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Ts Compliance

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Sharad Singh
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0% found this document useful (0 votes)
123 views138 pages

Ts Compliance

Uploaded by

Sharad Singh
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
You are on page 1/ 138

Complied

Complied
STANDARD SPECIFICATION OF TRANSMISSON LINE (SECTION-
HARDWARE FITTINGS & ACCESSORIES FOR CONDUCTOR & EARTHWIRE)

SECTION-VI A

HARDWARE FITTINGS & ACCESSORIES FOR


CONDUCTOR & EARTHWIRE

(Applicable for all hardware fittings and accessories for conductor


and earthwire of transmission line with all type of conductors
except Suspension clamp, dead end clamp and accessories for HTLS
conductor)

Complied
STANDARD SPECIFICATION OF TRANSMISSON LINE (SECTION-
HARDWARE FITTINGS & ACCESSORIES FOR CONDUCTOR & EARTHWIRE)

TECHNICAL SPECIFICATIONS

SECTION-VI A

HARDWARE FITTINGS & ACCESSORIES FOR CONDUCTOR & EARTHWIRE


Revision History
Revision Date Clause Ref Description
No.
Rev-0 June’2021 First Release

Rev-1 Oct’2021 First Revision

Complied
STANDARD SPECIFICATION OF TRANSMISSON LINE (SECTION-
HARDWARE FITTINGS & ACCESSORIES FOR CONDUCTOR & EARTHWIRE)

TECHNICAL SPECIFICATIONS

SECTION-VI A

HARDWARE FITTINGS & ACCESSORIES FOR CONDUCTOR & EARTHWIRE

CONTENTS

Clause Description Page


No.

1.0 Technical Description of Hardware Fitting 1


2.0 Technical Description of Accessories for Conductor 14
3.0 Technical Description of Accessories for GS Earthwire 25
4.0 Type Tests & Standards 29
Annexure-A Type Test Procedures 48
Annexure-B Standard Technical Particulars of Hardware Fittings and 75
Accessories for Conductor & Earthwire
Annexure-C Typical Placement Chart for spacer Damper 129

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.

SECTION-VI A (VOLUME-II), Rev 1 (Oct’2021) Page 1 of 121


STANDARD SPECIFICATION OF TRANSMISSON LINE (SECTION-
HARDWARE FITTINGS & ACCESSORIES FOR CONDUCTOR & EARTHWIRE)

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.

SECTION-VI A (VOLUME-II), Rev 1 (Oct’2021) Page 2 of 121


STANDARD SPECIFICATION OF TRANSMISSON LINE (SECTION-
HARDWARE FITTINGS & ACCESSORIES FOR CONDUCTOR & EARTHWIRE)

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

SECTION-VI A (VOLUME-II), Rev 1 (Oct’2021) Page 3 of 121


STANDARD SPECIFICATION OF TRANSMISSON LINE (SECTION-
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unfavorable loading conditions likely to be experienced as a result of


dimensional tolerances for disc insulators as well as components of hardware
fittings within the specified range. The plates shall have maintenance holes and
suitable holes for fixing corona control rings/ grading ring/ arcing horn. All the
corners and edges should be rounded off with a radius of at least 3 mm. Design
calculations i.e. for bearing & tensile strength, for deciding the dimensions of
yoke plate shall be furnished by the contractor. The holes provided for bolts in
the yoke plate should satisfy shear edge condition as per Clause No. 10.2.4.2
of IS 800.
1.10 Corona Control Rings/ Grading Ring
1.10.1 The Corona control rings/ grading ring shall be provided with hardware fittings
and shall be of such design that it should cover at least one-disc insulator/
equivalent length in insulator strings. It shall also improve corona and radio
interference performance of the complete insulator string along with
hardware fittings.
1.10.2 The corona control rings/ grading ring shall be made of high strength heat
treated aluminium alloy tube of minimum 2.5 mm wall thickness. If mild steel
brackets are used then the brackets shall not be welded to the pipe but shall
be fixed by means of bolts and nuts on a small aluminium plate attachment
welded to the pipe. The welded center of the corona control ring/ grading ring
shall be grinded before buffing. Alternately, Aluminium tube/ flats of suitable
dimensions welded to the corona control rings/ grading rings may be used for
connection to yoke plate.
1.10.3 The Corona control rings/ grading ring should have a smooth finish. No blemish
should be seen or felt when rubbing a hand over the metal.
1.10.4 The limiting dimensions of corona control ring/ grading ring shall be as per the
specification drawings.
1.10.5 The grading ring shall be of open type design with a gap of 125 mm for voltage
up to 765 kV AC lines and 150 mm for +500 kV & +800 kV HVDC lines. The open
ends shall be suitably terminated. The outside diameter of the tube of corona
control rings/ grading ring shall be minimum 75 mm for voltage above 400 kV
and minimum 60 mm for 400 kV and below voltage lines. The ends of grading
ring tube shall be sealed with welded aluminium cap duly buffed.
1.11 Sag Adjustment Plate
1.11.1 The sag-adjustment plate to be provided with the double/ triple/ quadruple/
tension hardware fitting shall be of three plate type. The sag adjustment plate
shall be provided with a safety locking arrangement. The device shall be of such
design that the adjustment is done with ease, speed and safety.

SECTION-VI A (VOLUME-II), Rev 1 (Oct’2021) Page 4 of 121


STANDARD SPECIFICATION OF TRANSMISSON LINE (SECTION-
HARDWARE FITTINGS & ACCESSORIES FOR CONDUCTOR & EARTHWIRE)

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

SECTION-VI A (VOLUME-II), Rev 1 (Oct’2021) Page 5 of 121


STANDARD SPECIFICATION OF TRANSMISSON LINE (SECTION-
HARDWARE FITTINGS & ACCESSORIES FOR CONDUCTOR & EARTHWIRE)

conditions as well as during wind induced conductor vibrations. It shall also


withstand power arcs & have required level of Corona/ RIV performance.
1.13.7 The magnetic power loss shall not be more than that stipulated in the Standard
Technical Particulars.
1.13.8 Free Center Type Suspension Clamp
For the Free Center Suspension Clamp seat shall be smoothly rounded and
curved into a bell mouth at the ends. The lip edges shall have rounded bead.
There shall be at least two U-bolts for tightening of clamp body and keeper
pieces together.
1.13.9 Standard Preformed Armour Rod Set
1.13.9.1 The Preformed Armour Rods Set, suitable for specific Conductor, shall be used
to minimise the stress developed in the sub-conductor due to different static
and dynamic loads because of vibration due to wind, slipping of conductor
from the suspension clamp as a result of unbalanced conductor tension in
adjacent spans and broken wire condition. It shall also withstand power arcs,
chafing and abrasion from suspension clamp and localised heating effect due
to magnetic power losses from suspension clamps as well as resistance losses
of the conductor.
1.13.9.2 The preformed armour rods set shall have right hand lay and the inside
diameter of the helics shall be less than the outside diameter of the conductor
to have gentle but permanent grip on the conductor. The surface of the armour
rod when fitted on the conductor shall be smooth and free from projections,
cuts and abrasions etc.
1.13.9.3 The pitch length of the rods shall be determined by the Contractor but shall be
less than that of the outer layer of conductor and the same shall be accurately
controlled to maintain uniformity and consistently reproducible characteristic
wholly independent of the skill of linemen.
1.13.9.4 The length of each rod along with permissible tolerances shall be as stipulated
in the Standard Technical Particulars. The ends of armour rods should be ball
ended for voltage upto 220kV and parrot billed for voltage above 220kV.
1.13.9.5 The number of armour rods in each set shall as stipulated in the Standard
Technical Particulars. Each rod shall be marked in the middle with paint for
easy application on the line.
1.13.9.6 The armour rod shall not loose their resilience even after five applications.
1.13.9.7 The conductivity of each rod of the set shall not be less than 40% of the
conductivity of the International Annealed Copper Standard (IACS) & Minimum
tensile strength shall not be less than 35kg/mm2.

SECTION-VI A (VOLUME-II), Rev 1 (Oct’2021) Page 6 of 121


STANDARD SPECIFICATION OF TRANSMISSON LINE (SECTION-
HARDWARE FITTINGS & ACCESSORIES FOR CONDUCTOR & EARTHWIRE)

1.13.10 Armour Grip Suspension Clamp


1.13.10.1 The armour grip suspension clamp shall comprise of retaining strap, support
housing, elastomer inserts with aluminium reinforcements and AGS preformed
rod set.

1.13.10.2 Elastomer insert shall be resistant to the effects of temperature up to 95 oC,


Ozone, ultraviolet radiations and other atmospheric contaminants likely to be
encountered in service. The physical properties of the elastomer shall be of
approved standard. It shall be electrically shielded by a cage of AGS performed
rod set. The elastomer insert shall be so designed that the curvature of the AGS
rod shall follow the contour of the neoprene insert.
1.13.10.3 The AGS preformed rod set shall be as detailed in the relevant clause of the
specifications. The length of the AGS preformed rods shall be such that it shall
ensure sufficient slipping strength as specified in the Standard Technical
Particulars and shall not introduce unfavorable stress on the conductor under
all operating conditions. However, the length of AGS preformed rods shall not
be less than that stipulated in the Standard Technical Particulars.
1.14 Envelope Type Suspension Clamp
1.14.1 The seat of the envelope type suspension clamp shall be smoothly rounded &
suitably curved at the ends. The lip edges shall have rounded bead. There shall
be at least two U-bolts for tightening of clamp body and keeper pieces
together. Hexagonal bolts and nuts with split-pins shall be used for attachment
of the clamp.
1.15 Dead end Assembly
1.15.1 The dead-end assembly shall be suitable for specific Conductor.
1.15.2 The dead-end assembly shall be compression type with provision for
comprising jumper terminal at one end. The angle of jumper terminal to be
mounted should be 30° with respect to the vertical line. The area of bearing
surface on all the connections shall be sufficient to ensure positive electrical
and mechanical contact and avoid local heating due to I2R losses. The
resistance of the clamp when compressed on Conductor shall not be more than
75% of the resistance of equivalent length of Conductor.
1.15.3 Die compression areas shall be clearly marked on each dead-end assembly
designed for continuous die compressions and shall bear the words
‘COMPRESS FIRST’ suitably inscribed near the point on each assembly where
the compression begins. If the dead-end assembly is designed for intermittent
die compressions it shall bear identification marks ‘COMPRESSION ZONE’ AND
‘NON-COMPRESSION ZONE’ distinctly with arrow marks showing the direction
of compressions and knurling marks showing the end of the zones. The letters,
number and other markings on the finished clamp shall be distinct and legible.

SECTION-VI A (VOLUME-II), Rev 1 (Oct’2021) Page 7 of 121


STANDARD SPECIFICATION OF TRANSMISSON LINE (SECTION-
HARDWARE FITTINGS & ACCESSORIES FOR CONDUCTOR & EARTHWIRE)

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.

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STANDARD SPECIFICATION OF TRANSMISSON LINE (SECTION-
HARDWARE FITTINGS & ACCESSORIES FOR CONDUCTOR & EARTHWIRE)

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)

Sl. Name of Material Process of Reference


No. item treatment Standard
1 Security Clips Stainless Steel - ASTM A240/
(AISI 304)/ IS-7811
Phosphor
Bronze
2 Arcing Horn Mild Steel Rod/ Hot dip IS 2062
Tubular Type galvanised

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STANDARD SPECIFICATION OF TRANSMISSON LINE (SECTION-
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Sl. Name of Material Process of Reference


No. item treatment Standard
3 Ball Fittings, Class-IV Drop forged & IS 2004/ BS970
Socket, forged steel/ normalized Hot
EN8D/ EN19 dip galvanised
4 Shackles, Class-IV Drop forged & IS 2004
links, clevis forged steel normalized Hot
dip galvanised
5 Yoke Plate, Mild Steel Hot dip IS 2062
Sag galvanized
Adjustment
plate
6(a) Corona High Strength Heat treated IS 733
Control ring/ Al. Alloy tube (for Al)
Grading ring 65032/ 63400
Type)
6(b) Supporting High Strentgth Heat treated IS 733
Brackets & Al Alloy 65032/ (for Al) /
Mounting 63400 Type) or
Bolts
Mild Steel Hot dip IS2062
galvanized
7 Turn Buckle Class-IV forged Forged hot dip IS 2004
steel galvanized
8(a) Free centre High Strength Casted or IS 617/ IS 733
type clamp/ Al. Alloy 4600/ forged & Heat
Envelope 65032 treated
type Clamp:
Clamp Body,
Keeper Piece
8(b) Envelope Stainless Steel Heat treated ASTM A240/
type Clamp: (AISI 304 or (Al Alloy) IS 733
U Bolts High Strength
Al alloy 65032/
63400
9 P. A. rod High strength Al Heat treatment IS 733
alloy type during
65032 manufacturing
10 AGS clamp

(a) High strength Casted or IS 617,


Supporting Al. alloy 4600/ forged & heat IS 733
house 65032 treated.

SECTION-VI A (VOLUME-II), Rev 1 (Oct’2021) Page 10 of 121


STANDARD SPECIFICATION OF TRANSMISSON LINE (SECTION-
HARDWARE FITTINGS & ACCESSORIES FOR CONDUCTOR & EARTHWIRE)

Sl. Name of Material Process of Reference


No. item treatment Standard
(b) Al insert High strength Al Forged and IS 733
and retaining alloy type Heat treated
strap 65032 or
equivalent
(c) Elastomer Neoprene/
cushion Moulded on Al
reinforcement
11(a) Dead End Aluminium IS 733
Assembly: Alloy 19500
Outer Sleeve
11(b) Steel Sleeve Forged Steel Hot Dip IS 2004
Class II Galvanised
Mild Steel IS 2062
12 Balancing Mild Steel/ Cast Hot dip IS 210/
weights iron MCI galvanised IS 2062

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.

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STANDARD SPECIFICATION OF TRANSMISSON LINE (SECTION-
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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

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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.

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2.0 Accessories for Conductor


2.1 General
2.1.1 This portion (under clause 2.0) details the technical particulars of the
accessories for Conductor.
2.1.2 For owner supplied accessories, 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 accessories included in the scope of the Contractor, Supplier is permitted
to get inspected and supply upto 2.5% extra fasteners and retaining rods to
take care of losses during erection. No payment shall be admissible for these
extra supplies.
2.2 Mid Span Compression Joint
2.2.1 Mid Span Compression Joint shall be used for joining two lengths of conductor.
The resistance of the joint when compressed on Conductor shall not be more
than 75% of the resistance of equivalent length of Conductor. The joint shall
not permit slipping off, 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.
2.2.2 The joint shall be made of steel and aluminium sleeves for jointing the steel
core and aluminium wires respectively. The steel sleeve should not crack or fail
during compression. The steel sleeve shall be hot dip galvanised. The
aluminium sleeve shall have aluminium of purity not less than 99.5%. The
dimensions and dimensional tolerances of mid span compression joint shall be
as per Standard Technical Particulars.
2.3 T-Connector
T-Connector of compression type shall be used for jumper connection at
transposition tower. It shall be manufactured out of 99.5% pure aluminium and
shall be strong enough to withstand normal working loads. The T-connector
shall comprise of two pieces with a provision of seat for sliding of the keeper
piece. The edges of the seat as well as the keeper piece shall be so rounded
that the conductor strands are not damaged during installation. The resistance
of the connector when compressed on Conductor shall not be more than 75%
of the resistance of equivalent length of Conductor. The T-connector shall not
permit slipping off, damage to or failure of complete conductor. The welded
portions shall be designed for 30 kN axial tensile load. Leg sleeve of T-
connector should be kept at an angle of 15 deg. from vertical and horizontal
plane of the conductor in order to minimise jumper pull at the welded portion.
The dimensions and dimensional tolerances of T-connector shall be as per
Standard Technical Particulars.

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2.4 Repair Sleeve


Repair Sleeve of compression type shall be used to repair conductor with not
more than two strands broken in the outer layer. The sleeve shall be
manufactured from 99.5% pure aluminium and shall have a smooth surface.
The repair sleeve shall comprise of two pieces with a provision of seat for
sliding of the keeper piece. The edges of the seat as well as the keeper piece
shall be so rounded that the conductor strands are not damaged during
installation. The dimensions and dimensional tolerances of repair sleeve shall
be as per Standard Technical Particulars.
2.5 Vibration Damper
2.5.1 Vibration dampers of 4R-stockbridge type with four (4) different resonances
spread within the specified Aeolian frequency band width corresponding to
wind speed of 1 m/s to 7 m/s shall be used at suspension and tension points
on each conductor in each span along with bundle spacers to damp out Aeolian
vibration as mentioned hereinafter.
2.5.2 Alternate damping systems or “Dogbone” dampers offering equivalent or
better performance also shall be accepted 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 Bidder along with the bid.
2.5.3 One damper minimum on each side per Conductor/Sub-conductor for
suspension points and two dampers minimum on each side per conductor/sub-
conductor for tension points shall be used for ruling design span as given in
relevant clause of section–I.
2.5.4 In case more dampers are recommended by the supplier, the payment shall be
restricted to the number of dampers indicated above.
2.5.5 The clamp of the vibration damper shall be made of high strength aluminium
alloy of grade 4600 as per IS 617. It shall be capable of supporting the damper
and prevent damage or chafing of the conductor during erection or continued
operation. The clamp shall have smooth and permanent grip to keep the
damper in position on the conductor without damaging the strands or causing
premature fatigue failure of the conductor under the clamp. The clamp groove
shall be in uniform contact with the conductor 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 other materials which could
cause damage to the conductor when the clamp is installed. Clamping bolts
shall be provided with self-locking nuts and designed to prevent corrosion of
threads or loosening in service.
2.5.6 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

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post formed quality in order to prevent subsequent drop of weight 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 other than
stainless steel shall be hot dip galvanised in accordance with the
recommendations of IS 4826 for heavily coated wires.
2.5.7 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, shrinkage, inclusions and blowholes etc. The surface of the damper
masses shall be smooth.
2.5.8 The damper clamp shall be casted over the messenger cable and offer
sufficient and permanent grip on it. The messenger cable shall not slip out of
the grip at a load less than the mass pull-off value of the damper. The damper
masses made of material other-than zinc alloy shall be fixed to the messenger
cable in a suitable manner in order to avoid excessive stress concentration on
the messenger cables which shall cause premature fatigue failure of the same.
The messenger cable ends shall be suitably and effectively sealed to prevent
corrosion. The damper mass made of zinc alloy shall be casted over the
messenger cable and have sufficient and permanent grip on the messenger
cable under all service conditions.
2.5.9 The damper assembly shall be so designed that it shall not introduce radio
interference beyond acceptable limits.
2.5.10 The vibration damper shall be capable of being installed and removed from
energised line by means of hot line technique. In addition, the clamp shall be
capable of being removed and reinstalled on the conductor at the designated
torque without shearing or damaging of fasteners.
2.5.11 The supplier 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.
2.5.12 The vibration damper shall not have magnetic power loss more than that
stipulated in the Standard Technical Particulars.
2.5.13 The vibration analysis of the system, with and without damper and dynamic
characteristics of the damper as detailed under Annexure-A, shall have to be
submitted. The technical particulars for vibration analysis and damping design
of the system are as follows:

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Sl. No. Description Technical particulars


1. Span length
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. Conductor/ sub-conductor 25% of UTS of conductor
tension
4. Armour rods used Standard preformed armour
rods/ AGS
5. Maximum permissible +/- 150 micro strains
dynamic strain

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

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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.

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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.

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The test line selected for the performance evaluation shall have been designed
for that purpose, be adequately exposed to wind and properly instrumented.

Sl. Description Technical Particulars


1 Configuration Refer to Section-I for configuration of lines
& mechanical properties of the conductor
1. Span length
i) Ruling design span As given in section-I
ii) Maximum span 1100 meters
iii) Minimum span 100 meters
3 Tension in each sub- 25% of UTS of Conductor
conductor
4 Armour rods used Yes
5 Maximum ± 150 micro strains
permissible dynamic
strains

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.

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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.

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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.

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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.

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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

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equipment is designed for intermittent die compressions, it shall bear the


identification marks ‘COMPRESSION ZONE’ and ‘NON-COMPRESSION ZONE’
distinctly with arrow marks showing the direction of compression and knurling
marks showing the end of the zones. The letters, number and other markings
on finished equipment shall be distinct and legible.
2.9 Drawings
2.9.1 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
2.9.2 The Contractor shall furnish detailed dimensioned drawings of the equipment
and all component parts. Each drawing shall be identified by a drawing
number. All drawings shall be neatly arranged. All drafting and lettering shall
be legible. The minimum size of lettering shall be 3 mm. All dimensions and
dimensional tolerances shall be mentioned in mm.
2.9.3 The drawings shall include: -
i. Dimensions and dimensional tolerances
ii. Material. fabrication details including any weld details and any
specified finishes and coatings. Regarding material, designations and
reference of standards are to be indicated.
iii. Marking
iv. Weight of assembly
v. Installation instructions, if any
vi. Design installation torque for the bolt or cap screw
vii. The compression die number with recommended compression
pressure.
viii. All other relevant technical details
3.0 G.S. Earth wire Accessories
3.1 General
3.1.1 This portion specifies the details of the technical particulars of the accessories
for Galvanised Steel Earth wire.
3.1.2 For owner supplied accessories, 2.5 % extra fasteners (excluding factory fitted
fasteners) & retaining rods shall be provided to the Contractor to take care of

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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

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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.

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(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/ trunion type etc.)
(4) The influence of mid span compression joints in the placement of
dampers.
3.4 Flexible Aluminium Bond
The flexible aluminium bond shall be manufactured from multi strand multi
wire fatigue resistant Aluminium alloy, conforming to IS 398 (Part 4) with a
minimum cross-sectional area of 95 sq.mm and not less than 750 mm in length.
The bond shall be flexible so as not to interfere with the clamp movement,
shall be terminated with compressed lugs. One lug shall be suitable for 12 mm
dia. bolt and the other for 16 mm dia bolt. The complete assembly shall also
include one 16 mm dia., 40 mm long HRH (Hex Round Hex) MS Bolt hot dip
galvanised with nut and lock washer.
3.5 Suspension Clamp
3.5.1 Standard anchor shackle/ twisted shackle for earth wire suspension clamp shall
be supplied for attaching to the hanger plate of tower.
3.5.2 At all suspension towers, suitable suspension clamps shall be used to support
the required earth wire. The clamps shall be of either free center type or
trunnion type and shall provide adequate area of support to the earth wire.
The groove of the clamp shall be smooth, finished in a uniform circular or oval
shape and shall slope downwards in a smooth curve to avoid edge support and
hence to reduce the intensity of bending moment on earth wire.
3.5.3 There shall be no sharp point in the clamps coming in contact with earth wire.
There shall not be any displacement in the configuration of the earth wire
strands nor shall the strands be unduly stressed in final assembly during
working conditions.
3.5.4 The clamping piece and the clamp body shall be clamped by at least two U-
bolts of size not less than 10 mm diameter having one nut and one 3 mm thick
lock nut with washer on each of its limbs. Suspension clamps shall be provided
with inverted type U-bolts. One limb of the U-bolt shall be long enough to
accommodate the lug of the flexible Aluminium bond.
3.5.5 The Contractor shall supply all the components of the suspension assembly
including shackles, bolts, nuts, washers, split pin etc. The total drop of the
suspension assembly from the center point of the attachment to the center
point of the earth wire shall not exceed 150 mm. The design of the assembly

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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

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a) Power frequency voltage withstand test


with corona control rings/ grading ring
As per IEC 60383/
and arcing horns under wet condition
IEC60060-1
(for AC transmission line & DMR for
HVDC line only)
b) DC voltage withstand test without
corona control rings/ grading ring and
Annexure-A
arcing horns under wet condition
(for DC transmission line only)
c) Switching surge voltage withstand test
under wet condition
As per IEC 60383
(for 400 kV & above voltage level line
only)
d) Impulse voltage withstand test under
As per IEC 60383
dry condition
e) Voltage distribution test
Annexure-A
(for Disc Insulator string only)
f) Corona and RIV test under dry condition
(for 400 kV & above voltage level line Annexure-A
only)
g) Mechanical Strength test Annexure-A
h) Vibration test Annexure-A

Note: Applicability of above type tests on hardware fittings covered under


BPS shall be as follows: -
a) 765 kV double circuit transmission line with Hex ZEBRA conductor

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)

b) 765 kV single circuit transmission line with Quad BERSIMIS conductor

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

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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)

c) 400 kV transmission line with quad MOOSE conductor

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)

d) 400 kV transmission line with triple SNOWBIRD conductor

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)

e) 400 kV transmission line with twin LAPWING/ MOOSE conductor

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)

f) 220 kV transmission line with single ZEBRA conductor

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

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g) 220 kV transmission line with twin MOOSE conductor

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)

h) 132 kV transmission line with single PANTHER/ ZEBRA conductor

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) +500 kV HVDC transmission line with quad BERSIMIS/ LAPWING


conductor

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)

j) +800 kV HVDC transmission line with hexa LAPWING conductor

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)

k) +800 kV HVDC transmission line (DMR)

i) Single ‘I’ suspension All type test as per clause no. 4.1.1
ii) Double tension except c) & f)

4.1.2 On Suspension Hardware Fittings only


a) Visual Examination IS 2486 (Part-I)
b) Verification of Dimensions IS 2486 (Part-I)
c) Chemical Analysis of Materials Annexure-A
d) Magnetic power loss test for suspension Annexure-A
assembly (for AC line only), if applicable
e) Slip Strength test on clamp Annexure-A

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f) Mechanical Strength test on Suspension Annexure-A


hardware fitting except clamp
g) Vertical damage load & Failure load test IEC 61284
on suspension clamp
h) OZONE resistance Test on elastomer IEC 61854, Clause
7.6.3
i) Galvanising/ electroplating tests Annexure-A

4.1.3 On Tension Hardware fittings only


a) Visual Examination IS 2486 (Part-I)
b) Verification of Dimensions IS 2486 (Part-I)
c) Chemical Analysis of Materials Annexure-A
d) Electrical resistance test for dead end IS 2486-(Part-I)
assembly
e) Heating cycle test for dead end Assembly IS 2486 (Part-I)
f) Mechanical strength test on hardware Annexure-A
fitting except clamps
g) Slip strength test for dead end assembly Annexure-A
h) Galvanising/ electroplating tests Annexure-A

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

4.1.5 T-Connector for Conductor


a) Visual Examination IS 2121(Part-IV)
b) Verification of Dimensions IS 2121(Part-IV)

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c) Chemical Analysis of Materials Annexure-A


d) Electrical resistance test IS 2121(Part-II)
e) Heating cycle test IS 2121 (Part-IV)
f) Tensile test IEC 61284; Clause 11.6.2
g) Axial tensile load test on welded Annexure-A
portion
h) Corona extinction voltage test (dry) Annexure-A
(for 400 kV & above voltage level
line only)
i) Radio interference voltage test Annexure-A
(dry) (for 400 kV & above voltage
level line only)
i) Galvanising test Annexure-A

4.1.6 Repair Sleeve for Conductor


a) Visual Examination IS 2121(Part-II)
b) Dimensional Verification IS 2121(Part-II)
c) Chemical Analysis of Materials Annexure-A
d) Failing load test Annexure-A
e) Corona extinction voltage test (dry) Annexure-A
(for 400 kV & above voltage level line
only)
f) Radio interference voltage test (dry) Annexure–A
(for 400 kV & above voltage level line
only)

4.1.7 Flexible Aluminium Bond


a) Visual Examination IS 2121(Part-III)
b) Dimensional Verification IS 2121(Part-III)
c) Chemical Analysis of Materials Annexure-A
d) Slip Strength Test Annexure–A
e) Galvanising test Annexure–A

4.1.8 Vibration Damper for Conductor and Earth wire


a) Visual Examination IS 9708
b) Verification of Dimensions IS 9708
c) Chemical Analysis of Materials Annexure–A
d) Resonance frequency test IS 9708
e) Dynamic characteristics test Annexure–A
f) Vibration analysis Annexure–A

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g) Clamp slip test Annexure-A


h) Clamp bolt torque test IS 9708
i) Fatigue test Annexure-A
j) Mass pull off test IS 9708
k) Attachment of clamp to messenger IEC 61897, Clause 7.9
cable
l) Damping efficiency test IS 9708
m) Magnetic power loss test (for AC line Annexure-A
only), if applicable
n) Corona extinction voltage test (dry) Annexure-A
(for 400 kV & above voltage level line
only)
o) Radio interference voltage test (dry) Annexure-A
((for 400 kV & above voltage level line
only)
p) Galvanising/Electroplating test Annexure-A
NOTE: ‘Magnetic Power Loss, ‘Corona extinction voltage’, ‘Radio
interference voltage’ tests are not applicable to Vibration damper for
Earthwire

4.1.9 Spacer Damper


(a) Visual examination & verification of IEC:61854; Clause 7.1 &
dimension, materials and mass 7.2
(b) Clamp slip test Annexure-A
(c) Performance Test*
(i) Aeolian Annexure-A
(ii) Sub span Oscillation Annexure-A
(d) Magnetic power loss test (if applicable) Annexure-A
(e) Characteristics of the Elastic & damping Annexure-A
Properties
(f) Fatigue (sub – oscillation) test IEC 61854; Clause 7.5.7.2
(g) Corona extinction voltage test (dry) Annexure-A
(h) Radio interference voltage test (dry) Annexure-A
(i) Compression & Tension test Annexure-A
(j) Ozone Resistance test on Elastomer IEC 61854; Clause 7.6.3

4.1.10 Bundle Spacer/Rigid Spacer

(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

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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.

4.1.11 Earth wire Suspension Clamp Assembly


a) Visual Examination IS 2121(Part-III)
b) Dimensional Verification IS 2121(Part-III)
c) Chemical Analysis of Materials Annexure-A
d) Mechanical Strength test Annexure-A
e) Slip strength test for suspension Annexure-A
clamp
f) Galvanising test Annexure–A

4.1.12 Earth wire Tension Clamp Assembly


a) Visual Examination IS 2121(Part-III)
b) Dimensional Verification IS 2121(Part-III)
c) Chemical Analysis of Materials Annexure-A
d) Mechanical Strength test (excluding Annexure-A
clamp)
e) Slip strength test for dead-end Annexure–A
clamp
f) Electrical Resistance test IS 2121 (Part-III)
g) Galvanising test Annexure–A

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

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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)

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b) Verification of Dimensions IS 2486 (Part-I)


c) Galvanising/Electroplating test Annexure-A
d) Mechanical strength test of each Annexure-A
component (excluding corona control
rings gradingring and arcing horn)
e) Mechanical Strength test of welded joint Annexure-A
f) Mechanical strength test for corona BS 3288 (Part-I), Clause
control rings/ grading ring and arcing 7.3.2
horn
g) Test on locking device for ball and socket IS 2486 (Part-IV)
coupling
h) Chemical analysis, hardness tests, grain Annexure-A
size, inclusion rating & magnetic particle
inspection for forgings/castings

4.2.2 On Suspension Hardware Fitting only


a) Clamp Slip strength test
b) Shore hardness test of elastomer Annexure-A
cushion for AG suspension clamp
c) Bend test for armour rod set IS 2121 (Part-I), Clause
7.10
d) Resilience test for armour rod set Annexure-A
e) Electrical Resistance test for armour Annexure-A
rods set

4.2.3 On Tension Hardware Fittings Only

(a) Slip strength test for dead end Annexure-A


assembly

4.2.4 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) Galvanising test Annexure-A
e) Failing load test Annexure-A
f) Hardness test Annexure-A

4.2.5 T-Connector for Conductor


a) Visual Examination IS 2121(Part-IV)
b) Verification of Dimensions IS 2121(Part-IV)
c) Chemical Analysis of Materials Annexure-A

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d) Axial tensile load test for welded Annexure-A


portion
e) Tensile test IEC 61284; Clause 11.6.2
f) Galvanising test Annexure-A

4.2.6 Repair Sleeve for Conductor


a) Visual Examination IS 2121(Part-II)
b) Dimensional Verification IS 2121(Part-II)
c) Chemical Analysis of Materials Annexure-A
d) Failing load test Annexure-A

4.2.7 Flexible Aluminium Bond


a) Visual Examination IS 2121(Part-III)
b) Dimensional Verification IS 2121(Part-III)
c) Chemical Analysis of Materials Annexure-A
d) Slip Strength Test Annexure-A

4.2.8 Vibration Damper for Conductor and Earthwire


a) Visual Examination IS 9708
b) Verification of Dimensions IS 9708
c) Chemical Analysis of Materials Annexure-A
d) Galvanising/ Electroplating test Annexure-A
e) Clamp slip test Annexure-A
f) Clamp bolt torque test IS 9708
g) Resonance frequency test IS 9708
h) Strength of messenger cable Annexure-A
i) Dynamic characteristics test Annexure-A
j) Mass pull off test IS 9708
k) Attachment of clamp to messenger IEC 61897, Clause 7.9
cable

4.2.9 Spacer Damper/ Bundle Spacer/ Rigid Spacer

(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

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(g) Assembly torque test Annexure–A


(h) Characteristics of the Elastic & damping Annexure-A
Properties
(i) Hardness test for elastomer (if Annexure–A
applicable)
(j) UTS of retaining rods (if applicable) Annexure–A

4.2.10 Earth wire Suspension Clamp Assembly


a) Visual Examination IS 2121(Part-III)
b) Dimensional Verification IS 2121(Part-III)
c) Chemical Analysis of Materials Annexure-A
d) Galvanising test Annexure–A
e) Mechanical Strength Test Annexure-A
f) Slip strength test for suspension Annexure-A
clamp

4.2.11 Earth wire Tension Clamp Assembly


a) Visual Examination IS 2121(Part-III)
b) Dimensional Verification IS 2121(Part-III)
c) Chemical Analysis of Materials Annexure-A
d) Galvanising test Annexure–A
e) Mechanical Strength test Annexure-A
(excluding clamp)
f) Slip strength test for dead-end Annexure-A
clamp

4.3 Routine Tests


4.3.1 For Hardware Fittings
a) Visual examination IS 2486-(Part-I)
b) Proof Load Test Annexure-A

4.3.2 For conductor and earthwire accessories

a) Visual examination IS 2121(Part-II/ III/ IV, as


applicable)
b) Dimensional verification IS 2121(Part-II/ III/ IV, as
applicable)

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4.4 Tests During Manufacture


on all components as applicable

a) Chemical analysis of Zinc used for IS 2486 (Part I)


galvanising
b) Chemical analysis, mechanical Annexure-A
metallographic test and magnetic
particle inspection for malleable
castings
c) Chemical analysis, hardness tests Annexure-A
and magnetic particle inspection
for forging

4.5 Testing Expenses


4.5.1 In the event of type testing, bidders shall indicate the laboratories in which
they propose to conduct the type tests. They shall ensure that the tests can be
completed in these laboratories within the time schedule
4.5.2 In case of failure in any type test, the supplier is either required to modify the
design of the material & successfully carryout all the type tests as has been
detailed out in Clause 4.1 of this specification or to repeat that particular type
test at least three times successfully at his own expenses.
4.5.3 In case of type test on the complete insulator string, the Contractor has to
arrange similar insulators at his own cost.
4.5.4 Bidder shall indicate the laboratories in which they propose to conduct the
type tests. They shall ensure that adequate facilities for conducting the tests
are available in the laboratory and the tests can be completed in these
laboratories within the time schedule guaranteed by them in the appropriate
schedule.
4.5.5 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/ CIF Price.
4.5.6 In case of failure in any type test, repeat type tests are required to be
conducted, then, all the expenses for deputation of Inspector/Employer's
representative shall be deducted from the contract price. Also, if on receipt of
the Contractor's notice of testing, the Employer's representative/Inspector
does not find 'plant' to be ready for testing the expenses incurred by the
Employer for re-deputation shall be deducted from contract price.
4.5.7 The Contractor shall intimate the Employer about carrying out of the type tests
along with detailed testing programme at least 3 weeks in advance (in case of
Domestic Contractor and at least 6 weeks advance in case of Foreign

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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.

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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.

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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

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4 IS 398 (Part-5) Aluminium Conductor for


overhead transmission purpose-
Specification: Aluminium
Conductor, Galvanised Steel-
Reinforced for Extra High voltage
(400 kV and above)
5 IS 398 (Part-6) Aluminium Conductor for
Overhead Transmission Purpose:
High Conductivity Aluminium Alloy
Stranded Conductors-
Specification
3 IS 1573 Electroplated Coating of Zinc on
iron and Steel
4 IS 2121 (Part-I) Specification for Conductor and
Earthwire Accessories for
Overhead Power lines: Armour
Rods, Binding wires & Tapes for
Conductors
5 IS 2121 (Part-II) Specification for Conductor and
Earthwire Accessories for
Overhead Power lines: Mid-span
Joints and Repair Sleeves for
Conductors
6 IS 2121 (Part 3) Conductors and Earthwire
Accessories for Overhead Lines:
Accessories for Earthwire:
Accessories for Earhwire-
Specification
7 IS 2121 (Part 4) Conductors and Earthwire
Accessories for Overhead Lines:
Non-Tension Joints-Specification
8 IS 2486 (Part-I) Metal Fittings of Insulators for
Overhead power Lines with
Nominal Voltage greater than
1000 V: General Requirements
and Tests
9 IS 2486 (Part-II) Insulator Fittings for Overhead
Power Lines with Nominal Voltage
greater than 1000 V-Specification:
Dimensional Requirements
10 IS 2486 (Part Specification for Insulator Fittings
III) for Overhead Power Lines with a
Nominal Voltage greater than
1000 volts: Locking Devices

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STANDARD SPECIFICATION OF TRANSMISSON LINE (SECTION-
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11 IS 2486 (Part Specification for Insulator Fittings


IV) for Overhead Power Lines with a
Nominal Voltage greater than
1000V: Tests for Locking Devices
12 IS 2629 Recommended Practice for Hot
Dip Galvanizing of Iron and Steel
13 IS 2633 Method of Testing Uniformity of
Coating on Zinc Coated Articles
14 IS 4826 Galvanised Coating on Round Steel
Wires
15 IS 6745 Methods of Determination of
Weight of Zinc Coating of Zinc
Coated Iron and Steel Articles
16 IS 6639 Hexagonal Bolts for Steel
Structures
17 IS 9708 Specification for Stock Bridge
Vibration Dampers for Overhead
Power Lines
18 IS 10162 Specification for Spacers Dampers
for Twin Horizontal Bundle
Conductors
19 IS 8263 Method of Radio Interference
Tests on High Voltage Insulators
20 Ozone test on Elastomer IEC 61284
21 Tests on insulators of Ceramic IEC 383-1993
material or glass for overhead
lines with a nominal voltage
greater than 1000V

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The standards mentioned above are available from:


Reference Abbreviation Name and Address

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.

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Annexure–A

1.0 Tests on Complete Strings with Hardware Fittings


1.1 D.C Voltage Withstand test (Wet)

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.

1.2 Voltage Distribution Test


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 as per table given below for different
transmission line configuration: -
Transmission line configuration Suspension string Tension string
765 kV line 6.5% 6.5%
400 kV line 9% 10%
220 kV line 13% 14%
132 kV line 20% 20%

1.3 Corona Extinction Voltage Test (Dry)


The sample assembly consisting of complete insulator string when subjected
to power frequency (for ac line) / DC voltage (for dc line) shall have a corona
extinction voltage of not less than the requirement stipulated in the table
below: -
Voltage Level Maximum Height of the Minimum Corona
conductor above ground (m) extinction voltage (kV)
400 kV 8.84 320 (305 for RIV test)
765 kV 15 510
+500kV HVDC Such that voltage gradient is 550
not less than 22 kV/cm
+800kV HVDC Such that voltage gradient is 880
not less than 22 kV/cm
There shall be no evidence of corona on any part of the sample. The test shall
be carried out as per IEC 61284. The atmospheric condition during testing shall
be recorded and the test results shall be accordingly corrected with suitable
correction factor as stipulated in IEC: 60383.

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1.4 Radio Interference Voltage Test (Dry)


Under the conditions as specified under (1.2) above, the insulator string along
with complete hardware fittings shall have a radio interference voltage level
below 1000 micro volts at one MHz. The test procedure shall be in accordance
with IS 8263.
1.5 Mechanical Strength Test
The complete insulator string along with its hardware fitting excluding arcing
horn, corona control ring, grading ring and suspension assembly/ dead end
assembly shall be loaded to reproduce design conditions. The testing
programme varies with string and tower types according to following table:

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

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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

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400kV (TWIN LAPWING)

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

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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

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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

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Triple Tension String for 1260 1 1 2


Pole conductor F***** 1 - 3
108 1 5 1
Single I Pilot String for 160 1 1 2
Pole conductor (160kN) F***** 1 - 3
108 1 5 1
Single I Suspension for 160 1 1 2
DMR (160kN) F***** 1 - 3
141 1 5 1
Single I Suspension for 210 1 1 2
DMR (210kN) F***** 1 - 3
281 1 5 1
Double Tension String 420 1 1 2
for DMR (2x210kN) 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.
3. Following with respect to vertical, half the string angle, along the axis of one
of the arm of the V-string
4. Following with respect to vertical, half the string angle +15 deg, along the
axis of one of the arm of the V-string
*** The insulator string 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 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

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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

2.2 Slip Strength Test for Suspension Clamp


The Clamp slip strength test shall be carried out as per Clause no. 11.1.1 of IS
2486 (Part-1) by keeping the clamp at minimum specified slip strength for one
minute and considering slip strength as specified in the Standard Technical
Particular (STP).
2.3 Mechanical Strength Test for Suspension/Tension Hardware Fittings except
clamp
The complete string excluding insulator, arcing horn, corona control ring,
grading ring and suspension assembly/ dead end assembly shall be loaded to

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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

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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

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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

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+/-500kV HVDC (QUAD LAPWING)


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
616 1 1 1
Quadruple Tension
920 1 1 2
(4X210 kN)
F**** 1 - 3
765kV S/C (QUAD BERSIMIS)
181 1 1 1
Double I
270 1 1 2
(2X160kN)
F**** 1 1 3
188 2 1 1
Single V
280 2 1 2
(2X210kN)
F**** 2 _ 3
332 2 1 1
Double V
495 2 1 2
(2X2X210kN)
F**** 2 _ 3
80 1 1 1
Single Tension
120 1 1 2
(120kN)
F**** 1 - 3
616 1 1 1
Quadruple Tension
920 1 1 2
(4X210kN)
F**** 1 - 3
80 1 1 1
Single I Pilot (120kN) 120 1 1 2
F**** 1 _ 3
140 2 1 1
Single V Pilot
208 2 1 2
(2X120kN)
F**** 2 _ 3
765kV D/C (HEXA ZEBRA)
235 1 1 1
Double I Suspension
350 1 1 2
(2X160kN)
F**** 1 - 3
107 1 1 1

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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
616 1 1 1
Quad Tension
920 1 1 2
(4X210kN)
F**** 1 - 3
±800kV HVDC (HEXA LAPWING)
Single ‘Y’ suspension 340 2 1 1
String for Pole 505 2 1 2
conductor F***** 2 - 3
884 1 1 1
Triple Tension String for 1320 1 1 2
Pole conductor F***** 1 - 3
108 1 1 1
Single I Pilot String for 160 1 1 2
Pole conductor (160kN) F***** 1 - 3
108 1 1 1
Single I Suspension for 160 1 1 2
DMR (160kN) F***** 1 - 3
141 1 1 1
Single I Suspension for 210 1 1 2
DMR (210kN) F***** 1 - 3
281 1 1 1
Double Tension String 420 1 1 2
for DMR (2x210kN) 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

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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.

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2.10 Mechanical Strength Test of Each Component (Acceptance Test)


Each component shall be subjected to a load equal to 50 % 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. The component shall then again be loaded to 50%
of UTS and the load shall be further increased at a steady rate till the specified
UTS and held for one minute. No fracture should occur. The applied load shall
then be increased until the failing load is reached and the value recorded.
2.11 Resilience test for armour rod set
The test shall be carried out as per Clause no. 7.11 of IS 2121 (Part-1) except
slip strength after resilience shall be carried out as per clause 2.2 above.
2.12 Electrical resistance test for armour rod set
The test shall be carried out as per Clause no. 7.5 of IS 2121 (Part-1) except the
conductivity of the armour rods shall be as specified in the STP.
3.0 Tests on Conductor and Earth wire Accessories

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

a) Axial Tensile Load Test for Welded Portion

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The sleeve portion of the T-Connector shall be compressed on conductor. The


compressed portion shall be held rigidly on some fixtures and axial load shall
be applied along with the jumper terminal The load shall be increased
gradually till breaking of welded joint occurs. The breaking load should be
above the value indicated in the Standard Technical Particulars.

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

(a) Dynamic Characteristics Test (As Type test)


The damper shall be mounted with its clamp tightened with torque
recommended by the manufacturer on shaker table capable of simulating
sinusoidal vibrations for aeolian vibration frequency band range from
0.18/d to 1.4/d, where d is the conductor/ Earthwire diameter in meters.
The damper assembly shall be vibrated vertically with a + 1 mm amplitude
upto 15 Hz frequency and beyond 15 Hz at ± 0.5mm to determine following
characteristics with the help of suitable recording instruments:
(i) Force Vs frequency
(ii) Phase angle Vs frequency
(iii) Power dissipation Vs frequency
The Force Vs frequency curve shall not show steep peaks at resonance
frequencies and deep troughs between the resonance frequencies. The
resonance frequencies shall be suitably spread within the aeolian vibration
frequency-band between the lower and upper dangerous frequency, limits
determined by the vibration analysis of conductor/earth wire without
dampers.

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Acceptance criteria for vibration damper.


(i) The above dynamic characteristics test on five dampers shall be conducted.
(ii) The mean reactance and phase angle Vs frequency curves shall be drawn
with the criteria of best fit method.
(iii) The above mean reactance response curve should lie within following limits:
Conductor name Range of mean reactance
ACSR LAPWING 0.227 f to 0.908 f
ACSR MOOSE 0.191 f to 0.762 f
ACSR ZEBRA 0.135 f to 0.540 f
ACSR PANTHER 0.0991 f to 0.495 f
7/3.66 mm GS EARTHWIRE 0.060 f to 0.357 f
7/3.15 mm GS EARTHWIRE 0.050 f to 0.300 f
7/4.5 mm GS EARTHWIRE 0.084 f to 0.504 f
(iv) The above mean phase angle response curve shall be between 25 o to 130o
within the frequency range of interest.
(v) If the above curve lies within the envelope, the damper design shall be
considered to have successfully met the requirement.
(vi) Visual resonance frequencies of each mass of damper is to be recorded and
to be compared with the guaranteed values.
(b) Vibration Analysis
The vibration analysis of the conductor/earthwire shall be done with and
without damper installed on the span. The vibration analysis shall be done
on a digital computer using energy balance approach. The following
parameters shall be taken into account for the purpose of analysis:
(i) The analysis shall be borne for single conductor/earthwire without armour
rods as per the parameters given under clause 2.5.13 and 3.3.8 of this part
of the Specification. The tension shall be taken as 25% of RTS of conductor/
earth wire for a span ranging from 100 m to 1100 m.
(ii) The self damping factor and flexural stiffness (El) for conductor and
earthwire shall be calculated on the basis of experimental results. The
details of experimental analysis with these data should be furnished.
(iii) The power dissipation curve obtained from Damper Characteristics Test
shall be used for analysis with damper.
(iv) Examine the aeolian vibration level of the conductor/earthwire with and
without vibration damper installed at the recommended location or wind
velocity ranging from 0 to 30 Km per hour, predicting amplitude, frequency
and vibration energy input.

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(v) From vibration analysis of conductor/earthwire without


damper, antinode vibration amplitude and dynamic strain levels at clamped
span extremities as well as antinodes shall be examined and thus lower and
upper dangerous frequency limits between which the aeolian vibration
levels exceed the specified limits shall be determined.
(vi) From vibration analysis of conductor/earthwire with damper/dampers
installed at the recommended location, the dynamic strain level, at the
clamped span extremities, damper attachment points and the antinodes on
the conductor/earthwire shall be determined. In addition to above damper
clamp vibration amplitude and antinode vibration amplitudes shall also be
examined.
The dynamic strain levels at damper attachment points, clamped span
extremities and antinodes shall not exceed the specified limits. The damper
vibration amplitude shall not be more than that of the specified fatigue
limits.
c) Clamp Slip and Fatigue Tests
(i) Test Set Up
The fatigue tests shall be conducted on a laboratory set up with a minimum
effective span length of 30 m. The conductor/earthwire shall be tensioned
at 25% of RTS of conductor/earthwire and shall not be equipped with
protective armour rods at any point. Constant tension shall be maintained
within the span by means of lever arm arrangement. After the
conductor/earthwire has been tensioned, clamps shall be installed to
support the conductor/earthwire at both ends and thus influence of
connecting hardware fittings are eliminated from the free span. The clamps
shall not be used for holding the tension on the conductor/earthwire. There
shall be no loose parts, such as suspension clamps, U bolts on the test span
supported between clamps mentioned above. The span shall be equipped
with vibration inducing equipment suitable for producing steady standing
vibration. The inducing equipment shall have facilities for stepless speed
control as well as stepless amplitude arrangement. Equipment shall be
available for measuring the frequency, cumulative number of cycles and
amplitude of vibration at any point along the span.
(ii) Clamp Slip test
The test shall be carried out as per Clause 7.9 of IS-9708. Further, the load
at which the clamp slips shall not be more than 5 kN.
(iii) Fatigue Test
The vibration damper shall be installed on the test span with the
manufacturer’s specified tightening torque. It shall be ensured that the

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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

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fittings assembled on the conductor. The reading of the wattmeter with


and without five units shall be recorded and tabulated graphical form.
The test is passed if the average power loss for vibration damper 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/ Lapwing 400 amps to 800 amps

e) Galvanising/ Electroplating test on Vibration damper


The test shall be carried out as per Clause no. 7.11 of IS: 9708 except that standard
preece test shall also be carried out and the results obtained shall satisfy the
requirements of this specification.
f) Dynamic Characteristics Test (Acceptance Test)
The test will be performed as acceptance test with the procedure
mentioned for type test with sampling mentioned below
Vibration Damper of - 1 Sample for 1000 Nos. & below
Conductor
- 3 Samples for lot above 1 000 &
up to 5000 nos.
- Additional 1 sample for every
additional 1500 pieces above
5000.
The acceptance criteria will be as follows
(i) The above dynamic characteristics curve for reactance & phase
angle will be done for frequency range of ranging from 0.18/d
to 1.4/d-where d is the conductor diameter in meters. The
damper assembly shall be vibrated vertically with a + 1 mm
amplitude upto 15 Hz frequency and beyond 15 Hz at ± 0.5mm
(ii) If all the individual curve for dampers are within the envelope
as already mentioned for type test for reactance & phase angle,
the lot passes the test.
(iii) If individual results do not fall within the envelope, averaging of
characteristics shall be done.

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(a) Force of each damper corresponding to particular frequency


shall be taken & average force of three dampers at the
frequency calculated.
(b) Similar averaging shall be done for phase angle.
(c) Average force Vs frequency and average phase Vs frequency
curves shall be plotted on graph paper. Curves of best fit shall
be drawn for the entire frequency range.
(d) The above curves shall be within the envelope specified.
g) Strength of the Messenger Cable
The messenger cable shall be fixed in a suitable tensile testing machine
and the tensile load shall be gradually applied until yield point is
reached. Alternatively, each strand of message caste may be fixed in a
suitable tensile testing machine and the tensile load shall be gradually
applied until yield point is reached. In such a case, the 95% of yield
strength of each wire shall be added to get the total strength of the
caste. The load shall be not less than the value guaranteed by the
Contractor
4.3 Spacer Damper, Bundle spacer & Rigid Spacer
(a) Performance Test
One very important quality of a spacer damper is its ability to control
Aeolian vibrations and subspan oscillations within acceptable limits.
Performance testing shall be carried out on an experimental test line, as
described in Clause 2.5, Section-VI. After testing, there shall not be any
slippage greater than 3mm on conductors, loosening of components or
damage to conductors or spacer damper components.
i) Aeolian Vibrations
Under the specified operating conditions, the spacer damper shall
control Aeolian vibrations in order to prevent damage to conductors
either at suspensions clamp or at the spacer damper clamps.
For measurements and evaluation purpose, the following criteria shall
apply:
- The peak to peak amplitude of any vibration cycle shall never
exceed 1.5 Yb, where Yb is the safe “Bending Amplitude”.
- The RMS value of any vibration measurement sample shall be
lower than 0.6 Yb/2, at 89mm from last point of contact with
suspension or spacer clamp.

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ii) Subspan Oscillations


The spacer damper system shall control subspan oscillations in order to
prevent conductor damage due to clashing or to severe bending
stresses at the spacer damper clamp, and avoid wear of spacer dampers
elements.
In order to achieve that performance level, subspan oscillation shall be
controlled within the following limits, for any wind speed below 60
km/hr.
- In any individual subspan, the peak to peak amplitude of each
subconductor shall never exceed 350mm.
- In any individual subspan, the RMS value (Y rms) of each
oscillation measurement sample shall be such that:
f.Yrms < 80 mm/sec.
Where
Y (rms) = antinode amplitude (mm)
f = frequency of the oscillation (cycle/sec.)
f = (1/2L) sqrt (T/m)
L = subspan length (m)
T = Conductor tension (N)
m = conductor mass (kg/m)
For any set of 10 or more measurement samples associated with
a given wind sector and a given subspan, the Y rms value shall be
such that:
f. Yrms < 70 mm/sec.
The wind sector is defined as a combination of 5 km/hr wind speed
range and 10º wind direction range.
Each measurement sample shall be at least one (1) minute long.
(b) Clamp Slip Test (for Spacer Damper, Bundle Spacer & Rigid Spacer)
The Longitudinal slip test shall be carried out. The spacer damper
assembly shall be installed as per conductor bundle configuration (as
stipulated in relevant clause of section -I) at a tension of 20% of its rated
tensile strength for ACSR Zebra/Moose/snowbird/Bersimis & 54 kN for
Lapwing conductor. In case of spacer for jumper, the clamp of sample
shall be tightened with a specified tightening torque. One of the sample

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clamps, when subjected to a longitudinal pull parallel to the conductor


axis for a minimum duration of one minute. The minimum slip under
longitudinal pull varies with clamp type as per the values stipulated in
the Standard Technical Particulars.
In order to determine the effect of conductor creep with the spacer
dampers only, the conductor shall be re-tensioned to 35% of RTS (in
case of ACSR Lapwing conductor shall be re-tensioned to 81 kN)
without further tightening the spacer damper clamps and the clamp
slip test shall be re-performed. The minimum slip under longitudinal
loads shall not be less than 80% of the values given in the Standard
Technical Particulars.
Similar testing shall be performed of the other clamps of the same
sample. For spacer dampers only, such clamp slip tests shall also be
conducted after each of the vibration tests mentioned in Clause 3.4 (a)
but under longitudinal loading corresponding to 80% of the values given
in the Standard Technical Particulars.
(c) Characteristic of the Elastic and Damping Properties Test
The test shall be carried out by stiffness-damping method as per clause
7.5.5(A) of IEC: 61854. The purpose of this test is to obtain quantitative
information regarding the dynamic characteristic of the spacer damper.
The values obtained during this test will serve as references to evaluate
the behaviour of the same spacer damper under the fatigue test.
The test frequency shall not be higher than 3 Hz. The test shall be
performed at five different displacement amplitudes. The amplitudes
shall be selected to reproduce 10, 20, 40, 60 and 90 percent of the
maximum displacement permitted by the spacer damper design.

The test shall be performed on three samples.

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)

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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 of 400 amps to 800
amps (per subconductor) 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. The reading of the wattmeter
with and without five units shall be recorded and tabulated graphical
form. The test is passed if the average power loss for spacer damper/
spacer at given ampere is less than or equal to the value indicated in the
Standard Technical Particulars.
f) Galvanising Test on Spacer damper, Bundle spacer & Rigid spacer
The test shall be carried out as per Clause no. 5.16 of IS: 10162 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.
g) Movement Test
The spacer assembly shall be capable of the following movements without
damaging the conductor, assuming one conductor is fixed and the other
moving:
(i) Longitudinal movement ± 50 mm
parallel to the conductor
(ii) Vertical movement in a ± 25 mm
vertical direction at right
angle to the conductor
(iii) Torsional movement/angular ± 5 deg.
movement in a vertical plane
parallel to the conductor
h) Assembly Torque Test
The spacer assembly shall be installed on conductor. The same shall not rotate
on either clamp on applying a torque of 0.04 kN in clockwise or anti-clockwise
direction.
i) Hardness test for Elastomer
The shore hardness at different points on the elastomer surface of cushion grip
clamp shall be measured by shore hardness meter. They shall lie between the
values indicated in the Standard Technical Particulars.

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STANDARD SPECIFICATION OF TRANSMISSON LINE (SECTION-
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j) UTS of Retaining Rods


The ultimate tensile strength of the retaining rods shall be measured. The
value shall not be less than 35 kg/sq.mm.

k) Vibration Tests on Bundle Spacer


The test set up shall be as per Clause No. 3.3 (c) (i) of Annexure - A. The spacer
assembly shall be clamped to conductor. During the vibration tests the axis of
the clamp of sample shall be maintained paralleled to its initial static position
by applying a tension 25% of RTS of the conductor. The spacer assembly shall
be free to vibrate and shall not be re-torqued or adjusted between the tests.
All the vibration tests mentioned hereunder shall be conducted on the same
sample on the same test span. The samples shall withstand the vibration tests
without slipping on the conductor. loosening, damage or failure of component
parts. After each vibration test, clamp slip test shall be carried out as per the
procedure given in Clause No. 3.4 (b).
(i) Longitudinal Vibration Test

The stationary conductor and the vibrating conductor/equivalent diameter of


aluminum alloy tube shall be restrained by fixed clamps. The displacement of
the vibrating conductor shall be 25mm minimum on either side. The
longitudinal movement shall be parallel to the conductor at frequency not
less than 2 Hz for minimum one million cycles.
(ii) Vertical Vibration Test
The spacer/spacer damper shall be installed in the middle of the test span and
the frequency chosen so as to get an odd number of loops. The shaker shall
be positioned at least two loops away from the test specimen to allow free
movement of the conductor close to the test specimen. One conductor shall
be connected to the shaker and vibrated to an amplitude such that.

f1.8 Ymax > 1000 mm/sec.

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.

(iii) Sub-span Oscillation Test

The test shall be conducted for oscillation in horizontal plane at frequency


higher than 3 Hz for minimum one million cycles. The amplitude for oscillation
shall be kept equivalent to an amplitude of 150 mm for a full sub-span of 80m.

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Both the conductor shall be vibrated 180 deg. out of phase with the above
minimum amplitude.

3.6 Corona Extinction Voltage Test (Dry) on conductor accessories


same as clause 1.3 of Annexure A.
3.7 Radio Interference Voltage Test (Dry) on conductor accessories
same as clause 1.4 of Annexure A.
3.8 Earthwire Suspension/Tension Clamp Assembly
a) Mechanical Strength Test for Suspension/ Tension Clamp Assembly
The suspension/ tension clamp 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 components shall not show any visual
deformation and it shall be possible to disassemble them by hand.
Hand tools may be used to remove cotter pins and loosen the nuts
initially. The assembly 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 the value recorded.
b) Slip Strength Test for Suspension Clamp Assembly
The Clamp slip strength test shall be carried out as per Clause no. 5.4a)
of IS: 2121 (Part-III) by keeping the clamp at minimum specified slip
strength for one minute and considering slip strength as specified in the
Standard Technical Particular (STP) enclosed with this specification at
Annexure C.
c) Slip Strength Test of dead end assembly
The fitting compressed on earth wire shall not be less than one meter
in length. The test shall be carried out as per IS:2121 (Part-III) except
that the load shall be steadily increased to 95% of minimum ultimate
tensile strength of earthwire and retained for one minute at this load.
There shall be no movement of the earthwire relative to the fittings and
no failure of the fittings during this one minute period.
4 Chemical Analysis Test

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.

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5 Tests on All components (As applicable)


a) Chemical Analysis of Zinc used for Galvanizing
Samples taken from the zinc ingot shall be chemically analysed as per IS-209-1979.
The purity of zinc shall not be less than 99.95%.
b) Tests for Forgings
The chemical analysis hardness tests and magnetic particle inspection for forgings,
will be as per the internationally recognized procedures for these tests. The,
sampling will be based on heat number and heat treatment batch. The details
regarding test will be as discussed and mutually agreed to by the Contractor and
Purchaser in Quality Assurance Programme.
c) Tests on Castings
The chemical analysis, mechanical and metallographic tests and magnetic particle
inspection for castings will be as per the internationally recognized procedures for
these tests. The samplings will be based on heat number and heat treatment batch.
The details regarding test will be as discussed and mutually agreed to by the
Contractor and Purchaser in Quality Assurance Programme.

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Annexure-B

A) Standardized Technical Particulars of Hardware Fittings 765 kV D/C Transmission Line


with ACSR ZEBRA conductor
1. Suspension hardware fittings for ACSR Zebra Conductor
Sl. Description Unit Particulars/ Value
Double ‘I’ Single ‘I’
PILOT

AGS clamp Free Envelope


Centre clamp
clamp
1. Maximum magnetic power loss of Watt 4 8
one suspension assembly at sub-
conductor current of 500 amperes
2. Slipping strength of suspension KN 16 - 24 16 - 24
assembly
3. Particulars of standard/ AGS
preformed armour rod set for
suspension assembly
a) No. of rods per set No. 12 NA
b) Direction of lay Right hand NA
c) Overall length after fitting on mm 2080 2540 NA
conductor
d) Diameter of each rod mm 7.87 NA
e) Tolerance in
i) Diameter of each rod ±mm 0.10 NA
ii) Length of each rod ±mm 25 NA
iii) Difference of length ±mm 13 NA
between the longest and
shortest rod in a set
f) Type of Aluminium alloy used 6061/ 65032 NA
for manufacture of PA rod set
g) Minimum UTS of each rod Kg/mm 35 NA
2

4. Particulars of Elastomer (For AGS Clamp only)


a) Type of elastomer Chloroprene NA NA
/
Neoprene
Rubber
b) Shore hardness of elastomer 65 to 80 NA NA
c) Temperature range for which Upto 95o C NA NA
elastomer is designed

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d) Moulded on insert Yes NA NA


5. Minimum Mechanical strength of KN 350 kN 160 kN
suspension fitting (excluding
suspension clamp)
6. Mechanical strength of KN 70 kN 70 kN
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 c) all others: 6 dips of 1 minute

2. Tension hardware fittings for ACSR Zebra Conductor


Sl. Description Unit Particulars/ Value
Tension String
1. Mechanical strength of Tension fitting KN Single Tension: 160kN
(excluding dead end clamp) Quadruple Tension: 920 kN
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 123.8
6. Galvanising
a) Minimum weight of Zinc coating for steel gm/m2 610
parts
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
the ferrous parts can withstand minute
b) Spring washers: 3 dips of 1
minute
c) all others: 6 dips of 1
minute

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B) Standardized Technical Particulars of Hardware Fittings 765 kV S/C Transmission Line


with ACSR BERSIMIS conductor
1. Suspension hardware fittings for ACSR BERSIMIS Conductor
Sl. Description Unit Particulars/ Value
Suspension Strings Suspension
PILOT
Strings
Single ‘V’ / Double ‘V’ / Single ‘I’ /
Double ‘I’ Single ‘V’

AGS clamp Free Envelope


Centre clamp
clamp
1. Maximum magnetic power loss of Watt 4 8
one suspension assembly at sub-
conductor current of 500 amperes
2. Slipping strength of suspension KN 20-29 20-29
assembly
3. Particulars of standard/ AGS
preformed armour rod set for
suspension assembly
a) No. of rods per set No. 13 NA
b) Direction of lay Right hand NA
c) Overall length after fitting on mm 2235 2540 NA
conductor
d) Diameter of each rod mm 9.27 NA
e) Tolerance in
i) Diameter of each rod ±mm 0.10 NA
ii) Length of each rod ±mm 25 NA
iii) Difference of length between ±mm 13 NA
the longest and shortest rod in a
set
f) Type of Aluminium alloy used 6061/ 65032 NA
for manufacture of PA rod set
g) Minimum UTS of each rod Kg/m 35 NA
m2
4. Particulars of Elastomer (For AGS Clamp only)
a) Type of elastomer Chloroprene NA NA
/
Neoprene
Rubber
b) Shore hardness of elastomer 65 to 80 NA NA

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c) Temperature range for which Upto 95o C NA NA


elastomer is designed
d) Moulded on insert Yes NA NA
5. Mechanical strength of KN Single ‘V’: 235 kN 130 kN
suspension fitting (excluding Double ‘V’: 470 kN
suspension clamp) Double ‘I’: 270 kN
6. Mechanical strength of KN Single ‘V’: 70kN 70kN
suspension clamp Double ‘V’: 120 kN
Double ‘I’: 70 kN
7. Purity of Zinc used for galvanising % 99.95 99.95
8. 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

2. Tension hardware fittings for Quad ACSR BERSIMIS Conductor


Sl. Description Unit Particulars/ Value
Quadruple Tension String
1. Mechanical strength of Tension fitting KN 920
(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 146.3
6. Purity of Zinc used for galvanising % 99.95
7. Min. No. of dips in standard preece test Nos. a) Fasteners: 4 dips of 1
the ferrous parts can withstand. minute
b) Spring washers: 3 dips of 1
minute
c) all others: 6 dips of 1 minute

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C) Standardized Technical Particulars of Hardware Fittings for 400 kV Transmission Line


with Quad ACSR MOOSE Conductor

1. Suspension hardware fittings for Quad ACSR MOOSE conductor


Sl. Description Unit Particulars / Value
Double ‘I’ Single ‘I’
Pilot
AGS Free Envelope
clamp centre clamp
clamp
1. Maximum magnetic power loss of suspension Watt 4 8
assembly at sub conductor current of 600
amperes, 50Hz AC
2. Slipping strength of suspension assembly kN 20-29
(clamp torque Vs slip curve shall be enclosed)
3. Particulars of standard/AGS Standard / AGS
preformed armour rod set for suspension
assembly
a) No. of rods per set No. 12 NA
b) Direction of lay Right Hand NA
c) Overall length after fitting on conductor mm 2235 2540 NA
d) Diameter of each rod mm 9.27 NA
e) Tolerance in NA
i) Diameter of each rod mm 0.10 NA
ii) Length of each rod ±mm 25 NA
iii) Difference of length between the longest ±mm 13 NA
and shortest rod in a set
g) Type of Aluminium alloy used for 6061/ 65032 NA
manufacture of PA rod set
h) UTS of each rod Kg/m 35 NA
m 2

(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

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7. Purity of Zinc used for galvanising % As per IS:209 / IS 13229


8. Min. No. of dips in standard preece test the No a) Fasteners: 4 dips of 1 min
ferrous parts can withstand b) Spring washers: 3 dips of 1
min
c) All others: 6 dips of 1 min

2. Tension hardware fittings for Quad ACSR MOOSE conductor

Sl. Description Unit Particulars / Value

Single Quad Tension


Tension
1. Mechanical Strength of Tension fittings kN 120 640
(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 153.2

6. Purity of Zinc used for galvanising % As per IS:209 / IS 13229

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

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D) Standardized Technical Particulars of Hardware Fittings for 400 kV Transmission Line


with twin ACSR MOOSE Conductor

1. Suspension hardware fittings for twin ACSR MOOSE conductor


Sl. Description Unit Particulars/ Value
Single “I” Double “V” Single
Suspension Suspension suspensi
Fittings Fittings with on Pilot
with (AACSR Fitting
MOOSE with
Conductor)
AGS Free AGS Free Envelop
clam Centr clam Centre e
p e p clamp clamp
clamp
1. Maximum magnetic power loss of Watt 4 4 8
one suspension assembly at sub-
conductor current of 600 amperes
2. Slipping strength of suspension KN 20-29 20-29 20-29
assembly
3. Particulars of standard/ AGS
preformed armour rod set for
suspension assembly
a) No. of rods per set No. 12 12 NA
b) Direction of lay Right hand Right hand NA
c) Overall length after fitting on mm 2540 NA
conductor 2235 2540 2235
d) Diameter of each rod mm 9.27 9.27 NA
e) Tolerance in
i) Diameter of each rod ±mm 0.10 0.10 NA
ii) Length of each rod ±mm 25 25 NA
iii) Difference of length between ±mm 13 13 NA
the longest and shortest rod in
a set
f) Type of Aluminium alloy used 6061/ 6061/ NA
for manufacture of PA rod set 65032 65032

g) Minimum UTS of each rod Kg/mm 35 35 NA


2

4. Particulars of Elastomer (For AGS Clamp only)


a) Type of elastomer Chloro NA Chloro NA NA
prene/ prene
Neopr /Neop
ene rene

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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

1. Tension hardware fittings for twin ACSR MOOSE conductor


Sl. Description Unit Particulars/ Value
Single Double Triple
Tension Tension Tension
(AACSR
MOOSE
Conduct
or)
1. Mechanical strength of Tension fitting KN 120 2x160 3x160
(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 153.2 214
(AACSR
‘MOOSE
’ to be
used)
6. Galvanising
a) Minimum weight of Zinc coating for gm/m 610
steel parts 2

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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 Nos. a) Fasteners: 4 dips of 1
the ferrous parts can withstand. minute
b) Spring washers: 3 dips of 1
minute
c) all others: 6 dips of 1 minute

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E) Standardized Technical Particulars of Hardware Fittings for 400 kV Transmission Line


with triple ACSR SNOWBIRD Conductor
Sl. Description Unit Particulars / Value

Double ‘I’ Single


‘I’
Pilot

AGS Free Envelo


clamp centre pe
clamp clamp
1. Maximum magnetic power loss of suspension Watt 4 8
assembly at sub conductor current of 600
amperes, 50Hz AC
2. Slipping strength of suspension assembly kN 20-29
(clamp torque Vs slip curve shall be enclosed)
3. Particulars of standard/AGS Standard / AGS
preformed armour rod set for suspension
assembly
a) No. of rods per set No. 11 NA
b) Direction of lay Right Hand NA
c) Overall length after fitting on conductor mm 2083 2083 NA
d) Diameter of each rod mm 7.87 NA
e) Tolerance in NA
i) Diameter of each rod ±mm 0.10 NA
ii) Length of each rod ±mm 25 NA
iii) Difference of length between the ±mm 13 NA
longest and shortest rod in a set
g) Type of Aluminium alloy used for 6061/ 65032 NA
manufacture of PA rod set
h) UTS of each rod Kg/m 35 NA
m2
(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. kN 70 70

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7. Purity of Zinc used for galvanising % As per IS:209 / IS 13229


8. Min. No. of dips in standard preece test the No a) Fasteners: 4 dips of
ferrous parts can withstand 1 min
b) Spring washers: 3
dips of 1 min
c)All others: 6 dips of 1
min

TENSION HARDWARE FITTINGS TRIPLE ACSR SNOWBIRD CONDUCTOR


Sl. Description Unit Particulars / Value

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

6. Purity of Zinc used for galvanising % As per IS:209 / IS 13229

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

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STANDARD SPECIFICATION OF TRANSMISSON LINE (SECTION-
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F) Standardized Technical Particulars of Hardware Fittings for 220 kV Transmission Line


with ACSR ZEBRA conductor

1. Suspension hardware fittings for ACSR ZEBRA Conductor


Sl. Description Unit Particulars/ Value
Single “I” Double “I” Single
Suspension Suspension suspensio
Fittings with Fittings with n Pilot
Fitting
with
AGS Free AGS Free Envelope
clamp Centr clamp Centre clamp
e clamp
clamp
1. Maximum magnetic power loss Watt 2 2 2 2 4
of one suspension assembly at
sub-conductor current of 500
amperes
2. Slipping strength of suspension KN 16-24 16-24 16-24 16-24 16-24
assembly
3. Particulars of standard/ AGS
preformed armour rod set for
suspension assembly
a) No. of rods per set No. 12 12 12 12 NA
b) Direction of lay Right Righ Right Right NA
hand t hand hand
hand
c) Overall length after fitting on mm 2080 2080 2540 NA
conductor 2540
d) Diameter of each rod mm 7.87 7.87 7.87 7.87 NA
e) Tolerance in
i) Diameter of each rod ±mm 0.10 0.10 0.10 0.10 NA
ii) Length of each rod ±mm 25 25 25 25 NA
iii) Difference of length ±mm 13 13 13 13 NA
between the longest and
shortest rod in a set
f) Type of Aluminium alloy used 6061/ 6061/ 6061/ 6061/ NA
for manufacture of PA rod set 65032 65032 65032 65032
2
g) Minimum UTS of each rod Kg/mm 35 35 35 35 NA
4. Particulars of Elastomer (For AGS Clamp only)
a) Type of elastomer Chloro NA Chloro NA NA
prene/ prene
Neo /Neo
prene prene

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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

2. Tension hardware fittings for ACSR ZEBRA Conductor


Sl. Description Unit Particulars/ Value
Single Tension Double Tension
1. Mechanical strength of Tension KN 120 2x120
fitting (excluding dead end
clamp)
2. Type of dead-end assembly Compression
3. Compression pressure MT 100
4. Maximum electrical resistance % 75
of dead-end assembly as a
percentage of equivalent
length of Conductor
5. Slip strength of dead-end KN 123.80
assembly
6. Galvanising
a) Minimum weight of Zinc coating gm/m2 610
for steel parts
b) Purity of Zinc used for % 99.95 (IS 209) or 98.5 (IS 13229)
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

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STANDARD SPECIFICATION OF TRANSMISSON LINE (SECTION-
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G) Standardized Technical Particulars of Hardware Fittings for 132 kV Transmission


Line with ACSR PANTHER Conductor

1. Suspension hardware fittings for ACSR PANTHER Conductor


Sl. Description Unit Particulars/ Value
Single “I” Double “I”
Suspension Fittings Suspension Fittings
with with
AGS Free AGS Free
clamp Centre clamp Centre
clamp clamp
1. Maximum magnetic power loss of Watt 2 2 2 2
one suspension assembly at sub-
conductor current of 350 amperes
2. Slipping strength of suspension KN 11-16 11-16 11-16 11-16
assembly
3. Particulars of standard/ AGS
preformed armour rod set for
suspension assembly
a) No. of rods per set No. 11 11 11 11
b) Direction of lay Right Right Right Right
hand hand hand hand
c) Overall length after fitting on mm 1760 1930 1760 1930
conductor
d) Diameter of each rod mm 6.35 6.35 6.35 6.35
e) Tolerance in
i) Diameter of each rod ±mm 0.10 0.10 0.10 0.10
ii) Length of each rod ±mm 16 16 16 16
iii) Difference of length between ±mm 13 13 13 13
the longest and shortest rod in a
set
f) Type of Aluminium alloy used 6061/ 6061/ 6061/ 6061/
for manufacture of PA rod set 65032 65032 65032 65032
g) Minimum UTS of each rod Kg/ 35 35 35 35
mm2
4. Particulars of Elastomer (For AGS Clamp only)
a) Type of elastomer Chloropr NA Chloropre NA
ene/Neo ne
prene /Neopren
Rubber e Rubber
b) Shore hardness of elastomer 65 to 80 NA 65 to 80 NA
o
c) Temperature range for which Upto NA Upto 95 NA
elastomer is designed 95o C C
d) Moulded on insert Yes NA Yes NA

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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

2. Tension hardware fittings for ACSR PANTHER Conductor


Sl. Description Unit Particulars/ Value
Single Tension Double Tension
1. Mechanical strength of Tension KN 90 2 X 90
fitting (excluding dead end
clamp)
2. Type of dead-end assembly Compression
3. Compression pressure MT 100
4. Maximum electrical resistance % 75
of dead-end assembly as a
percentage of equivalent
length of Conductor
5. Slip strength of dead-end KN 85.2
assembly
6. Galvanising
a) Minimum weight of Zinc coating gm/m2 610
for steel parts
b) Purity of Zinc used for % 99.95 (IS 209) or 98.5 (IS 13229)
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

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H) Standardized Technical Particulars of Hardware Fittings for ±800 kV HVDC


Transmission Line with ACSR LAPWING conductor
1. Suspension hardware fittings for ACSR LAPWING Conductor
Sl. Description Unit Particulars/ Value
Suspension Strings
Single ‘Y’

AGS Free Single I


clamp Centre PILOT
clamp
1. Maximum magnetic power loss of one Watt NA NA
suspension assembly at sub-conductor
current of 500 amperes
2. Slipping strength of suspension KN 20-29 20-29
assembly
3. Particulars of standard/ AGS preformed NA
armour rod set for suspension
assembly
a) No. of rods per set No. 14 NA
b) Direction of lay Right hand NA
c) Overall length after fitting on mm 2235 NA
conductor
d) Diameter of each rod mm 9.27 NA
e) Tolerance in
i) Diameter of each rod ±mm 0.10 NA
ii) Length of each rod ±mm 25 NA
iii) Difference of length between the ±mm 13 NA
longest and shortest rod in a set
f) Type of Aluminium alloy used for 6061/ 65032 NA
manufacture of PA rod set
g) Minimum UTS of each rod Kg/mm2 35 NA
4. Particulars of Elastomer (For AGS Clamp only)
a) Type of elastomer Chloropr NA NA
ene/
Neopren
e Rubber
b) Shore hardness of elastomer 65 to 80 NA NA
o
c) Temperature range for which Upto 95 NA NA
elastomer is designed C
d) Moulded on insert Yes NA NA
5. Mechanical strength of suspension KN Single ‘Y’ : 505 kN 160kN
fitting (excluding suspension clamp)

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6. Mechanical strength of suspension KN Single ‘Y’ : 130kN 70kN


clamp
7. Purity of Zinc used for galvanising % 99.95
8. 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

2. Tension hardware fittings for Hexa ACSR LAPWING Conductor


Sl. Description Unit Particulars/ Value
Triple Tension String
1. Mechanical strength of Tension fitting KN 1320
(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 178.6
6. Purity of Zinc used for galvanising % 99.95
7. Min. No. of dips in standard preece test Nos. 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

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STANDARD SPECIFICATION OF TRANSMISSON LINE (SECTION-
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I) Standardized Technical Particulars of Hardware Fittings for metallic return Conductor


with ACSR LAPWING conductor
1. Suspension hardware fittings for Metallic Return Conductor

Sl. Description Unit Particulars/ Value


Single “I” Suspension Fittings with
AGS clamp Free Centre clamp
1. Maximum magnetic power loss of Watt
one suspension assembly at sub-
conductor current of 350 amperes
2. Slipping strength of suspension KN 20-29 20-29
assembly
3. Particulars of standard/ AGS
preformed armour rod set for
suspension assembly
a) No. of rods per set No. 14 14
b) Direction of lay Right hand Right hand
c) Overall length after fitting on mm 2235 2385
conductor
d) Diameter of each rod mm 9.27 9.27
e) Tolerance in
i) Diameter of each rod ±mm 0.10 0.10
ii) Length of each rod ±mm 25 25
iii) Difference of length between ±mm 13 13
the longest and shortest rod in a
set
f) Type of Aluminium alloy used 6061/ 65032 6061/ 65032
for manufacture of PA rod set
g) Minimum UTS of each rod Kg/mm 35 35
2

4. Particulars of Elastomer (For AGS Clamp only)


a) Type of elastomer Chloroprene/Neopr NA
ene Rubber
b) Shore hardness of elastomer 65 to 80 NA
c) Temperature range for which Upto 95o C NA
elastomer is designed
d) Moulded on insert Yes NA
5. Mechanical strength of KN 160
suspension fitting (excluding
suspension clamp)
6. Mechanical strength of KN 120
suspension clamp
7. Galvanising

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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

2. Tension hardware fittings for Metallic Return Conductor

Sl. Description Unit Particulars/ Value


Double Tension
1. Mechanical strength of Tension KN 420
fitting (excluding dead end
clamp)
2. Type of dead-end assembly Compression
3. Compression pressure MT 100
4. Maximum electrical resistance % 75
of dead-end assembly as a
percentage of equivalent
length of Conductor
5. Slip strength of dead-end KN 178.6
assembly
6. Galvanising
a) Minimum weight of Zinc coating gm/m2 610
for steel parts
b) Purity of Zinc used for % 99.95 (IS 209) or 98.5 (IS 13229)
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

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J) Accessories for ACSR ZEBRA conductor for 765 kV transmission line with Hexa ZEBRA
conductor

1. Repair sleeve for ACSR Zebra Conductor


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 corner) mm 47.00 ± 0.5
ii) Outside dimension (face to face) mm 41.00 ± 0.5
4. Minimum corona Extinction voltage kV kV 510
(rms) under dry condition
5. Maximum Radio Interference Voltage at Micro 1000
1 MHz for phase to earth voltage of 510 Volts
kV (rms) under dry condition (V)

2. Mid span compression Joint for ACSR Zebra Conductor


Sl. Description Unit Particulars/ Value
Aluminium Steel Sleeve
Sleeve
1. Material of Joint Aluminium of Mild Steel
purity 99.5% (Fe-410,
IS:2062)
2. Range of Hardness of the steel sleeve BHN From 100 to 200
(Brinnel hardness)

3. Dimension of sleeve Before Aluminum Steel sleeve


compression sleeve
i) Inside diameter Mm 31.00 ± 0.5 10.00 ± 0.2
ii) Outside diameter Mm 48.00 ± 1.0 20.00 ± 0.5
iii) Length Mm 710 ± 5 241 ± 5

4. Dimensions of Sleeve after Aluminum Steel sleeve


compression sleeve
i) Outside dimension (Corner to corner) Mm 47.00 ± 0.5 19.00 ± 0.5
ii) Outside dimension (face to face) Mm 41.00 ± 0.5 16.00 ± 0.5

5. Slip strength KN 123.8

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6. Maximum resistance of the compressed % 75


unit expressed, as percentage of the
resistance of equivalent length of bare
conductor.
7. Minimum corona Extinction voltage kV kV 510
(rms) under dry condition
8. Maximum Radio Interference Voltage at Micro 1000
1 MHz for phase to earth voltage of 510 Volts
kV (rms) under dry condition
9. 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
the ferrous parts can withstand minute
b) Spring washers: 3 dips of 1
minute &
c) all others: 6 dips of 1 minute

3. T-connector for ACSR ZEBRA Conductor


Sl. Description Unit Particulars/ Value
1. Material Aluminium of 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 400.00 ± 5.0
3. Dimensions of Aluminum Sleeve after compression
i) Outside dimension (Corner to corner) mm 47.00 ± 0.5
ii) Outside dimension (face to face) mm 41.00 ± 0.5
4. Axial tensile strength of welded portion KN 30
of T-connector
5. Maximum resistance of the compressed % 75
unit expressed, as percentage of the
resistance of equivalent length of bare
conductor.
6. Minimum corona Extinction voltage kV kV 510
(rms) under dry condition
7. Maximum Radio Interference Voltage at Micro 1000
1 MHz for phase to earth voltage of 510 Volts
kV (rms) under dry condition

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STANDARD SPECIFICATION OF TRANSMISSON LINE (SECTION-
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4. HEX SPACER DAMPER FOR ACSR ZEBRA CONDUCTOR for 765kV Trans.Lines

Sl. Description Unit Particulars / Value

1. Type of Clamps Preformed rods.

2. Type of Damping element Spring / Elastomer / EPDM

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 °C Upto 95°C
designed
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 Longitud Maxm Slip
Clamp type nal Load permitted
(kN) (mm)
Preformed 2.5 12
rods
(b) After vibration test kN 80% of the above values
7. Maximum magnetic power loss of Watts Below 1 watt.
at sub conductor current of 500
amperes, 50Hz AC
8. Minimum corona Extinction kV 510
voltage kV (rms) under dry
condition
9. Radio Interference Voltage at 1 μV Below 1000
MHz for phase to earth voltage of
510 kV (rms) Microvolts under
dry condition
10. Galvanising

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STANDARD SPECIFICATION OF TRANSMISSON LINE (SECTION-
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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

5.HEX RIGID SPACER FOR ACSR ZEBRA CONDUCTOR for 765kV Trans.Lines

Sl. Description Unit Particulars / Value

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

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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

1. Mid span compression Joint for ACSR BERSIMIS Conductor


Sl. Description Unit Particulars/ Value
Aluminium Steel Sleeve
Sleeve
1. Material of Joint Aluminium of Mild Steel
purity 99.5% (Fe-410,
IS:2062)
2. Range of Hardness of the steel sleeve BHN From 100 to 200
(Brinnel hardness)
3. Weight of Zinc coating for steel sleeve gm/m2 610

4. Dimension of sleeve Before Aluminum Steel sleeve


compression sleeve
i) Inside diameter mm 37.40 ± 0.5 8.10 ± 0.2
ii) Outside diameter mm 58.4 ± 1.01.0 20.70 ± 0.5
iii) Length mm 865 ± 5 220 ± 5

5. Dimensions of Sleeve after Aluminum Steel sleeve


compression sleeve
i) Outside dimension (Corner to corner) mm 57.40 ± 0.5 20.20 ± 0.5
ii) Outside dimension (face to face) mm 49.70 ± 0.5 17.50 ± 0.5
iii) Length mm 938 (approx) 250 (approx)

5. Slip strength KN 146.3


6. Maximum resistance of the compressed % 75
unit expressed, as percentage of the
resistance of equivalent length of bare
conductor.
7. Minimum corona Extinction voltage kV kV 510
(rms) under dry condition
8. Maximum Radio Interference Voltage at Micro 1000
1 MHz for phase to earth voltage of 510 Volts
kV (rms) under dry condition

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STANDARD SPECIFICATION OF TRANSMISSON LINE (SECTION-
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2. Repair sleeve for ACSR BERSIMIS Conductor


Sl. Description Unit Particulars/ Value
1. Material Aluminium of minimum
purity 99.5%
2. Dimension of Aluminum sleeve Before compression
i) Inside diameter Mm 37.40 ± 0.5
ii) Outside diameter Mm 58.4 ±1.1.
iii) Length Mm 530 ± 5
3. Dimensions of Aluminum Sleeve After compression
i) Outside dimension (Corner to corner) Mm 57.40 ± 0.5
ii) Outside dimension (face to face) Mm 949.70 ± 0.5
iii) Length Mm 570 (approx)
4. Minimum corona Extinction voltage kV kV 510
(rms) under dry condition
5. Maximum Radio Interference Voltage at Micro 1000
1 MHz for phase to earth voltage of 510 Volts
kV (rms) under dry condition (V)

3. QUAD SPACER DAMPER FOR QUAD ACSR BERSIMIS CONDUCTOR


Sl. Description Unit Particulars / Value

1. Type of Clamps Preformed rods.

2. Type of Damping element Spring / Elastomer / EPDM

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 °C Upto 95°C
designed
5. Minimum ultimate tensile
strength of spacer
(a) Compressive load kN 15
(b) Tensile load kN 7.5
6. Slipping strength of spacer clamp

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(a) Before vibration test kN Longitud Maxm


Clamp type nal Load Slip
(kN) permitted
(mm)
Preformed 2.5 12
rods
(b) After vibration test kN 80% of the above values
7. Maximum magnetic power loss of Watt Below 1 watt.
at sub conductor current of 500 s
amperes, 50Hz AC
8. Minimum corona Extinction kV 510
voltage kV (rms) under dry
condition
9. Radio Interference Voltage at 1 μV Below 1000
MHz for phase to earth voltage of
510 kV (rms) Microvolts under dry
condition
10. 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

4. QUAD RIGID SPACER FOR QUAD ACSR BERSIMIS CONDUCTOR


Sl. Description Unit Particulars / Value

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

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STANDARD SPECIFICATION OF TRANSMISSON LINE (SECTION-
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4. Slipping strength of spacer clamp kN Longitudn Maxm Slip


Clamp type al Load permitted
(kN) (mm)
Metal – 6.5 1
Metal
Bolted
Rubber 2.5 2.5
loaded
5. Maximum magnetic power loss of Watts Below 1 watt.
at sub conductor current of 500
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/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

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L) Accessories for ACSR MOOSE conductor for 400 kV transmission line

1. Mid span compression Joint for ACSR MOOSE Conductor


Sl. Description Unit Particulars/ Value
Aluminium Steel Sleeve
Sleeve
1. Material of Joint Aluminium of Mild Steel (Fe-
purity 99.5% 410, IS:2062)
2. Range of Hardness of the steel sleeve BHN From 100 to 200
(Brinnel hardness)
3. Weight of Zinc coating for steel sleeve gm/m2 610

4. Dimension of sleeve Before Aluminum Steel sleeve


compression sleeve
i) Inside diameter mm 34.00 ± 0.5 11.10 ± 0.2
ii) Outside diameter mm 54.00 ± 1.0 21.00 ± 0.5
iii) Length mm 735 ± 5 250 ± 5

5. Dimensions of Sleeve after Aluminum Steel sleeve


compression sleeve
i) Outside dimension (Corner to corner) mm 53.00 ± 0.5 20.20 ± 0.5
ii) Outside dimension (face to face) mm 46.00 ± 0.5 17.50 ± 0.5
iii) Length mm 785 (approx) 286 (approx)
6. Slip strength KN 153.2
7. Maximum resistance of the compressed % 75
unit expressed, as percentage of the
resistance of equivalent length of bare
conductor.
8. Minimum corona Extinction voltage kV kV 320
(rms) under dry condition
9. Maximum Radio Interference Voltage at Micro 1000
1 MHz for phase to earth voltage of 305 Volts
kV (rms) under dry condition

2. Repair sleeve for ACSR MOOSE Conductor


Sl. Description Unit Particulars/ Value
1. Material Aluminium of minimum purity
99.5%
2. Dimension of Aluminum sleeve Before compression
i) Inside diameter mm 34.00 ± 0.5
ii) Outside diameter mm 54.00 ± 1.0
iii) Length mm 300.00 ± 5.0
3. Dimensions of Aluminum Sleeve after compression

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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. T-connector for ACSR MOOSE Conductor


Sl. Description Unit Particulars/ Value
1. Material Aluminium of purity 99.5%
2. Dimension of Aluminum sleeve Before compression
i) Inside diameter mm 34.00 ± 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
ii) Outside dimension (face to face) mm 46.00 ± 0.5
4. Axial tensile strength of welded portion KN 30
of T-connector
5. Maximum resistance of the compressed % 75
unit expressed, as percentage of the
resistance of equivalent length of bare
conductor.
6. Minimum corona Extinction voltage kV kV 320
(rms) under dry condition
7. Maximum Radio Interference Voltage at Micro 1000
1 MHz for phase to earth voltage of 305 Volts
kV (rms) under dry condition

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

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4. Minimum ultimate tensile strength of Kg/m 135


stranded messenger cable m2
5. Slip strength of stranded messenger KN 5
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 40
8. Maximum magnetic power loss per Watts 1
vibration damper watts for 600 amps,
50 Hz Alternating Current
9. Minimum corona Extinction voltage kV kV 320
(rms) under dry condition
10. Maximum Radio Interference Voltage Micro 1000
(RIV) at 1 MHz for phase to earth Volts
voltage of 305 kV (rms) under dry
condition
11. Percentage variation in reactance after % +/-40 (Maximum)
fatigue test in comparison with that.
before fatigue test
12. Percentage variation in power % +/-40 (Maximum)
dissipation after fatigue test in
comparison with that before fatigue test
13. 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 Nos. 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

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

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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

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(b) Tensile load kN 7.0


4. Slipping strength of spacer clamp kN 2.5
5. Maximum Magnetic power loss per
spacer for 600 Amps, 50 Hz Alternating Watts 1
Current
6. Minimum corona Extinction voltage kV kV 320
(rms) under dry condition
7. Maximum Radio Interference Voltage Micro 1000
(RIV) at 1 MHz for phase to earth volts
voltage of 305 kV (rms) under dry
condition

7. Quad Spacer Damper for ACSR MOOSE conductor

Sl. Description Unit Particulars / Value

1. Type of Clamps Preformed rods.

2. Type of Damping element Spring / Elastomer / EPDM

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

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(b) After vibration test kN 80% of the above values


7. Maximum magnetic power loss of at sub Watt Below 1 watt.
conductor current of 600 amperes, 50Hz
AC
8. Minimum corona Extinction voltage kV kV 320
(rms) under dry condition
9. Radio Interference Voltage at 1 MHz for μV Below 1000
phase to earth voltage of 305 kV (rms)
Microvolts under dry condition

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

8. Quad Rigid Spacer for Jumper for ACSR MOOSE conductor

Sl. Description Unit Particulars / Value

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

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5. Maximum magnetic power loss of at sub Watts Below 1 watt.


conductor current of 600 amperes, 50Hz
AC
6. Minimum corona Extinction voltage kV kV 320
(rms) under dry condition
7. Radio Interference Voltage at 1 MHz for μV Below 1000
phase to earth voltage of 305 kV (rms)
Microvolts under dry condition
8. 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

M) Accessories for ACSR Snowbird Conductor for 400 kV transmission line

Mid span compression Joint

Sl. Description Unit Particulars/ Value


Aluminium Steel Sleeve
Sleeve
1. Material of Joint Aluminium of Mild Steel (Fe-
purity 99.5% 410, IS:2062)
2. Range of Hardness of the steel sleeve BHN From 100 to 200
(Brinnel hardness)
3. Weight of Zinc coating for steel sleeve gm/m2 610

4. Dimension of sleeve Before Aluminum Steel sleeve


compression sleeve
i) Inside diameter mm 33.00 ± 0.5 7.00 ± 0.2
ii) Outside diameter mm 54.00 ± 1.0 19.20 ± 0.5
iii) Length mm 735 ± 5 250 ± 5

5. Dimensions of Sleeve after Aluminum Steel sleeve


compression sleeve
i) Outside dimension (Corner to corner) mm 53.00 ± 0.5 20.20 ± 0.5
ii) Outside dimension (face to face) mm 46.00 ± 0.5 17.50 ± 0.5
iii) Length mm 785 (approx) 286 (approx)
6. Slip strength KN 112

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7. Maximum resistance of the compressed % 75


unit expressed, as percentage of the
resistance of equivalent length of bare
conductor.
8. Minimum corona Extinction voltage kV kV 320
(rms) under dry condition
9. Maximum Radio Interference Voltage at Micro 1000
1 MHz for phase to earth voltage of 305 Volts
kV (rms) under dry condition

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

TRIPLE SPACER DAMPER FOR TRIPLE ACSR SNOWBIRD CONDUCTOR


Sl. Description Unit Particulars / Value

1. Type of Clamps Preformed rods.

2. Type of Damping element Spring / Elastomer / EPDM

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)

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4. Elastomer (if used)


(a) Shore hardness 65 – 80
(b) Temp. range for which °C Upto 95°C
designed
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 Maxm
Clamp type dnal Slip
Load permitte
(kN) d (mm)
Preformed 2.5 12
rods
(b) After vibration test kN 80% of the above values
7. Maximum magnetic power loss of Watt Below 1 watt.
at sub conductor current of 600
amperes, 50Hz AC
8. Minimum corona Extinction kV 320
voltage kV (rms) under dry
condition
9. Radio Interference Voltage at 1 μV Below 1000
MHz for phase to earth voltage of
305 kV (rms) Microvolts under dry
condition
10. 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

TRIPLE RIGID SPACER FOR TRIPLE ACSR SNOWBIRD CONDUCTOR


Sl. Description Unit Particulars / Value

1. Material of
(a) Clamp Al Alloy IS:4600 or Equivalent
(b) Body Galvanised Steel / Al Alloy 4600 or
Equivalent

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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 Longitu Maxm
Clamp type dnal Slip
Load permitte
(kN) d (mm)
Metal – Metal 6.5 1
Bolted
Rubber 2.5 2.5
loaded
5. Maximum magnetic power loss of Watts Below 1 watt.
at sub conductor current of 600
amperes, 50Hz AC
6. Minimum corona Extinction kV 320
voltage kV (rms) under dry
condition
7. Radio Interference Voltage at 1 μV Below 1000
MHz for phase to earth voltage of
305 kV (rms) Microvolts under dry
condition
8. 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

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

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ii) Outside dimension (face to face) mm 46.00 ± 0.5


4. Axial tensile strength of welded portion KN 30
of T-connector
5. Maximum resistance of the compressed % 75
unit expressed, as percentage of the
resistance of equivalent length of bare
conductor.
6. Minimum corona Extinction voltage kV kV 320
(rms) under dry condition
7. Maximum Radio Interference Voltage at Micro 1000
1 MHz for phase to earth voltage of 305 Volts
kV (rms) under dry condition

N) Accessories for ACSR ZEBRA conductor for 220 kV transmission line

1. Mid span compression Joint


Sl. Description Unit Particulars/ Value
Aluminium Sleeve Steel Sleeve
1. Material of Joint Aluminium of Mild Steel (Fe-
minimum purity 410, IS:2062)
99.5%
2. Range of Hardness of the steel BHN From 100 to 200
sleeve (Brinnel hardness)

3. Dimension of sleeve Before Aluminum sleeve Steel sleeve


compression
i) Inside diameter mm 31.00 ± 0.5 10.00 ± 0.2
ii) Outside diameter mm 48.00 ± 1.0 20.00 ± 0.5
iii) Length mm 710 ± 5 241 ± 5

4. Dimensions of Sleeve after Aluminum sleeve Steel sleeve


compression
i) Outside dimension (Corner to mm 47.00 ± 0.5 19.00 ± 0.5
corner)
ii) Outside dimension (face to mm 41.00 ± 0.5 16.00 ± 0.5
face)

5. Slip strength KN 123.8


6. Maximum resistance of the % 75
compressed unit expressed, as
percentage of the resistance of
equivalent length of bare
conductor.
7. Galvanising

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a) Minimum weight of Zinc coating gm/m2 610


for steel parts
b) Purity of Zinc used for % 99.95 (IS 209) or 98.5 (IS 13229)
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

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

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8. Maximum magnetic power loss Watts 1


per vibration damper watts for
500 amps, 50 Hz Alternating
Current
9. Percentage variation in % +/-40 (Maximum)
reactance after fatigue test in
comparison with that before
fatigue test
10. Percentage variation in power % +/-40 (Maximum)
dissipation after fatigue test in
comparison with that before
fatigue test
11. Galvanising
a) Minimum weight of Zinc coating gm/m2 610
for steel parts
b) Purity of Zinc used for % 99.95 (IS 209) or 98.5 (IS 13229)
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

O) Accessories for ACSR PANTHER conductor for 132 kV transmission line

1. Mid span compression Joint for ACSR PANTHER Conductor


Sl. Description Unit Particulars/ Value
Aluminium Sleeve Steel Sleeve
1. Material of Joint Aluminium of Mild Steel (Fe-410,
minimum purity IS:2062)
99.5%
2. Range of Hardness of the steel BHN From 100 to 200
sleeve (Brinnel hardness)

3. Dimension of sleeve Before Aluminum sleeve Steel sleeve


compression
i) Inside diameter mm 23.00 ± 0.5 9.50 ± 0.2
ii) Outside diameter mm 38.00 ± 1.0 18.00 ± 0.5
iii) Length mm 610 ± 5 203 ± 5

4. Dimensions of Sleeve after Aluminum sleeve Steel sleeve


compression
i) Outside dimension (Corner to mm 37.00 ± 0.5 17.40 ± 0.5
corner)

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ii) Outside dimension (face to mm 32.00 ± 0.5 15.10 ± 0.5


face)

5. Slip strength KN 85.2


6. Maximum resistance of the % 75
compressed unit expressed, as
percentage of the resistance of
equivalent length of bare
conductor.
7. Galvanising
a) Minimum weight of Zinc coating gm/m2 610
for steel parts
b) Purity of Zinc used for % 99.95 (IS 209) or 98.5 (IS 13229)
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

2. Repair sleeve for ACSR PANTHER Conductor


Sl. Description Unit Particulars/ Value
1. Material Aluminium of minimum purity 99.5%
2. Dimension of Aluminum sleeve Before compression
i) Inside diameter mm 23.00 ± 0.5
ii) Outside diameter mm 38.00 ± 1.0
iii) Length mm 241.00 ± 5.0
3. Dimensions of Aluminum Sleeve after compression
i) Outside dimension (Corner to mm 37.00 ± 0.5
corner)
ii) Outside dimension (face to mm 32.00 ± 0.5
face)

3. Vibration Damper for ACSR PANTHER Conductor


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

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4. Minimum ultimate tensile Kg/m 135


strength of stranded m2
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
8. Maximum magnetic power loss Watts 1
per vibration damper watts for
350 amps, 50 Hz Alternating
Current
9. Percentage variation in % +/-40 (Maximum)
reactance after fatigue test in
comparison with that before
fatigue test
10. Percentage variation in power % +/-40 (Maximum)
dissipation after fatigue test in
comparison with that before
fatigue test
11. Galvanising
a) Minimum weight of Zinc coating gm/m2 610
for steel parts
b) Purity of Zinc used for % 99.95 (IS 209) or 98.5 (IS 13229)
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

P) Accessories for ACSR Lapwing conductor for ±800 kV HVDC Transmission Line.

Mid span compression Joint for ACSR Lapwing


Sl. Description Unit Particulars/ Value
Aluminium Steel Sleeve
Sleeve
1. Material of Joint Aluminium of Mild Steel
purity 99.5% (Fe-410,
IS:2062)
2. Range of Hardness of the steel sleeve BHN From 120 to 200
(Brinnel hardness)
3. Weight of Zinc coating for steel sleeve gm/m2 610

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4. Dimension of sleeve Before Aluminum Steel sleeve


compression sleeve
i) Inside diameter: Nominal mm 41 10
Tolerance mm ± 0.5 ± 0.5
ii) Outside diameter: Nominal mm 64 21
Tolerance mm ± 1.0 ± 0.5
iii) Length mm As per As per
design* design*
*As per design to meet specified strength requirement
(Min. Length- Al-Sleeve-860mm, Steel Sleeve-225mm)
5. Dimensions of Sleeve after Aluminum Steel sleeve
compression sleeve
i) Outside dimension (Corner to corner) mm As per design As per design
ii) Outside dimension (face to face) mm As per design As per design
iii) Length mm As per design As per design

5. Slip strength KN 178.6


6. Maximum resistance of the compressed % 75
unit expressed, as percentage of the
resistance of equivalent length of bare
conductor.
7. Minimum corona Extinction voltage kV kV 880
(rms) under a voltage gradient of 22
kV/cm on conductor under dry
condition
8. Maximum Radio Interference Voltage at Micro 1000
1 MHz when subjected to conductor Volts
surface gradient of 22 kV/cm (positive)
under dry condition

Repair sleeve for ACSR LAPWING Conductor


Sl. Description Unit Particulars/ Value
1. Material Aluminium of minimum
purity 99.5%
2. Dimension of Aluminum sleeve Before compression
i) Inside diameter: Nominal mm 41 ±
Tolerance mm 0.5
ii) Outside diameter: Nominal mm 64
Tolerance ±1.0
iii) Length mm As per design
*As per design to meet specified strength requirement
(Min. Length- 495mm)
3. Dimensions of Aluminum Sleeve After compression

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i) Outside dimension (Corner to corner) Mm As per design


ii) Outside dimension (face to face) Mm As per design
iii) Length Mm As per design
4. Minimum corona Extinction voltage kV kV 880
(rms) under a voltage gradient of 22
kV/cm on conductor under dry
condition
5. Maximum Radio Interference Voltage at Micro 1000
1 MHz when subjected to conductor Volts
surface gradient of 22 kV/cm (positive) (V)
under dry condition

Q) Accessories for 7/3.66 mm GS Earthwire for 400 kV and 765 kV transmission line

1. Mid span compression Joint for 7/3.66 mm GS Earthwire


Sl. Description Unit Particulars/ Value

Aluminium / Steel Sleeve


Filler Sleeve
1. Material of Joint Aluminium of Mild Steel
minimum purity (Fe-410,
99.5% IS:2062)
2. Range of Hardness of the steel sleeve BHN From 100 to 200
(Brinnel hardness)
3. Weight of Zinc coating gm/m2 610
4. Dimension of sleeve Before compression
Aluminiu Steel Alu filler
m Sleeve Sleeve sleeve
i) Inside diameter mm 22.00 ± 11.50 ± 11.50 ±
0.5 0.2 0.2
ii) Outside diameter mm 32.00 ± 21.00 ± 21.00 ±
0.5 0.5 0.5
iii) Length mm 400 ± 5 230 ± 5 60 ± 5

5. Dimensions of Sleeve after compression


Aluminium Steel Sleeve
Sleeve
i) Outside dimension (Corner to Corner) mm 29.40 ± 0.5 20.20 ± 0.5
ii) Outside dimension (face to face) mm 25.00 ± 0.5 17.50 ± 0.5
iii) Length mm 430 (approx) 265 (approx)
6. Slip strength KN 65
7. Maximum resistance of the % 75
compressed unit expressed, as

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percentage of the resistance of


equivalent length of bare Earthwire

2. Flexible AL Bond for 7/3.66 mm GS Earthwire


Sl. Description Unit Particulars/ Value
1. Stranding 19(12+6+1)/dia2.54
2. Cross sectional area Sq.mm 95
3. Length of aluminium cable mm 750+5
4. Material of lugs Aluminum alloy
5. Bolt Size
i) Diameter mm 16
ii) Length mm 40

3. Vibration Damper for 7/3.66 mm GS Earthwire


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 hop 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
4. Minimum ultimate tensile strength of Kg/mm2 135
stranded messenger cable
5. Slip strength of stranded messenger kN 2.5
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 reactance after % +/-40 (Maximum)
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

4. Suspension Clamp for 7/3.66 mm GS Earthwire


Sl. Description Unit Particulars/ Value
1. Material of components
(a) Shackle Forged Steel

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(b) Clamp Body & Keeper Malleable cast iron / SGI


(c) U- Bolt Mild Steel
2. Total Drop (Maximum) mm 150
3. Breaking Strength (Minimum) kN 25
4. Slipping Strength kN 12 to 17
5. Galvanising
a) Minimum weight of Zinc coating for steel gm/m2 610
parts
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 the No. a) Fasteners: 4 dips of 1
ferrous parts can withstand (wherever minute
applicable) b) Spring washers: 3 dips of
1 minute &
c) all others: 6 dips of 1
minute

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5. Tension Clamp for 7/3.66 mm GS Earthwire


Sl. Description Unit Particulars/ Value
1. Material of components
(i) Anchor Shackle Forged Steel
(ii) Compression Clamp
a) Steel Sleeve Mild Steel
b) Aluminium sleeve Aluminium of purity 99.5%
c) Aluminium Filler sleeve Aluminium of purity 99.5%
2. Range of Hardness of the steel sleeve BHN 120-200
(Brinnel hardness)
3. Dimension of sleeve Before compression
Aluminiu Steel Alu
m Sleeve Sleeve filler
sleeve
i) Inside diameter mm 22.00 ± 11.50 ± 11.50 ±
0.5 0.2 0.2
ii) Outside diameter mm 30.00 ± 21.00 ± 21.00 ±
0.5 0.5 0.5
iii) Length mm 245 ± 5 205 ± 5 25 .0
4. Dimensions of Sleeve after compression
Aluminium Steel Sleeve
Sleeve
i)Outside dimension (Corner to Corner) mm 29.40 ± 0.5 20.20 ± 0.5
ii) Outside dimension (face to face) mm 25.00 ± 0.5 17.50 ± 0.5
5. Slip strength KN 65
6. Minimum Breaking strength of assembly KN 70
(excluding clamp)
7. Compression Pressure Ton 100
8. Galvanising
a) Minimum weight of Zinc coating for steel gm/ 610
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 preece test the No. a) Fasteners: 4 dips of 1 minute
ferrous parts can withstand (wherever b) Spring washers: 3 dips of 1
applicable) minute &
c) all others: 6 dips of 1 minute

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R) Accessories for 7/3.15 mm GS Earthwire for 220 kV and 132 kV transmission line

1. Mid span compression Joint for 7/3.15 mm GS Earthwire


Sl. Description Unit Particulars/ Value
Aluminium / Filler Steel Sleeve
Sleeve
1. Material of Joint Aluminium of Mild Steel (Fe-
minimum purity 410, IS:2062)
99.5%
2. Range of Hardness of the steel BHN From 100 to 200
sleeve (Brinnel hardness)

3. Dimension of sleeve Before compression


Alumini Steel Sleeve Alu filler
um sleeve
Sleeve
i) Inside diameter mm 22.00 ± 10.00 ± 0.2 11.50 ± 0.2
0.5
ii) Outside diameter mm 30.00 ± 21.00 ± 0.5 21.00 ± 0.5
0.5
iii) Length mm 315 ± 5 230 ± 5 25 ± 2

4. Dimensions of Sleeve after compression


Aluminium Sleeve Steel Sleeve
i) Outside dimension (Corner to mm 29.40 ± 0.5 20.20 ± 0.5
Corner)
ii) Outside dimension (face to mm 25.00 ± 0.5 17.50 ± 0.5
face)

5. Slip strength KN 53.20


6. Maximum resistance of the % 75
compressed unit expressed, as
percentage of the resistance of
equivalent length of bare
Earthwire
7. Galvanising
a) Minimum weight of Zinc coating gm/m2 610
for steel parts
b) Purity of Zinc used for % 99.95 (IS 209) or 98.5 (IS 13229)
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

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2. Flexible AL Bond for 7/3.15 mm GS Earthwire


Sl. Description Unit Particulars/ Value
1. Stranding 19(12+6+1)/dia2.54
2. Cross sectional area Sq.mm 95
3. Length of aluminium cable mm 750+5
4. Material of lugs Aluminum alloy
5. Bolt Size
i) Diameter mm 16
ii) Length mm 40

3. Vibration Damper for 7/3.15 mm GS Earthwire


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/m 135
strength of stranded m 2

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

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a) Minimum weight of Zinc coating gm/m2 610


for steel parts
b) Purity of Zinc used for % 99.95 (IS 209) or 98.5 (IS 13229)
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

4. Suspension Clamp for 7/3.15 mm GS Earthwire


Sl. Description Unit Particulars/ Value
1. Material of components
(a) Shackle Forged Steel
(b) Clamp Body & Keeper Malleable cast iron / SGI
(c) U- Bolt Mild Steel (Fe 410, IS 2062)
2. Total Drop (Maximum) mm 150
3. Breaking Strength (Minimum) kN 25
4. Slipping Strength kN 9 to 14
5. 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

5. Tension Clamp for 7/3.15 mm GS Earthwire


Sl. Description Unit Particulars/ Value
1. Material of components
(i) Anchor Shackle Forged Steel
(ii) Compression Clamp
a) Steel Sleeve Mild Steel (Fe 410, IS 2062)
b) Aluminium sleeve Aluminium of purity 99.5%
c) Aluminium Filler sleeve Aluminium of purity 99.5%
2. Range of Hardness of the steel BHN 100-200
sleeve (Brinnel hardness)
3. Dimension of sleeve Before compression
Aluminium Steel Alu filler
Sleeve Sleeve sleeve
i) Inside diameter mm 22.00 ± 0.5 10.00 ± 0.2 11.50 ± 0.2
ii) Outside diameter mm 30.00 ± 0.5 21.00 ± 0.5 21.00 ± 0.5
iii) Length mm 220 ± 5 180 ± 5 25 .0+2
4. Dimensions of Sleeve after compression
Aluminium Sleeve Steel Sleeve

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i) Outside dimension (Corner to mm 29.40 ± 0.5 20.20 ± 0.5


Corner)
ii) Outside dimension (face to face) mm 25.00 ± 0.5 17.50 ± 0.5

5. Slip strength KN 53.20


6. Minimum Breaking strength of KN 70
assembly (excluding clamp)
7. Compression Pressure Ton 100
8. 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

S) Accessories for 7/4.5 mm GS Earthwire for ±800 kV transmission line


Mid span compression Joint for 7/4.5 mm GS Earthwire
Sl. Description Unit Particulars/ Value

Aluminium / Steel Sleeve


Filler Sleeve
1. Material of Joint Aluminium Mild Steel
of minimum (Fe-410,
purity 99.5% IS:2062)
2. Range of Hardness of the steel sleeve BHN From 100 to 200
(Brinnel hardness)
3. Weight of Zinc coating gm/m2 610
4. Dimension of sleeve Before compression
Aluminiu Steel Alu filler
m Sleeve Sleeve sleeve
i) Inside diameter: Nominal mm 24-28 14-15 14-15
Tolerance mm ± 0.5 ± 0.5 ± 0.5
ii) Outside diameter: Nominal Mm 32-38 24-27 24-27
Tolerance mm ± 0.5 ± 0.5 ± 0.5
iii) Length mm As per As per As per
design* design* design*
* As per design to meet specified strength requirement
(Minimum length-Al-Sleeve-525mm, Steel sleeve-345mm, Alu filler tube-50mm)
5. Dimensions of Sleeve after compression
Aluminium Steel Sleeve
Sleeve
i) Outside dimension (Corner to Corner) mm As per design As per design

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ii) Outside dimension (face to face) mm As per design As per design


iii) Length mm As per design As per design
6. Slip strength KN 100.9
7. Maximum resistance of the compressed % 75
unit expressed, as percentage of the
resistance of equivalent length of bare
Earthwire

2. Flexible AL Bond for 7/4.5 mm GS Earthwire


Sl. Description Unit Particulars/ Value
1. Stranding 19(12+6+1)/dia2.54
2. Cross sectional area Sq.mm 95
3. Length of aluminium cable mm 750+5
4. Material of lugs Aluminum alloy
5. Bolt Size
i) Diameter mm 16
ii) Length mm 40
3. Vibration Damper for 7/4.5 mm GS Earthwire
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 hop 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
4. Minimum ultimate tensile strength of Kg/mm2 135
stranded messenger cable
5. Slip strength of stranded messenger kN 5
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 reactance after % +/-25(Maximum)
fatigue test in comparison with that
before fatigue test
9. Percentage variation in power % +/-25 (Maximum)
dissipation after fatigue test in
comparison with that before fatigue test

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4. Suspension Clamp for 7/4.5 mm GS Earthwire


Sl. Description Unit Particulars/ Value
1. Material of components
(a) Shackle Forged Steel
(b) Clamp Body & Keeper Malleable cast iron / SGI
(c) U- Bolt Mild Steel
2. Total Drop (Maximum) mm 150
3. Breaking Strength (Minimum) kN 45
4. Slipping Strength kN 19 to 27
5. Galvanising
a) Minimum weight of Zinc coating for steel gm/m2 610
parts
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 the No. a) Fasteners: 4 dips of 1
ferrous parts can withstand (wherever minute
applicable) b) Spring washers: 3 dips of
1 minute &
c) all others: 6 dips of 1
minute

Tension Clamp for 7/4.5 mm GS Earthwire


Sl. Description Unit Particulars/ Value
1. Material of components
(i) Anchor Shackle Forged Steel
(ii) Compression Clamp
a) Steel Sleeve Mild Steel
b) Aluminium sleeve Aluminium of purity 99.5%
c) Aluminium Filler sleeve Aluminium of purity 99.5%
3. Range of Hardness of the steel sleeve BHN 120-200
(Brinnel hardness)
4. Dimension of sleeve Before compression
Aluminium Steel Alu
Sleeve Sleeve filler
sleeve
i) Inside diameter: Nominal mm 24-28 14-14.5 14-14.5
Tolerance mm ± 0.5 ± 0.5 ± 0.5
ii) Outside diameter: Nominal mm 32-38 24-28 24-28
Tolerance mm ± 0.5 ± 0.5 ± 0.5
iii) Length mm As per As per As per
design design design
5. Dimensions of Sleeve after compression

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Aluminium Sleeve Steel Sleeve


i) Outside dimension (Corner to Corner) mm As per design As per design
ii) Outside dimension (face to face) mm As per design As per design
6. Slip strength KN 100.9
7. Minimum Breaking strength of assembly KN 120
(excluding clamp)
8. Compression Pressure Ton 100

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Annexure-C

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