the Employer in writing. In the latter case also, the material shall be dispatched
only after all tests specified herein have been satisfactorily completed.
4.9.5 The acceptance of any quantity of material shall in no way relieve the
Contractor of his responsibility for meeting all the requirements of the
Specification, and shall not prevent subsequent rejection, if such material is
later found to be defective.
4.10 Packing and Marking
4.10.1 All material shall be packed in strong and weather resistant wooden
cases/crates. The gross weight of the packing shall not normally exceed 200 Kg
to avoid handling problems.
4.10.2 The packing shall be of sufficient strength to withstand rough handling during
transit, storage at site and subsequent handling in the field.
4.10.3 Suitable cushioning, protective padding, dunnage or spacers shall be provided
to prevent damage or deformation during transit and handling.
4.10.4 Bolts, nuts, washers, cotter pins, security clips and split pins etc. shall be
packed duly installed and assembled with the respective parts and suitable
measures shall be used to prevent their loss.
4.10.5 Each component of Hardware fittings and accessories shall be legibly and
indelibly marked with trade mark of the manufacturer. However, in such type
of component/ item, which consists of many parts and are being supplied in
assembled condition (suspension clamp, vibration damper, spacer/ rigid
spacer, spacer damper etc.), the complete assembly shall be legibly and
indelibly marked on main body/on one of the parts. The symbol
alongwith the word ‘TOP’ shall be marked on the main body of the spacer
damper for installing spacer damper in correct position.
4.10.6 All the packing cases shall be marked legibly and correctly so as to ensure safe
arrival at their destination and to avoid the possibility of goods being lost or
wrongly dispatched on account of faulty packing and faulty or illegible
markings. Each wooden case/ crate shall have all the markings stenciled on it
in indelible ink.
4.11 Standards
4.11.1 The Hardware fittings and accessories for conductor and earth wire shall
conform to the following Standards which shall mean latest revisions, with
amendments/ changes adopted and published, unless specifically stated
otherwise in the Specification.
4.11.2 In the event of the supply of hardware fittings; conductor and earth wire
accessories conforming to standards other than specified, the Bidder shall
confirm in his bid that these standards are equivalent to those specified. In
case of award, salient features of comparison between the Standards proposed
by the Contractor and those specified in this document will be provided by the
Contractor to establish their equivalence.
Sl. Indian Title International
No. Standard Standard
1 IS 209 Specification for zinc
2 IS 398 (Part 2) Aluminium Conductor for
overhead transmission purpose-
Specification: Aluminium
Conductor, Galvanised Steel-
Reinforced
3 IS 398 (Part 4) Aluminium Conductor for
overhead transmission purpose:
Aluminium Alloy Stranded
Conductor (Aluminium-
Magnesium-Silicon type)-
Specification
BS British Standards,
British Standards Institution
101, Pentonvile Road,
N 19-ND
UK
IEC/CISPR International Electro technical Commission,
Bureau Central de la Commission,
electro Technique international,
1 Rue de verembe.
Geneva
SWITZERLAND
BIS/ IS Beureau Of Indian Standards.
Manak Bhavan,
9, Bahadur Shah Zafar Marg,
New Delhi - 110001
INDIA
ISO International Organisation for
Standardization.
Danish Board of Standardization
Danish Standardizing Sraat,
Aurehoegvej-12
DK-2900, Heeleprup,
DENMARK
NEMA National Electric Manufacture Association,
155, East 44th Street.
New York, NY 10017
U.S.A.
Annexure–A
The procedure for this test be the same as specified in BS 137 (Part-I) Clause
3.4 and 3.5 except that the insulator string shall be tested without the Corona
Control rings.
Duration Sequence
Total Test Direction**
String Type of Load of Testing
Load* (kN) of Load
(Min.) ***
132kV (SINGLE PANTHER)
94 1 5 1
Double I Suspension
140 1 1 2
(2X70kN)
F**** 1 - 3
47 1 5 1
Single I Suspension
70 1 1 2
(70kN)
F**** 1 - 3
60 1 5 1
Single Tension
90 1 1 2
(90 kN)
F**** 1 - 3
120 1 5 1
Double Tension
180 1 1 2
(2X90kN)
F**** 1 - 3
220 kV (SINGLE ZEBRA)
94 1 5 1
Double I Suspension
140 1 1 2
(2X70kN)
F**** 1 - 3
47 1 5 1
Single I Suspension
70 1 1 2
(70kN)
F**** 1 - 3
47 1 5 1
Single I Suspension
70 1 1 2
Pilot (70kN)
F**** 1 - 3
80 1 5 1
Single Tension
120 1 1 2
(120kN)
F**** 1 - 3
160 1 5 1
Double Tension
240 1 1 2
(2X120kN)
F**** 1 - 3
220 kV (TWIN MOOSE)
80 1 5 1
Single I Suspension
120 1 1 2
(120kN)
F**** 1 - 3
80 1 5 1
Single I Suspension
120 1 1 2
Pilot (120kN)
F**** 1 - 3
80 1 5 1
Single Tension (120kN) 120 1 1 2
F**** 1 - 3
214 1 5 1
Double Tension
320 1 1 2
(2X160kN)
F**** 1 - 3
400 kV (TWIN MOOSE)
80 2 5 1
60 3 5 2
Single V
60 4 5 3
(2x90kN)
90 3 1 4
F**** 3 _ 5
80 1 5 1
Single I Suspension
120 1 1 2
(120kN)
F**** 1 - 3
80 1 5 1
Single I Suspension
120 1 1 2
Pilot (120kN)
F**** 1 - 3
80 1 5 1
Single Tension (120kN) 120 1 1 2
F**** 1 - 3
214 1 5 1
Double Tension
320 1 1 2
(2X160kN)
F**** 1 - 3
107 1 5 1
Single I Suspension
160 1 1 2
(160kN)
F**** 1 - 3
107 1 5 1
Single I Suspension
160 1 1 2
Pilot (160kN)
F**** 1 - 3
107 1 5 1
Single Tension (160kN) 160 1 1 2
F**** 1 - 3
281 1 5 1
Double Tension
420 1 1 2
(2 X210kN)
F**** 1 - 3
400kV (TRIPLE SNOWBIRD)
161 1 5 1
Double I Suspension
240 1 1 2
(2X120kN)
F**** 1 - 3
80 1 5 1
Single I Suspension
120 1 1 2
Pilot (120kN)
F**** 1 - 3
80 1 5 1
Single Tension (120kN) 120 1 1 2
F**** 1 - 3
281 1 5 1
Double Tension
420 1 1 2
(2 X210kN)
F**** 1 - 3
400kV (QUAD MOOSE)
161 1 5 1
Double I Suspension
240 1 1 2
(2X160kN)
F**** 1 - 3
80 1 5 1
Single I Suspension
120 1 1 2
Pilot (120kN)
F**** 1 - 3
80 1 5 1
Single Tension (120kN) 120 1 1 2
F**** 1 - 3
429 1 5 1
Quad Tension
640 1 1 2
(4X160kN)
F**** 1 - 3
+/-500kV HVDC (QUAD BERSIMIS)
155 2 5 1
130 3 5 2
Single V
130 4 5 3
(2x210kN)
210 3 1 4
F**** 3 - 5
320 2 5 1
Double V 280 3 5 2
(2x2x210kN) 280 4 5 3
420 3 1 4
F**** 3 - 5
429 1 5 1
Quadruple Tension 640 1 1 2
(4X160 kN)
F**** 1 - 3
+500kV HVDC (QUAD LAPWING)
155 2 5 1
130 3 5 2
Single V
130 4 5 3
(2x210kN)
210 3 1 4
F**** 3 - 5
320 2 5 1
Double V 280 3 5 2
(2x2x210kN) 280 4 5 3
420 3 1 4
F**** 3 - 5
560 1 5 1
Quadruple Tension
840 1 1 2
(4X210 kN)
F**** 1 - 3
765kV S/C (QUAD BERSIMIS)
160 1 5 1
Double I
240 1 1 2
(2X160kN)
F**** 1 1 3
Single V 155 2 5 1
(2X210kN) 130 3 5 2
130 4 5 3
210 3 1 4
F**** 3 _ 5
280 2 5 1
260 3 5 2
Double V
260 4 5 3
(2X2X210kN)
420 3 1 4
F**** 3 _ 5
80 1 5 1
Single Tension
120 1 1 2
(120kN)
F**** 1 - 3
540 1 5 1
Quadruple Tension
840 1 1 2
(4X210kN)
F**** 1 _ 3
Single I Pilot (120kN) 80 1 5 1
& Single V Pilot 120 1 1 2
(2X120kN) F**** 1 _ 3
765kV D/C (HEXA ZEBRA)
214 1 5 1
Double I Suspension
320 1 1 2
(2X160kN)
F**** 1 - 3
107 1 5 1
Single I Suspension
160 1 1 2
Pilot (160kN)
F**** 1 - 3
107 1 5 1
Single Tension (160kN) 160 1 1 2
F**** 1 - 3
560 1 5 1
Quad Tension
840 1 1 2
(4X210kN)
F**** 1 - 3
±800kV HVDC (HEXA LAPWING)
340 2 5 1
250 3 5 2
Single ‘Y’ suspension 250 4 5 3
String for Pole 420 3 1 4
conductor F***** 3 - 5
845 1 5 1
The insulators string shall be deemed acceptable if, for all test loads except
failure load F, the string components do not show any visual signs of
deformation or fracture, and the same components may be disassembled by
hand, except for removal of cotter pins and initial loosening of the nuts. The
failure load F shall be recorded and must me greater than all previous test
loads.
1.6 Vibration Test
The suspension string shall be tested in suspension mode, and tension string in
tension mode itself in laboratory span of minimum 30 meters. In the case of
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 sub conductors each tensioned at 25% of UTS shall be
secured with clamps. The system shall be suitable to maintain constant tension
on each sub-conductors throughout the duration of the test. Vibration dampers
shall not be used on the test span. Both the sub-conductors shall be vertically
vibrated simultaneously at one of the resonance frequencies of the insulators
string (more than 10 Hz) by means of vibration inducing equipment. The peak
to peak displacement in mm of 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 in cycles/sec. The insulator string shall be
vibrated for not less than 10 million cycles without any failure. After the test
the disc insulators shall be examined for looseness of pins and cap or any crack
in the cement. The hardware shall be examined for looseness, fatigue failure
and mechanical strength test. There shall be no deterioration of properties of
hardware components and disc insulators after the vibration test.
2.0 Tests on Hardware Fittings
2.1 Magnetic Power Loss Test for Suspension Assembly
The sample shall be tested in a manner to simulate service conditions for 50
Hz pure sine-wave. This test shall be carried out as per Clause 12.0 of IEC 61284.
An alternating current over the range as stipulated below (per sub-conductor)
shall be passed through a suitable length of conductor and the power losses
shall be measured both with and without the fittings assembled on the
conductor. Armour rods shall be applied to the conductor if they are used in
service. The reading of the wattmeter with and without five suspension clamps
shall be recorded and tabulated graphical form. The test is passed if the
average power loss for suspension clamp at given ampere is less than or equal
to the value indicated in the Standard Technical Particulars.
Conductor name Alternating current range
ACSR PANTHER 200 amps to 500 amps
ACSR ZEBRA/ MOOSE/ 400 amps to 800 amps
SNOWBIRD/ BERSIMIS/LAPWING
reproduce design conditions. The testing programme varies with string and
tower types according to following table:
Sequence
Total Test Direction** of Duration of
String Type of Testing
Load* (kN) Load Load (Min.)
***
132kV (SINGLE PANTHER)
94 1 1 1
Double I Suspension
140 1 1 2
(2X70kN)
F**** 1 - 3
47 1 1 1
Single I Suspension
70 1 1 2
(70kN)
F**** 1 - 3
60 1 1 1
Single Tension
90 1 1 2
(90 kN)
F**** 1 - 3
120 1 1 1
Double Tension
180 1 1 2
(2X90kN)
F**** 1 - 3
220 kV (SINGLE ZEBRA)
94 1 1 1
Double I Suspension
140 1 1 2
(2X70kN)
F**** 1 - 3
47 1 1 1
Single I Suspension
70 1 1 2
(70kN)
F**** 1 - 3
47 1 1 1
Single I Suspension
70 1 1 2
Pilot (70kN)
F**** 1 - 3
80 1 1 1
Single Tension
120 1 1 2
(120kN)
F**** 1 - 3
160 1 1 1
Double Tension
240 1 1 2
(2X120kN)
F**** 1 - 3
220kV (TWIN MOOSE)
80 1 1 1
Single I Suspension
120 1 1 2
(120kN)
F**** 1 - 3
80 1 1 1
Single I Suspension
120 1 1 2
Pilot (120kN)
F**** 1 - 3
80 1 1 1
Single Tension (120kN) 120 1 1 2
F**** 1 - 3
214 1 1 1
Double Tension
320 1 1 2
(2X160kN)
F**** 1 - 3
400kV (TWIN MOOSE)
80 2 1 1
Single V
90 2 1 2
(2x90kN)
F**** 2 _ 3
80 1 1 1
Single I Suspension
120 1 1 2
(120kN)
F**** 1 - 3
80 1 1 1
Single I Suspension
120 1 1 2
Pilot (120kN)
F**** 1 - 3
80 1 1 1
Single Tension (120kN) 120 1 1 2
F**** 1 - 3
214 1 1 1
Double Tension
320 1 1 2
(2X160kN)
F**** 1 - 3
400kV (TWIN LAPWING)
107 1 1 1
Single I Suspension
160 1 1 2
(160kN)
F**** 1 - 3
107 1 1 1
Single I Suspension
160 1 1 2
Pilot (160kN)
F**** 1 - 3
107 1 1 1
Single Tension (160kN) 160 1 1 2
F**** 1 - 3
Double Tension 281 1 1 1
(2 X210kN) 420 1 1 2
F**** 1 - 3
400kV (TRIPLE SNOWBIRD)
161 1 1 1
Double I Suspension
240 1 1 2
(2X120kN)
F**** 1 - 3
80 1 1 1
Single I Suspension
120 1 1 2
Pilot (120kN)
F**** 1 - 3
80 1 1 1
Single Tension (120kN) 120 1 1 2
F**** 1 - 3
281 1 1 1
Double Tension
420 1 1 2
(2 X210kN)
F**** 1 - 3
400kV (QUAD MOOSE)
161 1 1 1
Double I Suspension
240 1 1 2
(2X160kN)
F**** 1 - 3
80 1 1 1
Single I Suspension
120 1 1 2
Pilot (120kN)
F**** 1 - 3
80 1 1 1
Single Tension (120kN) 120 1 1 2
F**** 1 - 3
429 1 1 1
Quad Tension
640 1 1 2
(4X160kN)
F**** 1 - 3
+/-500kV HVDC (QUAD BERSIMIS)
176 2 1 1
Single V
263 2 1 2
(1x210kN)
F**** 2 - 3
352 2 1 1
Double V
525 2 1 2
(2x210kN)
F**** 2 - 3
482 1 1 1
Quadruple Tension 720 1 1 2
(4X160 kN)
F**** 1 - 3
Notes:
* : The total test must be established gradually at a steady rate.
**: Direction of load
1. following string axis
2. following bisector of string angle.
*** : The hardware assembly must be completely unloaded and examined, then
the proper direction of loading established before proceeding to the next
sequential test.
****: F denotes Failure load
The hardware components shall be deemed acceptable if, for all test loads
except failure load F, the string components do not show any visual signs of
deformation or fracture, and the same components may be disassembled by
hand, except for removal of cotter pins and initial loosening of the nuts. The
failure load F shall be recorded and must me greater than all previous test
loads.
2.4 Galvanising /Electroplating Test on clamp & fittings
The test shall be carried out as per Clause no. 9.4 of IS 2486 (Part-1) except
that both uniformity of zinc coating and standard preece test shall be carried
out and the results obtained shall satisfy the requirements of this specification.
2.5 Slip Strength Test of dead end assembly
The fitting compressed on conductor/earth wire shall not be less than one
meter in length. The test shall be carried out as per IS 2486 (Part-I) except that
the load shall be steadily increased to 95% of minimum ultimate tensile
strength of conductor and retained for one minute at this load. There shall be
no movement of the conductor relative to the fittings and no failure of the
fittings during this one minute period.
2.6 Mechanical Strength Test of Welded Joint
The welded portion of the component shall be subjected to a Load of 2000 kgs
for one minute. Thereafter, it shall be subjected to die-penetration/ultrasonic
test. There shall not be any crack at the welded portion.
2.7 Tests for Forging Casting and Fabricated Hardware
The chemical analysis, hardness test, grain size, inclusion rating and magnetic
particle inspection for forging, castings and chemical analysis and proof load
test for fabricated hardware shall be as per the internationally recognized
procedures for these tests. The sampling will be based on heat number and
heat treatment batch. The details regarding test will be as in the Quality
Assurance programme.
2.8 Shore Hardness Test for Elastomer Cushion for AG Suspension Assembly
The shore hardness at various points on the surface of the elastomer cushion
shall be measured by a shore hardness meter and the shore hardness number
shall be between the values indicated in the Standard Technical Particulars.
2.9 Proof Load Test (Routine Test)
Each component shall be subjected to a load equal to 50% of the specified
minimum ultimate tensile strength which shall be increased at a steady rate to
67% of the UTS specified. The load shall be held for one minute and then
removed. After removal of the load the component shall not show any visual
deformation.
3.1 Mid span compression joint for conductor/ earthwire & Repair sleeve for
conductor
a) Failing load Test of Mid span compression joint for conductor/
earthwire & Repair sleeve for conductor
The test shall be carried out as per IS 2121 (Part-II), clause 6.4 except that the
load shall be steadily increased to 95% of minimum ultimate tensile strength
of conductor and retained for one minute at this load. There shall be no
movement of the conductor relative to the fittings and no failure of the fittings
during this one-minute period.
b) Galvanising Test on Mid span compression joint
The test shall be carried out as per Clause no. 6.7 of IS 2121 (Part-II) except
that standard preece test shall also be carried out and the results obtained
shall satisfy the requirements of this specification.
c) Hardness Test
The Brinnel hardness at various points on the steel sleeve of conductor core
and of the earthwire compression joint and tension clamp shall be measured.
4.0 T-Connector for Conductor
b) Galvanising Test
The test shall be carried out as per Clause no. 6.7 of IS: 2121- (Part-IV) except
that standard preece test shall also be carried out and the results obtained
shall satisfy the requirements of this specification.
4.1 Flexible Aluminum Bond
a) Slip Strength Test
On applying a load of 3 kN between the two ends, stranded flexible aluminium cable
shall not come out of the connecting lugs and none of its strands shall be damaged.
After the test, the lugs shall be cut open to ascertain that the gripping of cable has
not been affected.
b) Galvanising Test
The test shall be carried out as per Clause no. 5.7 of IS: 2121- (Part-III) except that
standard preece test shall also be carried out and the results obtained shall satisfy
the requirements of this specification.
4.2 Vibration Damper for conductor and Earth wire
damper shall be kept minimum three loops away from the shaker to
eliminate stray signals influencing damper movement.
The damper shall then be vibrated at the highest resonant frequency of each
damper mass. For dampers involving torsional resonant frequencies, tests
shall be done at torsional modes also in addition to the highest resonant
frequencies at vertical modes. The resonance frequency shall be identified
as the frequency at which each damper mass vibrates with the maximum
amplitude on itself. The amplitude of vibration of the damper clamp shall
be maintained not less than ± 25/f mm, where f is the frequency in Hz.
The test shall be conducted for minimum ten million cycles at each resonant
frequency mentioned above. During the, test if resonance shift is observed
the test frequency shall be tuned to the new resonant frequency.
The clamp slip test as mentioned hereinabove shall be repeated after
fatigue test without retorquing or adjusting the damper clamp, and the
clamp shall withstand a minimum load equal to 80% of the slip strength for
a minimum duration of one minute.
After the above tests, the damper shall be removed from conductor/
earthwire and subjected to dynamic characteristics test. There shall not be
any major deterioration in the characteristic of the damper. The damper
then shall be cut open and inspected. There shall not be any broken, loose,
or damaged part. There shall not be significant deterioration or wear of the
damper. The conductor/earthwire under clamp shall also be free from any
damage.
For the purpose of acceptance, the following criteria shall be applied.
i. There shall not be any resonant frequency shift before and after the test
by more than + 20 %.
ii. The power dissipation of the damper before and after test at the
individual resonant frequencies do not differ by more than + 20 %.
iii. power dissipation of the damper shall not be less than guaranteed %
variation in power dissipation before fatigue test by the Contractor.
However, it shall not be less than minimum power dissipation which shall
be governed by lower limits of reactance and phase angle indicated in
the envelope.
d) Magnetic Power Loss Test for Vibration Damper
The sample shall be tested in a manner to simulate service conditions for
50 Hz pure sine-wave. This test shall be carried out as per Clause 12.0 of
IEC:61284. An alternating current over the range as stipulated below (per
subconductor) shall be passed through a suitable length of conductor
and the power losses shall be measured both with and without the
d) Compression and Tension Tests (for Spacer Damper, Bundle Spacer &
Rigid spacers)
The test shall be carried out as per clause 7.5.4.2 of IEC: 61854. Three
samples of spacer/spacer dampers shall be subjected to a compression
and tension test. A compressive load as specified in the Standard
Technical Particulars shall first be applied and held for five minutes.
Then a tensile load as specified in the Standard Technical Particulars
shall be applied on the same pair of arms. The test shall be repeated on
the other pair of arms. The acceptance criteria shall be as per
IEC:61854.
e) Magnetic Power Loss Test (for Spacer Damper, Bundle Spacer & Rigid
spacers)
Where Ymax being the antinode displacement (mm) and f is the test
frequency (Hz). The test frequency shall be greater than 24 Hz and the total
number of cycles shall be more than 10 million.
Both the conductor shall be vibrated 180 deg. out of phase with the above
minimum amplitude.
Chemical analysis of the material used for manufacture of items shall be conducted to
check the conformity of the same with Technical Specification and approved drawing.
Annexure-B
(Min)
4. Particulars of Elastomer (For AGS Clamp only)
a) Type of elastomer Chloropren NA NA
e/
Neoprene
b) Shore hardness of elastomer 65 - 80 NA NA
c) Temperature range for which elastomer is °C Upto 95°C NA NA
designed
d) Moulded on insert Yes NA NA
5. Mechanical Strength of Suspension fitting KN 240 120
(excluding suspension clamp)
6. Mechanical Strength of suspension clamp. 70 70 70
7. Min. No. of dips in standard preece test Nos a) Fasteners: 4 dips of 1 min
the ferrous parts can withstand. b) Spring washers: 3 dips of 1
min
c) All others: 6 dips of 1 min
Rubbe Rubbe
r r
b) Shore hardness of elastomer 65 to NA 65 to NA NA
80 80
c) Temperature range for which Upto NA Upto NA NA
o o
elastomer is designed 95 C 95 C
d) Moulded on insert Yes NA Yes NA NA
5. Mechanical strength of KN 120 2 x160 (along 120
suspension fitting (excluding one limb)
suspension clamp)
6. Mechanical strength of KN 70 120 70
suspension clamp
7. Galvanising
a) Minimum weight of Zinc coating gm/m 610
for steel parts 2
b) Purity of Zinc used for galvanising % 99.95 (IS 209) or 98.5 (IS 13229)
c) Min. No. of dips in standard No. a) Fasteners: 4 dips of 1 minute
preece test the ferrous parts can b) Spring washers: 3 dips of 1 minute
withstand c) all others: 6 dips of 1 minute
Single Double
Tension Tension
1. Mechanical Strength of Tension fittings kN 120 420
(excluding dead end clamp)
2. Type of Dead-End assembly Compression
3. Compression Pressure MT 100
4. Maximum electrical resistance of dead- % 75
end assembly as a percentage of
equivalent length of Conductor
5. Slip strength of dead-end assembly kN 112
7. Min. No. of dips in standard preece test Nos a) Fasteners: 4 dips of 1 min
the ferrous parts can withstand. b) Spring washers: 3 dips of
1 min
c) All others: 6 dips of 1 min
Rubbe Rubbe
r r
b) Shore hardness of elastomer 65 to NA 65 to NA NA
80 80
c) Temperature range for which Upto NA Upto NA NA
elastomer is designed 95o C 95o C
d) Moulded on insert Yes NA Yes NA NA
5. Mechanical strength of KN 70 2 x 70 70
suspension fitting (excluding
suspension clamp)
6. Mechanical strength of KN 70 70 70
suspension clamp
7. Galvanising
a) Weight of Zinc coating for steel gm/m2 610
parts
b) Purity of Zinc used for % 99.95 (IS 209: 1992) or 98.5 (IS 13229:1991)
galvanising
c) Min. No. of dips in standard No. a) Fasteners: 4 dips of 1 minute
preece test the ferrous parts can b) Spring washers: 3 dips of 1 minute &
withstand (wherever applicable) c) all others: 6 dips of 1 minute
5. Mechanical strength of KN 70 2 x 70
suspension fitting (excluding
suspension clamp)
6. Mechanical strength of KN 70 70
suspension clamp
7. Galvanising
a) Minimum weight of Zinc coating gm/m2 610
for steel parts
b) Purity of Zinc used for galvanising % 99.95 (IS 209) or 98.5 (IS 13229)
c) Min. No. of dips in standard No. a) Fasteners: 4 dips of 1 minute
preece test the ferrous parts can b) Spring washers: 3 dips of 1 minute &
withstand (wherever applicable) c) all others: 6 dips of 1 minute
J) Accessories for ACSR ZEBRA conductor for 765 kV transmission line with Hexa ZEBRA
conductor
4. HEX SPACER DAMPER FOR ACSR ZEBRA CONDUCTOR for 765kV Trans.Lines
3. Material of
(a) Clamp Al Alloy IS:4600 or Equivalent for
Casting & Al Alloy 6061 or Equivalent
(for Forging)
5.HEX RIGID SPACER FOR ACSR ZEBRA CONDUCTOR for 765kV Trans.Lines
1. Material of
(a) Clamp Al Alloy IS:4600 or Equivalent
(b) Body Galvanised Steel / Al Alloy 4600 or
Equivalent
2. Elastomer (if used)
(a) Shore hardness 65 - 80
(b) Temp. range for which °C Upto 95°C
designed
3. Minimum ultimate tensile
strength of spacer
(a) Compressive load kN 14
(b) Tensile load kN 7.0
4. Slipping strength of spacer clamp kN Longitud Maxm Slip
Clamp type nal Load permitted
(kN) (mm)
Metal – Metal 6.5 1
Bolted
Rubber loaded 2.5 2.5
5. Maximum magnetic power loss of Watt Below 1 watt.
at sub conductor current of 500 s
amperes, 50Hz AC
6. Minimum corona Extinction kV 510
voltage kV (rms) under dry
condition
7. Radio Interference Voltage at 1 μV Below 1000
MHz for phase to earth voltage of
510 kV (rms) Microvolts under
dry condition
8. Galvanising
a) Minimum weight of Zinc coating gm/ 610
for steel parts m2
b) Purity of Zinc used for galvanising % 99.95 (IS 209) or 98.5 (IS 13229)
c) Min. No. of dips in standard No. a) Fasteners: 4 dips of 1 minute
preece test the ferrous parts can b) Spring washers: 3 dips of 1 minute
withstand c) all others: 6 dips of 1 minute
K) Accessories for ACSR BERSIMIS conductor for 765 kV transmission line with Quad
BERSIMIS conductor
3. Material of
(a) Clamp Al Alloy IS:4600 or Equivalent for
Casting & Al Alloy 6061 or Equivalent
(for Forging)
1. Material of
(a) Clamp Al Alloy IS:4600 or Equivalent
( b) Body Galvanised Steel / Al Alloy 4600 or
Equivalent
2. Elastomer (if used)
(a) Shore hardness 65 - 80
(b) Temp. range for which °C Upto 95°C
designed
3. Minimum ultimate tensile
strength of spacer
(a) Compressive load kN 15
(b) Tensile load kN 7.5
4. Vibration Damper for ACSR MOOSE conductor (For twin bundle conductor line only)
Sl. Description Unit Particulars/ Value
1. Type of Damper 4R-Stockbridge type
2. Materials of components
a) Damper masses Cast iron/mild steel/Zinc alloy
duly hot dip galvanised
b) Clamp Aluminum alloy 4600
c) Messenger cable High tensile strength galvanized
steel
3. Number of strands in stranded Nos. 19
messenger cable
5. Bundle Spacer for ACSR MOOSE conductor (For twin bundle conductor line only)
Sl. Description Unit Particulars/ Value
1. Type of Bundle Spacer Armour grip type
2. Insert Main Retaining
body rods (if any)
Tube Aluminum
Alumi Aluminu alloy
num m alloy 6061/65032
(i) Materials of components alloy 6063/63
6061/ 400;
65032 6061/
65032
Heat
Tube- treatment
Manufacturing process of component
(ii) Forged extrusio during
parts
n manufacturi
ng
3. Retaining rods (if used)
(a) Number of retaining rods used for no. 8
each spacer
(b) Diameter mm 7.87-0.1
(c) Length mm 1100+15
(d) Minimum UTS of rods Kg/mm
2 35
4. Elastomer
(a) Type Chloroprene/Neoprene
(c) Moulded on insert Yes
(d) Shore hardness 65 to 80
(e) Thickness on insert mm 5(Average)
(f) Temp. range for which designed °C 95
5. Minimum ultimate tensile strength of spacer
(a) Compressive load kN 14
(b) Tensile load kN 7
6. Slipping strength of spacer clamp
a) Before vibration test KN 2.5
b) After vibration test KN 2
7. Minimum corona Extinction voltage kV kV 320
(rms) under dry condition
8. Maximum Radio Interference Voltage Micro 1000
(RIV) at 1 MHz for phase to earth volts
voltage of 305 kV (rms) under dry
condition
6. Rigid Spacer for Jumper for ACSR MOOSE conductor (For twin bundle conductor line
only)
Sl. Description Unit Particulars/ Value
1. Material of component parts
(a) Clamp Aluminum alloy (4600)
(b) Main body Galvanised Steel / Al Alloy 4600
or Equivalent
2. Elastomer (if used)
(a) Shore hardness 65 - 80
(b) Temp. range for which designed °C Upto 95°C
Minimum ultimate tensile strength of
3. spacer
(a) Compressive load kN 14
3. Material of
(a) Clamp Al Alloy IS:4600 or Equivalent for
Casting & Al Alloy 6061 or
Equivalent (for Forging)
( b) Body Al Alloy 4600 or Equivalent for
Casting & Al Alloy 6061 or
Equivalent (for Forging)
4. Elastomer (if used)
(a) Shore hardness 65 - 80
(b) Temp. range for which designed °C Upto 95°C
5. Minimum ultimate tensile strength of
spacer
(a) Compressive load kN 14
(b) Tensile load kN 7.0
6. Slipping strength of spacer clamp
(a) Before vibration test kN Longitu Max
Clamp type dnal m
Load Slip
(kN) permi
tted
(mm)
Preformed 2.5 12
rods
10. Galvanising
a) Minimum weight of Zinc coating for gm/m 610
steel parts 2
b) Purity of Zinc used for galvanising % 99.95 (IS 209) or 98.5 (IS 13229)
c) Min. No. of dips in standard preece test No. a) Fasteners: 4 dips of 1 minute
the ferrous parts can withstand b) Spring washers: 3 dips of 1
minute
c) all others: 6 dips of 1 minute
1. Material of
(a) Clamp Al Alloy IS:4600 or Equivalent
( b) Body Galvanised Steel / Al Alloy 4600
or Equivalent
2. Elastomer (if used)
(a) Shore hardness 65 - 80
(b) Temp. range for which designed °C Upto 95°C
3. Minimum ultimate tensile strength of
spacer
(a) Compressive load kN 14
(b) Tensile load kN 7.0
4. Slipping strength of spacer clamp kN Longit Maxm
Clamp type udnal Slip
Load permitt
(kN) ed (mm)
Metal – 6.5 1
Metal
Bolted
Rubber 2.5 2.5
loaded
Repair sleeve
Sl. Description Unit Particulars/ Value
1. Material Aluminium of minimum
purity 99.5%
2. Dimension of Aluminum sleeve Before compression
i) Inside diameter mm 33.00 ± 0.5
ii) Outside diameter mm 54.00 ± 1.0
iii) Length mm 300.00 ± 5.0
3. Dimensions of Aluminum Sleeve after compression
i) Outside dimension (Corner to corner) mm 53.00 ± 0.5
ii) Outside dimension (face to face) mm 46.00 ± 0.5
iii) Length mm 330.00(Approx.)
4. Minimum corona Extinction voltage kV kV 320
(rms) under dry condition
5. Maximum Radio Interference Voltage at Micro 1000
1 MHz for phase to earth voltage of 305 Volts
kV (rms) under dry condition
3. Material of
(a) Clamp Al Alloy IS:4600 or Equivalent for
Casting & Al Alloy 6061 or Equivalent
(for Forging)
( b) Body Al Alloy 4600 or Equivalent for
Casting & Al Alloy 6061 or Equivalent
(for Forging)
1. Material of
(a) Clamp Al Alloy IS:4600 or Equivalent
(b) Body Galvanised Steel / Al Alloy 4600 or
Equivalent
T-connector
Sl. Description Unit Particulars/ Value
1. Material Aluminium of purity 99.5%
2. Dimension of Aluminum sleeve Before compression
i) Inside diameter mm 33.00 ± 0.5
ii) Outside diameter mm 54.00 ± 1.0
iii) Length mm 400.00 ± 5.0
3. Dimensions of Aluminum Sleeve after compression
i) Outside dimension (Corner to corner) mm 53.00 ± 0.5
2. Repair sleeve
Sl. Description Unit Particulars/ Value
1. Material Aluminium of minimum purity 99.5%
2. Dimension of Aluminum sleeve Before compression
i) Inside diameter mm 31.00 ± 0.5
ii) Outside diameter mm 48.00 ± 1.0
iii) Length mm 275.00 ± 5.0
3. Dimensions of Aluminum Sleeve after compression
i) Outside dimension (Corner to mm 47.00 ± 0.5
corner)
ii) Outside dimension (face to mm 41.00 ± 0.5
face)
3. Vibration Damper
Sl. Description Unit Particulars/ Value
1. Type of Damper 4R-Stockbridge type
2. Materials of components
a) Damper masses Cast iron/ mild steel hot dip galvanised
/ Zinc alloy
b) Clamp Aluminum alloy 4600
c) Messenger cable High tensile strength galvanized steel
3. Number of strands in stranded Nos. 19
messenger cable
4. Minimum ultimate tensile Kg/mm2 135
strength of stranded
messenger cable
5. Slip strength of stranded KN 5
messenger cable (mass pull
off)
6. Slipping strength of damper
clamp
(a) Before fatigue test KN 2.5
(b) After fatigue test KN 2
7. Resonance frequencies range Hz 5 to 45
P) Accessories for ACSR Lapwing conductor for ±800 kV HVDC Transmission Line.
Q) Accessories for 7/3.66 mm GS Earthwire for 400 kV and 765 kV transmission line
R) Accessories for 7/3.15 mm GS Earthwire for 220 kV and 132 kV transmission line
messenger cable
5. Slip strength of stranded kN 2.5
messenger cable (mass pull
off)
6. Slipping strength of damper
clamp
(a) Before fatigue test kN 2.5
(b) After fatigue test kN 2
7. Resonance frequencies range Hz 10 to 60
8. Percentage variation in % +/-40 (Maximum)
reactance after fatigue test in
comparison with that before
fatigue test
9. Percentage variation in power % +/-40 (Maximum)
dissipation after fatigue test in
comparison with that before
fatigue test
10. Galvanising
Annexure-C