Volume – 2
Technical Specifications and GTP’s
The technical specifications of major items have been given herewith.
The items for which technical specifications have not been given shall be as per the latest
relevant REC/ CBIP/ CEA/ BIS/ IEC standards
In case of any contradictions between GTP and National / International Standards, the later shall
prevail.
Line Item
B1
TECHNICAL SPECIFICATION FOR CROSS ARM
B5
TECHNICAL SPECIFICATION FOR LT & HT GUY INSULATOR
B6
TECHNICAL SPECIFICATION FOR 11/33 KV H.T. PIN INSULATORS
B7
TECHNICAL SPECIFICATION FOR LT PIN / SHACKLE INSULATORS
B8
TECHNICAL SPECIFICATION FOR 11 kV AIR BREAK SWITCH
B9
TECHNICAL SPECIFICATION FOR 11 & 33 KV HORN GAP FUSES
B10
TECHNICAL SPECIFICATION FOR EARTHING SETS (A & B) TYPES
B11
TECHNICAL SPECIFICATION FOR HT/LT STAY SETS
B13
TECHNICAL SPECIFICATION FOR G.I. STAY WIRE
TECHNICAL SPECIFICATION FOR JOINTING SLEEVE, AL BINDING WIRE,
B14
TAPE
B15
TECHNICAL SPECIFICATION FOR BARBED WIRE
B16
TECHNICAL SPECIFICATION FOR DANGER PLATE
B17
DELETED
B19
TECHNICAL SPECIFICATION FOR LT 16, 25, 63, 100, 250, 400, 630 KVA
DISTRIBUTION BOX WITH MCCB
TECHNICAL SPECIFICATION FOR L.T.AERIAL BUNCHED CABLES FRLS
B20
TYPE
B21
B23
B24
B29
TECHNICAL SPECIFICATION FOR POLYMERIC INSULATOR
TECHNICAL SPECIFICATION FOR HT AB CABLE ACCESSORIES
TECHNICAL SPECIFICATION FOR LT AB CABLE ACCESSORIES
TECHNICAL SPECIFICATION FOR WEDGE CONNECTOR
GENERAL REQUIREMENTS
All the items & equipment procured for the project shall be suitable for following general requirements.
1. SERVICE CONDITIONS:
All the equipment supplied shall be suitable for the climatic conditions specified as follows
1.1. Equipment supplied against the specification shall be suitable for satisfactory operation under the
following tropical conditions:i) Maximum ambient temperature in open air (°C):
38
ii) Maximum ambient temperature in shade (°C)
30
iii) Minimum temperature (°C):
iv) Relative humidity (%)
v) Maximum annual rainfall (mm)
vi) Maximum wind pressure (Kg/ Sqmtr.)
vii) Maximum altitude above mean sea level (Mtrs)
viii) Isoceraunic level (days/year)
ix) Seismic Zone
Reference Ambient Temperature for Temperature rise
nature of climate:
summers
-15
10 to 100
1000
150
2000
15
x)
50 deg C1.2. General
Moderately hot
and cold winters with
moderate to heavy
snowfall
and freezing temperatures. The
climatic conditions are prone to wide
variations in ambient conditions and
hence the equipment shall be of
suitable design to work satisfactorily
under these conditions.
2. VENDORS EXPERIENCE
The successful bidder shall purchase Materials/Equipment as per the approved GTP from the already
approved Vendors by JKPDD Vendor shall furnish here a list of similar orders executed/under execution by
him to whom a reference may be made by Employer in case he considers such a reference necessary.
..
3. INSPECTION
Inspection may be carried out by the Employer or third party nominee at any stage of manufacture. The
contractor/supplier shall grant free access to the Employer's representative or third party nominee.
acceptance of any equipment under this specification by the Employer shall not relieve the
contractor/supplier of his obligation of furnishing equipment in accordance with the specification and
shall not prevent subsequent rejection if the equipment is found defective. Inspection, Testing &
Rejection shall be carried out as per Volume I, Part A Section 2 of SBD.
4. All the equipments & items shall be type tested within last 5 years as per latest revision of relevant
Indian Standards / IEC / international standards as applicable. All the type test shall be carried out in a
laboratory accredited by National Accreditation Board of Testing and Calibration Laboratories (NABL).
5. All the GTP’s along with drawings and type test reports for each item will be submitted by the bidder.
The bidders shall furnish an undertaking that all the items & equipments supplied shall be duly type
tested within last 5 years and as per the specification mentioned in the bid document and /or latest
revision of relevant standard specification.
6. ACCEPTANCE TEST: All equipment & items shall be subjected to acceptance tests as per latest
revision of relevant Indian Standards / IEC / international standards as applicable
7. ROUTINE TEST: All equipment & items shall be subjected to routine tests as per latest revision of
relevant Indian Standards / IEC / international standards as applicable
8. WAIVER OF INSPECTION: Waiver of inspection, if any, shall be obtained from CE EM&RE Wing
Kaskmir.
9. DELIVERY: Delivery of all items shall be effected at the designated store of the contractor duly
approved by JKPDD.
10. DISPATCH: All equipment & items shall be dispatched only after receipt of dispatch instructions
issued by CE EM&RE Kashmir.JKPDD. The dispatch of materials shall be accompanied by delivery
challan, inspection report, test certificates, O & M Manuals and a copy of dispatch instructions.
11. RECEIPT INSPECTION & ACCEPTANCE OF MATERIAL ON SITE: All the materials shall be
subjected to receipt inspection by JKPDD representative for visual, dimensional checks and other
checks as required and checking of dispatch documents for acceptance of material at site along with
correlation of material inspected and received wherever applicable.
12. Deleted.
13. All ferrous metal parts should be hot dip galvanized unless and until specified otherwise. The
thickness of galvanization shall be as per IS Specification. No MS accessories shall be used in this
project. Adequate number of electronic instruments for measurement of thickness of galvanization shall
be provided.
14. All distribution transformers shall be earthed through three no. 2.5 mtr GI pipe earth electrodes as
per drawing no. F5 and F10 of REC manual.
15. All PCC poles shall be provided with concrete pad of 400 X 400 X 100 mm at the bottom before
erection of the pole.
16. At tension points PCC poles shall be installed in Transverse/ Lateral Position.
17. Two pole, three pole and four pole structures shall be provided with cross bracings as per REC
construction drawing no. A-21.
18. For constructional purpose REC/ CBIP/ CEA/ BIS/ IEC Construction Standard are to be referred and
followed.
19. Fixing of guys to trees, buildings, structures, poles, pipe lines etc. Shall not be allowed in any case
whatsoever.
20. Guy insulator shall be provided above 2.6 mtrs from the ground level.
21. The clearances of 33KV, 11KV and LT lines from ground and from buildings shall be as per J&K
Electricity Rules which are as under:
(a) Minimum clearance above ground of the lowest conductor:
Line Voltage
(Phase to Phase)
Clearance across
street (Mtr)
Along street
(Mtr)
Elsewhere than along
or across street (Mtr)
LT Lines
11 KV lines
33 KV lines
5.791
6.069
6.965
5.486
5.791
6.965
4.572
4.572
5.182
(J&K Electricity Rules 1978 page 44)
(b) Clearance from buildings
Where an electrical line passes above or adjacent to or terminates on any building, the following
minimum clearance from any accessible point, on the basis of maximum sag shall be observed:
Line Voltage
(Phase to Phase)
Vertical Clearance from
highest point of building
(Mtr)
Horizontal Clearance from highest
point of building (Mtr)
LT Lines
11 KV lines
33 KV lines
2.439
3.658
3.658
1.219
1.319
1.529
(J&K Electricity Rules 1978 page 45&46)
Note: The horizontal clearances shall be measured when the line is at a maximum deflection from the
vertical due to wind pressure.
(c) Phase to phase Clearances
The phase-to-phase clearances of 33kV, 11kV and LT lines shall be as per Rural Electrification
Corporation Construction Standards, which are as under:
Line Voltage
(Phase to Phase)
Minimum phase to phase
clearance (MM)
LT Lines
300 Vertical
Preferred Configuration
11 KV lines
33 KV lines
450 Horizontal
1070
1525
Triangular on V cross arms
Triangular on V cross arms
The preferred configuration for LT lines is vertical.
(d) 11kV/ 433V Distribution Sub Station Installation
Clearances: As per REC standard specification no. F-1, F-2, F-3 and F-4 shall be maintained for
11/0.433kV Sub Stations
Description
Pole mounted
Transformer
Pad mounted Transformer
Phase to Phase spacing of
down conductors
760mm
460mm
Phase to Earth clearance of
down conductors
(Horizontal)
460mm
460mm
HT terminal of 11kV bushing
up to ground
5440 mm
2200 mm
22. The items for which technical specifications have not been given shall be as per the latest relevant
REC/ CBIP/ CEA/ BIS/ IEC standards & guidelines. In case of any contradictions between GTP and
National / International Standards, the later shall prevail.
TECHNICAL SPECIFICATION FOR 11kV SURGE ARRESTER WITH DISCONNECT
1. SCOPE:
This specification covers the design, manufacture, assembly, testing at manufacturer's works, of Metal
Oxide (gapless) Surge arrester in polymer housing with Arrester Disconnect for 11kV systems for use in
various substations/ lines in the State of Jammu & Kashmir in India.
1.1. It is not the intent to specify completely herein all the details of design and construction of Surge
arrester with Disconnect. However, Surge arrester with Disconnect shall conform in all respect to the
high standard of design and workmanships and be capable of performing in continuous commercial
operation up to Vendor’s guarantee in a manner acceptable to Employer, who will interpret the
meanings of drawing and specifications and shall have the power to reject any work or material which in
his judgment are not in accordance therewith. The Surge arrester with Disconnect offered shall be
complete with all parts, necessary for their effective and trouble free operation. Such components shall
be deemed to be within the scope of Vendor's supply, irrespective of whether they are specifically
brought out in the specification or not.The Surge Arrester with Disconnect is intended to perform the
following operations.
1) Disconnect from the power system any failed Arrester to which Disconnect is connected in series in
order to prevent loss of energy to the ground.
2) Provide visual indication of "failed" Arrester to facilitate its timely replacement.
3) The Disconnect should be suitable for retrofitting on the existing silicon- conventional Gapped/Metal
Oxide Gapless distribution class Arrester of any make. For this purpose a small conducting adaptor may
be provided if necessary.
.
4. SPECIFIC TECHNICAL REQUIREMENTS:
4.1. The Surge arrester with Disconnect shall conform to the technical requirements as per Annexure-II.
4.2. PROTECTIVE LEVELS:
The basic insulation levels of lines and equipments to be protected have been specified in relevant IS.
The required protective levels of the Surge arrester with Disconnect have been specified in Annexure-II.
The protective characteristics of the Surge arrester with Disconnect offered shall be clearly brought out
in the guaranteed & other technical particulars, i.e. G.T.P.
5. GENERAL REQUIREMENT:
5.1. Each individual unit of Surge arrester with Disconnect shall be hermetically sealed and fully
protected against ingress of moisture. The hermetic seal shall be effective for the entire lifetime of the
arrester with disconnect and under the specified service conditions.
A suitable pressure-relieving device shall be provided to avoid damage to the external insulator in case
of a severe discharge.
5.2. The corresponding units of Surge Arrester with Disconnect of the same rating shall be
interchangeable without adversely affecting the performance.
5.3. The Surge arrester with Disconnect shall be suitable for bracket type mounting.
5.4. All the necessary flanges, bolts, nuts, clamps etc. required for assembly of complete Surge arrester
with Disconnect with accessories and mounting on Employer's support structure shall be included in
Vendor's scope of supply and shall be galvanized.
5.5. POLYMER RUBBER HOUSING:
5.5.1. Polymer Rubber Housing shall be free from cavities or other flaws affecting the mechanical and
electrical strengths.
5.5.2. The Polymer Rubber housing shall be non-porous. The housing shall conform to the degree of
protection as per IP53 ( IS 1394 part-I,1993)
5.5.3. The creepage distance of the Arrester housing shall be as indicated in Annexure-II.
5.5.4. The Surge arrester with Disconnect housing shall conform to the requirements of IEC-99-4
specification for surge arrester without gaps for A.C.System.
5.6. GALVANIZATION, NICKEL PLATING ETC.:
5.6.1. Line terminal pads, ground terminal pads, and nameplate bracket shall be hot dip galvanized as
per IS 4759- 1996.
5.6.2. The material shall be galvanized only after completing shop operations.
6. ACCESSORIES & FITTING:
The grounding terminals shall be suitable for accommodating grounding leads.
6.1. NAME PLATE:
The Surge arrester with Disconnect shall be provided with non- corrosive legible nameplate marked with
punching or engraving the following information.
1) Jammu & Kashmir Power Development Department.
2) Contract No. and Project Name
3) Manufacturer's name or trade mark and identification of the supplied Surge arrester with Disconnect.
4) Rated voltage.
5) Maximum continuous operating voltage.
6) Type
7) Rated frequency.
8) Nominal discharge current.
9) Long duration discharge class.
10) Identification of assembly position of the unit.
11) Year of manufacture.
7. DOCUMENTATION:
7.1. All drawings shall conform to International Standards Organization (ISO) "A" series of drawing
sheet/Indian standards specification IS:656. All drawings shall be in ink and suitable for microfilming. All
dimensions and data shall be in System International Units.
7.2. The manufacturing of the equipment shall be strictly in accordance with the approved drawings and
no deviation shall be permitted without the written approval of the Employer. All manufacturing and
fabrication work in connection with the equipment prior to the approval of the drawing shall be at the
Vendor's risk.
7.3. Approval of drawings/works by Employer shall not relieve the Vendor of any of his responsibility and
liability for ensuring correctness and correct interpretation of the drawings for meeting the requirement of
the latest revision of applicable standards, rules and codes of practices. The Employer shall have the
power to reject any work or material, which in his judgment is not in accordance therewith.
8. PACKING AND FORWARDING:
8.1. The equipment shall be packed in suitable crates so as to withstand handling during transport and
outdoor storage during transit. The Vendor shall be responsible for any damage to the equipment during
transit, due to improper and inadequate packing. The easily damageable material shall be carefully
packed and marked with the appropriate caution symbols. Wherever necessary, proper arrangement for
lifting such as lifting hooks etc. shall be provided. Vendor without any extra cost shall supply any
material found short inside the packing cases.
8.2. Each consignment shall be accompanied by a detailed packing list containing the following
information.
a) Name of the consignee.
b) Details of consignment.
c) Destination.
d) Total weight of consignment.
e) Sign showing upper/lower side of the crate.
f) Handling and unpacking instructions.
8.3. The Vendor shall ensure that the Employer before dispatch approves the packing list and bill of
material.
8.4. The material shall be transported within Jammu & Kashmir to the respective destination by Road
Transport/Rail Transport as the case may be at the option of Employer
ANNEXURE-I
LIST OF STANDARDS
Sr.No.
1
2
Standard Ref.No.
IEC-99-4/1991
. 3
ISS-3070 (Part1)/1985 &(Part3)/1993
ISS-4759/1996
4
ISS-2633/1986
5
ISS-5621/1980
6
ISS-13947/1993
(Part-I)
-
7
Title
Specification for Surge arrester without gap of
A.C.system.
Specification for Lightning Arrester for Alternating
Current Systems
Hot dip zinc-coating on structural steel and other allied
products.
Method for testing uniformity of coating on zinc coated
articles.
Specification for large hollow porcelain for use in
Electrical installation.
Degree of protection provided by enclosures for low
voltage switch gear and control
Indian Electricity Rules 1956
NOTE
i) For the purpose of this specification all technical used in this specification shall have the meaning
terms as per IEC specification.
ii) For the parameters of the Surge arrester with Disconnect which are not specified in IEC specification
for surge arrester, the provisions of IS-3070 (Part-3) shall be applicable.
ANNEXURE – II
REQUIREMENTS OF PARAMETERS FOR SURGE ARRESTER WITH DISCONNECT
Sr. No.
1
Particulars
Rated Voltage ** (kV rms)
2
Maximum Continuous Operating Voltage
(M.C.O.V.) in kV rms.
3
Installation
4
Class
11 kV
9
8
Outdoor
Distribution
5
Type of construction
6
Nominal discharge current corresponding
7
Type of mounting
8
Connection (Between phase to earth P/E)
9
Long duration discharge class
10
Min. creepage distance of arrestor housing
(mm).
Single Column, Single Phase
5
Bracket type
P/E
75 AMPS 1000 Micro Sec.
300
** Rated Voltage means max permissible r.m.s. value of power frequency voltage at which Surge
arrester is designed to operate correctly.
ANNEXURE – III
SYSTEM PARTICULARS
The surge arrester offered under this specification shall confirm to the parameters given below: -
Sr. No.
Particulars
For 11 KV Surge Arrestor
1
Nominal system voltage ( kV r.m.s.)
11
2
Highest system voltage ( kV r.m.s.)
3
1.2/50 microsecond impulse voltage
withstand level
12
75
4
System frequency (HZ)
5
Neutral Grounding
6
Number of phases
One minute power frequency withstand
voltage (kV r.m.s.) of arrester
housing.
7
50
Effectively Earthed.
Three
28
5. TESTS:
5.1. Special Tests:
Special tests listed in Annexure III shall be carried out in presence of Employer's representative.
6. DOCUMENTATION:
6.1. All drawings shall conform to international standards. All drawings shall be "A3" size only. All
dimensions and data shall be in System International units.
6.2. After selection by the Employer, the successful vendors shall submit 3 sets of complete drawings
along with detailed bill of materials for approval. to Chief Engineer, System and Operation/RAPDRP-B
Kashmir Planning & Design, JKPDD, Bemina Srinagar. Space for stamp and signature of approving
authority shall be kept at right hand bottom corner above name block. If any modifications are required
on these, the same will be conveyed to the vendor who shall modify the drawings accordingly and
furnish final drawings for approval. In no case delivery extension will be granted for any delay in drawing
approval.
6.3. Four sets of the type test reports, duly approved by the Employer, shall be submitted by the vendor
for distribution, before commencement of supply. Adequate copies of acceptance and routine test
certificates, duly approved by the Employer, shall accompany the dispatched consignment.
6.4. The manufacturing of the equipments shall be strictly in accordance with the approved drawings
and no deviation shall be permitted without the written approval of the Employer. All manufacturing and
fabrication work in connection with the equipment prior to the approval of the drawing shall be at the
vendor's risk.
6.5. Approval of drawings/work by Employer shall not relieve the vendor of his responsibility and liability
for ensuring correctness and correct interpretation of the latest revision of applicable standards, rules
and codes of practices.
6.6. INSTRUCTION MANUALS:
Three copies of the erection, operation and maintenance manuals in English shall be supplied for each
type of the disconnect one month prior to dispatch of the equipment. The manual shall
be bound volume and shall contain all drawings and information required for erection, operation and
maintenance of the disconnect including but not limited to the following particulars:
a. Marked erection prints identifying the component parts of the disconnect as shipped with assembly
drawings.
b. Detailed dimensions and description of all auxiliaries.
c. Detailed views of the insulator stacks, metallics, operating mechanism, structure, interlocks, spare
parts etc.
ANNEXURE-I
LIST OF STANDARDS
(REF CLAUSE NO.3.1)
Sr.No.
Standard No.
Title
1
IS:1818
Alternating current isolators (disconnect) and
earthing switches
2
IS:9921
-do-
3
IEC:129
-do-
4
IS:2544
Insulators
5
IS 13947
Degree of protection provided by enclosures
6
IS:4691
-do-
7
IS:325
Three phase induction motors
8
IS:4722
Rotating Electrical Machines
9
IS:2629
Recommended practice for hot dip
galvanizing of iron and steel
10
IS:4759
Hot dip galvanization coating on Structural
Steel.
11
IS:2633
Method o f testing w eight thickness and u
uniformity o f coating o n fasteners
12
IS:1573
Electro plated coating of zinc on Iron & Steel.
13
IS:3033
Spring Washers
14
IS:2016
Plain washers
15
IE Rules 1956
Indian Electricity Rules
16
IEC:168
Tests on Indoor and Outdoor post Insulator
17
IS:3961
18
IS: 5561
Recommended current rating for PVC
Insulated and PVC Sheated heavy Duty
Cables.
Power Connectors
19
IS:1554
PVC Cables
IS:5578
Guide for marking o f Insulated conductors
and arrangement for switchgear bus bar
main connectors & Auxiliary wirings.
IS:11353
Guide for Uniform system of marking and
identification of conductors and apparatus
terminals.
20
21
ANNEXURE-II
PRINCIPAL TECHNICAL PARAMETERS
(REF.CLAUSE NO.4.0)
Sr.No Technical parameter
1
Rated Freq.
2
Units
Requirement
Hz
50
3
System Neutral
Earthing
No.of phases(Poles)
No.
3
4
Temperature rise
°C
As per relevant IS/IEC
5
Safe duration of
overload
Minutes
6
7
8
a) 150% of rated
current
b) 120% of rated
current
Rated voltage
Type of disconnect
(AB)
Rated normal current
Effectively earthed.
5 minutes
30 minutes
KV rms
36
DBCR
Arms
800
Rated short time
withstand current of
MS
and EB for 3 seconds.
Rated Peak current of
MS and EB
KArms
25
KA peak
63
11
Rated short circuit
making current of E.B.
KA peak
63
13
Basic insulation level
9
10
i) Lightning impulse
withstand voltage
KV peak
a) To earth and
between poles
170
b) Across isolating
distance.
195
ii) Rated power
frequency withstand
voltage
kV rms
a) To earth and
between poles
70
b) Across isolating
distance
80
14
Minimum Creepage
mm
900
15
Center to Center
spacing for installation
mm
1500
16
Minimum clearances
mm
i) Phase to earth
430
ii)Between the rotating
post and fixed post on
one phase
485
17
Height of centre line of
terminal pad above
ground level
18
Special requirements
mm
3885
a. Earthing blades shall be capable to discharge the trapped charge of the line.
b. Isolator Main switch shall be required to make or break the line charging current
when no significant change in voltage occurs across the isolating distance on account
of make or break
c. The Isolator required is not with turn and twist mechanism, it is rotating type
NOTES:DBCR - DOUBLE BREAK CENTRE POLE ROTATING ISOLATOR
AB - AIR BREAK
MS - MAIN SWITCH
EB - EARTH BLADE
APP – APPROXIMATE
ANNEXURE-III
LIST OF SPECIAL TESTS TO BE CARRIED OUT
(REF.CLNO.6.4)
Sr.No.
1
2
3
Name of the Test
Standard to which it conforms
Tests on Insulators
----------do--------Tests on terminal connectors
Tests on Galvanized components
IS : 2544
IEC : 168
IS : 5561
IS : 2623
4
5
Operation tests on operating
mechanism and interlock
Endurance tests on auxiliary
Switches
Annexure IV
List of Type Tests (Ref.Cl.No.6.1)
Isolators (with and without E.B.) IS:9921 (Part IV)
Sr. No.
1.
2.
3.
4.
5.
Description of Type Test
IS Clause No.
Lightning Impulse Voltage withstand Test
Power Frequency Voltage Withstand Test
a) Dry
b) Wet
Temperature Rise Test
Short Time Withstand Current and Peak
Withstand Current Test
Mechanical Endurance Test
3.1.6
3.1.8
3.1.1
3.3
3.5
Post Insulators (IS 2544)
Sr. No.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Visual Examination
Verification of Dimensions
Visible discharge test
Impulse voltage withstand test
Dry power frequency Voltage withstand test
Wet power frequency Voltage withstand test
Temperature cycle test
Test for mechanical strength
Puncture Test (For insulator type B only)
Porosity test
Galvanizing test
9.12
9.7
9.2
9.3
9.4
9.5
9.8
9.6
9.9
9.10
9.11
Terminal connectors (IS: 5561)
Sr. No.
IS Clause No.
1.
2.
3.
4.
5.
6.
Tensile test
Resistance test
Temperature rise test
Short time current test
Dimensional check
Galvanizing test where applicable
10
11
12
13
14
15
TECHNICAL SPECIFICATION FOR HEAT SHRINKABLE TYPE CABLE JOINTING AND
TERMINATION KITS FOR 33 KV AND 11 KV XLPE CABLES
1.
SCOPE:
This specification covers the design, manufacturing, testing and supply of Heat Shrinkable type cable
straight-through joints and cable end termination kits suitable for use with and installation on 33 KV and
11 KV XLPE aluminum conductor cables.
1.1. The cable accessories specified in this specification i.e., cable end terminations, either indoor or
outdoor, and straight- through, shall be complete in all respects. Such complete set of accessories shall
be termed as kithereinafter in this specification.
1.2. Termination and jointing kits shall be heat-shrinkable type o f proven make and of a design and type
which have already been extensively used and fully type tested. The offered kits shall be easy in
handling and simple to install without much s kill, with minimum tools at site.
2.
TYPE
2.1. Termination Kits & Joints shall be heat shrinkable type for 33 kV & 11 kV XLPE cables suitable for
Outdoor and Indoor Cable End Terminations and Straight through Joints
2.2. It is not the intent to specify completely herein all the details of the design, manufacture & assembly
of cable accessories; however, cable accessories shall confirm in all respects to a high standard of
design & workmanship and be capable of performing in continuous commercial operation up to bidders
guarantee in a manner acceptable to the Employer, who will interpret the meanings of the drawings and
specifications and shall have the power to reject any works or material which in his judgment are not in
accordance therewith. The cable accessories
offered shall be complete with all components
necessary for the effective and trouble- free operations. Such components shall be deemed to be within
the scope of vendor's supply irrespective of whether they are specifically brought out in this specification
and/ or in the commercial order or not.
3. SYSTEM PARAMETERS
1
Nominal
voltage
2
Maximum
voltage
3
4
5
operating
system
Frequency (Hz.):
Number of Phases
Type of Earthing
6
Environmental
conditions
7
Basic
Insulation
33 kV rms
11 kV rms
33 kV rms
12 kV rms
50 +/- 1.5
50 +/- 1.5
3
3
Solid
Solid
Humid Tropical Climate with polluted atmosphere, and/or
direct burial in water- logged ground.
170 kV (Peak)
75 kV (Peak)
Level
4. SERVICE CONDITIONS
The kits shall be provided with protection against rodent and termite attacks.
5. DESIGN FEATURES.
The following considerations shall be taken into account in the design of the product, material properties
and the components of the jointing and termination kits.
I). Electrical stresses at the screen cut back in case of XLPE cables shall be controlled to a safe value.
The stress control may be either through stress control tubing / stress control cone or other suitable
means. The bidder shall furnish details of the technique employed by them for stress control in cableend terminations / straight-through joints. The application of stress control system shall be safe,
foolproof and independent of cable jointers’ skills. The stress control method used should withstand
expansion and contraction of the cable during load cycling.
ii). The cable end termination and jointing kits shall be so designed so as to prevent discharge/ leakage
at the cut back and nicks / scratches on XLPE insulations.
iii). The cable end termination and jointing kits shall be so designed so as to give track - resistant
erosion and weather resistant protection to the cable insulation. The outdoor end terminations and
straight through joints shall be totally sealed against ingress of moisture of environment.
iv). All Outdoor End Termination kits as well as Indoor End Termination kits shall be provided
with
rain ( weather) sheds or creepage-extending petticoats. These shall be non-tracking, weather resistant,
hydrophobic and have smooth surface to deflect any water/ dirt etc. The design of this rain (weather)
sheds or creepage-extending petticoats shall avoid any shed to shed conducting path under heavy rain
conditions.
v). The cable end terminations & jointing kits shall be class 1 as defined in IEEE standard 48/1996 with
latest amendments. Documentary proof shall be required to prove compliance in this regard without
which the bid may be ignored.
vi). The lugs and ferrules provided should be suitable for compacted conductors and should withstand
thermal short circuit of 250 deg. centigrade.
6. GENERAL REQUIREMENT FOR CABLE END TERMINATIONS / STRAIGHT THROUGH JOINTS.
i). The term heat shrinkable refers to extruded or moulded polymeric materials which are cross linked to
develop elastic memory by irradiation method and supplied in expanded or otherwise deformed sizes/
shapes, subsequently heating in a s trained state to a temperature above the shrink temperature
resulting in the material recovering o r shrinking to its original shape.
a). The stress control tubes used in heat shrinkable cable accessories shall have volume resistivity of
minimum 1,00,00,000 ohm meters for both terminations & straight through joints.
The relative
permittivity shall be minimum 15. Further, impedance of stress control tubes shall not change over a
range of temperature from 0 de g C to 125 deg C . The s tress control tubes must have a thermal
endurance equivalent to 35 years life. The impedance should also remain constant in spite of the
difference in stress which will exist within the sleeve due to heating effect within the conductor and the
temperature of the environment.
b). Bidder must submit graph showing effect on the impedance value of stress control tube due to
effects of stress, temperature variations and thermal ageing of minimum 10,000 Hrs. with the offer.
ii).The heat shrinkable polymeric material to be used for external leakage insulation between the high
voltage conductors and grounds should be non-tracking, weather and erosion resistant and hydrophobic in nature. A heat-shrinkable flexible polymeric tubing, preferably coloured red, and possessing
non -tracking erosion and weather resistant properties shall work as an external covering for the cable
covers.
Rain - Sheds (skirts) provided should be of same material as the non tracking tube specified in the
paragraph above
ii). Since the sealants or adhesives to be used between the heat shrinkable materials and XLPE cable
shall be exposed to high electrical stresses, they must be track resistant.
iii). All cuts/ nicks inadvertently occurred to XLPE insulation must be rendered discharge free by using
suitable discharge suppression compound.
vi). The heat shrinkable tubes may be either extruded or moulded type.
v). The higher w all-thickness o f heat shrinkable tubes / sleeves s hall b e preferred to counter the effect
of erosion due to pollution.
7. OTHER REQUIREMENTS
i). The kit shall be suitable for storage without deterioration at a temperature up to 50 Deg. C and shall
have unlimited shelf life. Conducting paints having limited shelf life are not acceptable.
ii). Proper stress control, stress grading and non tracking arrangement in the termination shall be offered
by means of proven methods.
iii). The straight through joints shall be suitable for underground buried installation with incorporated
back-fill and chances of flooding by water. The straight through joints should be absolutely impervious to
the entry of water. The manufacturer shall use proven technology and design to prevent entry of water
or any other liquid inside the straight through joints and cables.
iv). The end termination kits shall provide for total environmental sealing of the cable crutch and at the
lugs end.
v). Provisions for effective screening over each core s hall be made The materials and components not
specifically stated in the specification but which are essential for satisfactory operation of the cable shall
be deemed to be included in the kit without any extra cost.
vi). The terminations / joints shall be of better tracking resistant properties and fully reliable earthing
system to maintain continuous contacts with screening/ armouring as the case may be.
vii). The armour / earthing arrangement shall form part of the terminations/ joints and shall be protected
from erosion either by suitable tape or tube.
Viii).The terminations/ jointing kits shall have provision for shield connection and earthing whichever
required.
ix). The fault level as well as duration withstands capacity of termination / jointing kits should be strictly
matching with the parameters of cables for which the kits are intended to be used.
x). The trade / brand name of the manufacturer shall be embossed / engraved or suitably marked with
indelible ink / paint for the purpose of identification on the tubings and components which are visible
from the outside. The words “JVVNL” along with the trade / brand name of the manufacturer, TN No. ,
month / year of manufacture, size etc. shall be suitably printed / marked on the kit packing/Cartoon
xi).Suitable creepage extension/ rain protection sheds for outdoor cable end terminations shall be
provided.
xii).Adequate provisions for eliminating the chances of entrapment of air at steps formed by semicon
screen shall be made.
xiii). The terminations/ joints shall be supplied in kit form. All insulation and sealing materials,
consumable items, conductor fittings, earthing arrangements and lugs etc. should be provided.
xiv).The bidder shall furnish the constructional features of material offered.
xv). An instruction manual in English and , optionally in Hindi script, indicating the complete method/
proceedings adopted for installation of kits, preferably with more diagrams/ pictorial presentation shall
be supplied with each k it. Various items, quantity thereof included in each kit must be indicated in the
instruction manual / packing slip provided in the kit packing.
8. CABLE SIZE AND ITS REQUIREMENT
If the design of the cable jointing kits is such that same kit is suitable for more than one of the cable
sizes mentioned above, then the bidder shall furnish the details of kit number and corresponding cable
sizes for which the kit is suitable.
9. CIRCULAR SHAPED CONDUCTOR:The terminations/ jointing kits offered shall be suitable to be used on circular compacted XLPE cable
conductor.
10. LUGS/ FERRULES
Requisite number and size of lugs/ ferrules depending upon the type of the cable shall be provided in
the kit. Lugs and Ferrules shall be of crimping type, shall confirm to the relevant standards in case of
XLPE cables.
11. EARTH/SCREEN CONTINUITY
i). Screen continuity by using tinned copper mesh and earth continuity by tinned copper braids of
appropriate size shall be provided for transfer of screen/ earth in straight through joints.
ii).Tinned copper braids of appropriate size along with copper lugs of proper size shall be provided for
the continuity of screen/ armour along with adequate clamping arrangement.
12. EARTHING
Earthing shall be as per relevant standards
13. FIRE RESISTANCE
The cable end terminations and straight-through joints shall be fire resistant. The components of kits
shall have flame retardant property.
14. INTERCHANGEABILITY
The components of different size of the kits shall be interchangeable between more than one cable
sizes in case the need so arises. Bidders should indicate the range / limits of such interchangeability.
15. EASY INSTALLATION
The bidder shall offer complete material and components for each kit so as to make one termination/
joint complete in all respects. The bidder shall indicate the list of the material/ components with the
supplied quantities of each for each type of cable end termination and straight-through joint.
I). The detailed bill of material and installation instructions shall be provided with each kit for verification
by the Employer's inspecting officer and at stores / site.
ii). All components s hall be sealed separately and marked clearly for the purpose of identification of
each component. All components shall be supplied in a single package as a complete kit for one
termination/ joint and shall bear the manufacturer's name and the cable size or range of cable sizes for
which the kit can be used.
9. CABLE GLANDS AND LUGS
Cable glands shall be Double compression type, tinned/Nickel plated ( coating thickness not
less than 20 microns in case of tin and 10 to 15 microns in case of nickel) brass cable glands
for all power cables. They shall provide dust and weather proof terminations. They shall
comprise of heavy duty brass casting, machine finished and tinned to avoid corrosion and
oxidation. Rubber components used in cable glands shall be neoprene and of tested quality.
Required number of packing glands to close unused openings in gland plates shall also be
provided. The cable glands shall be tested as per BS: 6121. The cable glands shall also be duly
tested for dust proof and weather proof termination. Cables lugs shall be tinned copper solder
less crimping type conforming to IS: 8309 and 8394 suitable for aluminum conductor. The cable
lugs shall suit the type of terminals provided. The cable lugs shall be of Dowell make or
equivalent.
0
FURNITURE
&
FIRST-AID
BOX:
21.1 Providing of furniture for the substation shall be of standard quality as per ISO-9001. The list of
furniture shall be subject to approval of the Employer.
21.2 Standard First–Aid Box consisting of all required medicines and items meant for providing First Aid
treatment should be supplied in the Sub-Station control room.
TECHNICAL SPECIFICATION FOR CROSS ARM
1. Scope
This covers manufacturing, transport to site, insurance, storage, erection and commissioning of different
types of Cross Arms suitable for 33 kV, 11 kV and L T lines.
2. Standards
A. Cross Arm for 33/11 KV / LT Lines.
• The Cross Arms shall be made out of 100 X 50 X 6 mm MS Channel and MS Flat 75 X 8 mm
• The Cross Arm shall be hot dipped galvanized generally conforming to the IS- 2633/1972
• The Clamps for the Cross Arms shall be made out of 75 X 8 mm MS Flat and shall be hot dipped
galvanized conforming to IS-2633/1972
• The Clamps shall be designed to fit for ST/PCC Poles.
• The rolling and cutting tolerance for steel products conforming to IS-226 shall be those specified in IS1852/1972 or latest version.
B. Horizontal Type Cross Arm for 33 KV
• It shall comprise of 100 X 50 X 6 mm, 3.2 mtr long MS Channel for 33 KV to be provided on ST/ PCC
Poles
• The rolling and cutting tolerance for steel products conforming to IS-226 shall be those specified in IS1852/1972 or latest version.
• The Cross Arm shall be hot dipped galvanized generally conforming to the IS- 2633/1972
• The clamps for the Cross Arms shall be made of 50 X 8 MS Flat and shall be hot dipped galvanized.
• The Cross Arm should not have any welded joints.
TECHNICAL
SPECIFICATION FOR LT & HT GUY INSULATOR
1. Scope
This specification covers design, manufacture, testing, transport to site, insurance, storage, erection and
commissioning of the strain type porcelain Guy Insulator used in distribution overhead power lines.
2. Standard
This insulators shall comply with Indian Standard specification IS: 5500/1969 and as amended from time
to time except where they conflict with the requirements in this specification. Offers conforming to any
other internationally accepted standard which ensure equal or higher quality than the standard
mentioned will be acceptable.
3. General Requirements
This porcelain shall be sound, free from defects, thoroughly vitrified and smooth glazed. The design of
the insulator shall be such that stresses to expansion and contraction at any part of the insulator shall
not load to its deterioration. The glaze, unless otherwise specified, shall be brown in colour. The glaze
shall cover the entire porcelain surface parts except those areas that serves as supports during firing or
area otherwise required to be left unglazed.
4. Insulator Characteristics
The Guy Strain Insulators shall have the electrical and mechanical characteristics as shown below:
L.T. Strain Type Porcelain Guy Insulator
1.
Length
90 mm
2.
Diameter
65 mm
3.
Cable hole dia
16 mm ± 1.5
4.
Minimum failing load
44 kN
5.
Min. Creepage distance
41 mm
6.
Dry one minute power frequency withstand voltage
18 kV (rms)
7.
Wet one minute power frequency withstand voltage
8 kV (rms)
H.T. Strain Type Porcelain Guy Insulator (11 KV)
1.
Length
140 mm
2.
Diameter
85 mm
3.
Cable hole dia
25 mm ± 1.5
4.
Minimum failing load
88 kN
5.
Min. Creepage distance
57 mm
6.
Dry one minute power frequency withstand voltage
27 kV (rms)
7.
Wet one minute power frequency withstand voltage
13 kV (rms)
5. Marking
Each
insulator shall be legibly and indelibly marked to shown the following:
a. Name of trade mark of the manufacturer
b. Year of manufacture and name of project.
Marking on porcelain shall be printed and shall be applied before firing. Insulators may also be marked
with the ISI certification mark.
6. Inspection
All tests and inspections shall be carried out at the place of manufacturer unless otherwise agreed by
the Employer and the manufacturer at the time of purchase. The manufacturer shall afford the inspector
representing the Employer or the third party nominee, all reasonable facilities, without charge, to satisfy
that materials are being furnished in accordance with the specification. The Employer reserves the right
to have the test carried out at his own cost by an independent agency whenever there is dispute
regarding the quality of materials supplied.
7. Drawing
Drawing specifically showing all dimensions is to be submitted.
GUARANTEED
TECHNICAL PARTICULARS
L.T. / H.T. GUY STRAIN INSULATORS
Sr. No.
Parameter Name
Parameter Type
1
Type of guy strain insulator L.T.(designation A) / H.T
(designation C)
2
Are insulators manufactured as per IS : 5300/1969 or latest
revisions thereof.
3
Type of material used in manufacture of the insulator
Text
4
Colour of the guy strain insulator shall be white for
designation A and Brown for designation C
Text
5
Porcelain used in the manufacture is sound, free from
defects, thoroughly vitrified and smoothly glazed.
Text
6
The dimensions of the insulators are as per specified
drawings of the specification.
Text
7
Designation of insulator as per IS :5300/1969 (A or C)
Text
8
Minimum failing load of Guy Strain insulator (44 KN / 88
KN)
Text
9
Creepage distance (Min.) for Guy Strain insulator (41mm /
57mm)
Text
10
Cable hole diameter (16mm / 25 mm)
Text
11
Insulator suitable for use with Power line voltage V (rms)
Numeric
12
Dry One Minute Power frequency withstand voltage KV
(rms)
Numeric
13
Wet One Minute Power frequency withstand voltage KV
(rms)
Numeric
14
Marking on the insulator is as per specification Text
15
Weight of insulator (Kg)
Numeric
16
Insulators are type tested for the type tests as per
specifications & relevant IS and Type Test Reports
enclosed.
Boolean
17
Any other particulars which the bidder may like to give
Text
Boolean
Text
File
TECHNICAL SPECIFICATION FOR 11/33 KV H.T. PIN INSULATORS
1. SCOPE:
This specification covers the manufacture, testing and works supply and delivery of 11kV & 33 kV Pin
insulators. The Insulators shall be porcelain/composite type pin insulators.
1.1. Vendor must be an indigenous manufacturer and supplier of porcelain/composite type insulators of
ratings 33 kV or above OR must have developed proven in house technology and manufacturing
process for porcelain/composite type insulators of above rating OR possess technical
collaboration/association with a manufacturer of porcelain type insulators of ratings 33 kV or above.
2. SYSTEM PARTICULARS:
a)
Nominal System Voltage
11 kV, 33 kV
b)
Corresponding highest system Voltage
12 kV, 36 kV
c)
Frequency
50 Hz with 3% tolerance
d)
Number of phase
----------- 3 -----------e)
Neutral earthing
effectively grounded.
f)
Min. Impulse withstand voltage
75 kV, 170 kV
3. STANDARDS:
Unless otherwise specified elsewhere in the specifications insulators shall confirm to IS: 731/1971/ IEC:
61109 / 92-93 with the latest revisions at the time of placement of the order. The standards are listed in
Annexure ‘D’.
4. GENERAL TECHNICAL REQUIREMENTS:
The porcelain insulators shall generally conform to IS: 731/1971 and any amendments up to date to the
same. The insulators shall confirm to type ‘B’ of IS: 731/1971.
4.1. Conductors:
The pin insulators will be used on lines on which the conductors will be A.A.A. Conductor size up to 200
sq.mm. and ACSR of any size up to Panther (0.2 sq. inch copper equivalent). The insulators should
withstand the conductor tension, the reversible wind load as well as the high frequency vibrations set up
to due to wind.
4.2. Design Specification:
4.2.1. The Porcelain Pin Insulators shall conform to the provisions of IS: 731-1971 or its latest version in
all respects. The pin insulators shall be suitable for the spindle detailed below:
Pin Insulator Suitable for head
Shank dia
Remarks
Lead thimbles suitable for
Small head as per Fig.I A of IS11 kV
20 mm
the pin heads shall be
2486 (II)/1989 or latest version.
provided
Lead thimbles suitable for
Large head as per Fig.I B of IS33 kV
24 mm
the pin heads shall be
2486 (II)/1989 or latest version.
provided
4.3. Strength:
For pin insulators of 11 kV the minimum failing load shall be 5 kN and for 33 kV the minimum failing load
shall be 10 kN.
4.4. Creepage Distance :
The minimum creepage distance shall be those given below:
Insulators
Creepage distance
11 kV Pin Insulator
320 mm
33 kV Pin Insulators
840 mm
4.5. Material Quality and Workmanship
The quality of porcelain/composite material and hardware and all workmanship should be of the highest
grade and such as is suitable and customary for extra high tension lines and shall conform to current IS
or IEC. (Only in absence of the relevant I.S.S.).
The porcelain shall be sound, free from defect, thoroughly vitrified and smoothly glazed and brown in
colour. Unless otherwise specified the glaze shall cover all exposed porcelain parts of the insulator.
Glazing shall be uniform and free from defects. Small and isolated defects in the insulator glaze of a
total surface less than 0.5 sq.cm. will however be ignored. Deviation on this account may be supported
by relevant IS.
4.6. Mechanical Design:
The design shall be such that stresses due to expansion and contraction in any part of insulator shall not
lead to deterioration. Cement used in manufacture of insulator shall not cause fracture due to expansion
or loosening due to contraction.
4.7. Design and construction for composite insulators.
The composite insulator shall have a core, housing & weather shed of insulating material and
steel/aluminum hardware components for attaching it to the support/conductor.
4.7.1. Core
It shall be a glass-fiber reinforced epoxy resin rod of high strength (FRP rod). Glass fibers and resin
shall be optimized in the FRP rod. Glass fibers shall be Boron free electrically corrosion resistant (ECR)
glass fiber or boron free E-Glass and shall exhibit both high electrical integrity and high resistance to
acid corrosion. The matrix of the FRP rod shall be Hydrolysis resistant. The FRP rod shall be
manufactured through Pultrusion process. The FRP rod shall be void free.
4.7.2. Housing (Sheath)
The FRP rod shall be covered by a seamless sheath of a silicone elastomeric compound or silicone
alloy compound of a thickness of 3 mm minimum. It should protect the FRP rod against environmental
influences, external pollution and humidity. It shall be extruded or directly molded on the core and shall
have chemical bonding with the FRP rod. The strength of the bond shall be greater than the tearing
strength of the polymer. Sheath material in the bulk as well as in the sealing / bonding area shall be free
from voids.
4.7.3.
Weather sheds
The composite polymer weather sheds made of silicone elastomeric compound or silicon alloy shall be
firmly bonded to the sheath, vulcanized to the sheath or molded as part of the sheath and shall be free
from imperfections. The weather sheds should have silicon content of minimum 30% by weight. The
strength of the weather sheds to sheath interface shall be greater than the tearing strength of the
polymer. The interface, if any, between sheds and sheath (housing) shall be free from voids.
4.7.4. Metal
End Fitting:
End fitting transmit the mechanical load to the core. They shall be made of forged steel. G. I. pin shall be
connected to the rod by means of a controlled compression technique. G.I. pins shall be of respective
specified mechanical load and shall be hot dip galvanized after, all fittings have been completed. The
material used in fittings shall be corrosion resistant. As the main duty of the end fittings is the transfer of
mechanical loads to the core the fittings should be properly attached to the core by a coaxial or
hexagonal compression process & should not damage the individual fibers or crack the core. The gap
between fitting and sheath shall be sealed by a flexible silicone elastomeric compound or silicone alloy
compound sealant. System of attachment of end fitting to the rod shall provide superior sealing
performance between housing, i.e. seamless sheath and metal connection. The sealing must be
moisture proof. The dimensions of end fittings of Insulators shall be in accordance with the standard
dimensions stated in IEC: 60120/IS: 2486 - Part-II /1989.
4.7.5.
Corona and RI Performance
All surfaces shall be clean, smooth, without cuts, abrasions or projections. No part shall be subjected to
excessive localized pressure. The insulator and metal parts shall be so designed and manufactured that
it shall avoid local corona formation and not generate any radio interference beyond specified limit under
the operating conditions.
5.
DRAWINGS:
The detailed drawings with dimensions for each rating of pin insulators i.e.11 & 33 KV shall be
furnished. The Supplier shall furnish full description and illustration of the material offered.
5.1.
The Supplier shall furnish the outline drawing of each insulator unit including a cross sectional view of
the long rod insulator unit. The drawing shall include but not be limited to the following information:
a) Minimum Creepage distance with positive tolerance
b) Protected creepage distance
c) Unit mechanical and electrical characteristics
d) Size and weight of ball and socket/tongue & clevis
e) Weight of composite long rod units
f) Materials
i) Identification mark
ii) Manufacturer’s catalogue number
6.
Markings:
6.1. Each insulator shall be legibly and indelibly marked to show the following:
a) Name or trademark of the manufacturer.
b) Highest system Voltage
c) Month and year of manufacturing.
d) Min. failing load in ‘KN’.
e) JKPDD
6.2.
Marking on porcelain shall be printed and applied before firing.
7.
Packing:
All insulators shall be packed in crates or boxes suitable for rough handling. Packing shall be marked
with the strength and KV rating.
8.
Guaranteed Technical Particulars:
The tenderer shall furnish in the attached form (Schedule 'A') all the guaranteed technical particulars.
Schedule A-1
GUARANTEED TECHNICAL PARTICULARS
FOR 11 KV PIN INSULATOR UNIT.
Sr. No.
1
2
3
4
4(a)
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
Parameter Name
Name of Manufacturer.
Type of Insulator
Parameter type 11 KV
Text
Text
Standard according to which the insulators manufactured &
tested.
Name of material used in manufacture of the insulator with
class / grade
Text
Material of housing & weather sheds (Silicon content by
weight)
Text
Diameter of first outer shell
Diameter of second middle shell
Diameter of third lower shell in mm (min.)
Height of Insulator in mm
Minimum failing load in KN (5)
Min. creepage distance in mm. (320)
Suitable for shank diameter in mm (20)
Net weight of single Pin. Ins.
Nominal System Voltage in kV.
Highest System Voltage in kV (rms).(12)
Dry 1 min. power frequency withstand Voltage kV (rms)
Wet 1 min. power frequency withstands Voltage. KV (rms)
Dry flashover voltage. kV (rms)
Wet flashover voltage. KV (rms)
Dry lighting Impulse Withstand Voltage (Positive) kV (Peak)
Dry lighting Impulse Withstand Voltage test (Negative) kV
(Peak)
Dry lighting Impulse flashover Voltage (Positive) kV (Peak)
Dry lighting Impulse flashover Voltage test (Negative) kV
(Peak)
Numeric
Numeric
Numeric
Numeric
Text
Numeric
Numeric
Text
Text
Text
Text
Text
Text
Text
Text
Text
Text
Text
Method of fixing of sheds to housing (Specify):Single mould
or
23
24
Modular construction (Injection moulding/Compression
moulding)
Any other particulars which the supplier may like to give
Text
File
25
26
Type test reports as per specification are submitted
Boolean
Type test reports
File
Annexure ‘D’
List of Standards applicable
Sr. No.
Specified Standards with
latest amendments
Particulars
3
Specifications for Porcelain insulators for overhead lines with
IS- 731/1971
nominal voltage greater than 1000V
Specifications for Composite insulators for A.C. overhead
IEC: 61109 / 92-93
lines with nominal voltage greater than 1000V
Metal fittings of insulators for overhead lines.
IS: 2486 part-1 / 1993
Dimensional Requirements for Insulators fittings
IS: 2486 part-2 / 1989
4
Methods of Random Samplings
5
Methods of High Voltage Testing
1
2
3
IEC: 61109 / 92-93 IS731/1971
IS: 2071
TECHNICAL
SPECIFICATION FOR LT PIN / SHACKLE INSULATORS
1. SCOPE:
The specification covers the manufacture, testing at works supply and delivery of Porcelain insulators for
overhead power lines with a nominal voltage below 1000 volts. Both Pin and Shackle type insulators are
covered.
2. SYSTEM PARTICULARS:
2.1. The insulators will be installed on three-phase, 433 volts AC & 50 Hz system in which the neutral is
effectively grounded. The insulators shall be designed to work continuously at a voltage 10% in excess
of the normal rated voltage.
3. DESIGN SPECIFICATIONS:
3.1. The insulators shall conform to provisions under IS : 1445/1977 or its latest version in all respects.
The Pin insulators shall be threaded to take mild Steel Pin of dimensions given below:
Pin
insulator
Suitable for Head Shank
Dia
Remarks
Type – I
Steel Head threads as per
profile of threads as insulators
as given in Fig.5 of IS : 1445
/1977
16 mm
Pin insulators Threads as per profile
given in Fig.5 of IS:1445/1977
3.2. The design of the insulators shall be such that stresses due to expansion and contraction in any
part of the insulators shall not lead to its deterioration.
3.3. The insulators shall be suitable for use with all Aluminum Conductor or Copper conductor or ACSR
up to100 sq.mm. The insulators should withstand the conductor tension the reversible wind load as well
as the high frequency vibrations set due to wind.
4. INSULATION CHARACTRISTICS:
4.1. The insulators shall have the electrical and mechanical characteristic given in the table below:
Type of
insulator
Power frequency
flashover voltage in KV
(RMS)
Dry
Wet
One minute power
frequency withstand
voltage in KV(RMS)
Dry
Wet
Power
frequency
puncture
withstand
voltage
KV(RMS)
Min. failing
load (Kg.)
Pin
25
10
23
10
Shackle
Type-I
25
10
22
10
Type-II
25
10
22
10
1.3 x the
actual
flashover
voltage
1.3 x the
actual
flashover
voltage
860
1150
1600
5. GENERAL REQUIREMENTS :
5.1. The porcelain used in the manufacture shall be sound, free from defects, thoroughly vitrified and
smoothly glazed.
5.2. The glaze on the insulator shall generally be white/cream/brown except for the screw threads and
the parts on which the porcelain is supported during fitting, which may be left unglazed, all other
surfaces of the insulator, shall be efficiently glazed.
5.3. The insulator shall be in one piece. The pin type shall have a top groove
5.4. The insulator shall be marked properly in accordance with clause 6 of IS: 1445.
6. TESTING FACILITIES:
6.1. The tenderer must clearly indicate what testing facilities are available in the works of the
manufacturer and whether the facilities are adequate to carry out all the routine as well as type tests.
These facilities should be made available to JKPDD’s Engineers, if deputed to carry out or witness the
tests. If any tests cannot be carried out at the manufacturer’s works, the reasons should be clearly
stated in the tender.
7. MARKING:
Each insulator shall be legibly and indelibly marked to show the following:
a) Name of trademark of the manufacturer
b) Year of manufacturer
c) ISI certificate, mark, if any.
d) Tender Ref.
Marking on porcelain shall be applied before firing.
8. PACKING:
All insulators shall be packed in suitable double gunny bags and shall be transported by road.
9. SCHEDULES:
The tenderer shall fill in the following schedule,
Schedule ‘A’ - Guaranteed Technical Particulars
SCHEDULE – A
GUARANTEED TECHNICAL PARTICULARS
LT PIN/SHACKLE INSULATORS
SR. No.
1
2
3
4
Parameter Name
Type of insulator LT Pin insulator/LT shackle
insulator
Are insulators manufactured as per IS
1445/1977or latest revisions thereof
Type of material used in manufacture of the
insulator
Colour of the insulator (white/cream/brown)
6
Porcelain used in the manufacture is sound,
free from defects, thoroughly vitrified and
smoothly glazed.
The dimensions of the insulators are as per
the drawing specified in the specification.
7
Pin insulator Type as per IS 1445/1977 is (
Type-1)
5
Parameter type
Text
Boolean
Text
Text
Text
Text
Text
8
Shackle insulator Type as per IS 1445/1977
is ( Type-1/Type-2)
Text
9
Minimum failing load for Pin Insulator KN
(3.5KN)
Text
10
Minimum failing load for Shackle Insulator
KN (11.5KN/16.0KN)
Text
11
Creepage distance (Min.) for pin insulator
(mm)
Text
12
Electrical characteristics
Dry One Minute Power frequency withstand
voltage KV (rms)
Numeric
13
Wet One Minute Power frequency withstand
voltage KV (rms)
Numeric
14
Dry Power frequency flashover voltage in KV
(RMS)
Numeric
15
Wet Power frequency flashover voltage in
KV (RMS)
Numeric
16
Power frequency Puncture withstand voltage
in KV (rms)
Numeric
17
Marking on the insulator is as per
specification
19
Weight of insulator (Kg)
Insulators are type tested for the type tests
as per specifications & relevant IS and Type
Test Reports enclosed.
20
Any other particulars which the may like to
give
18
Text
Numeric
Boolean
File
TECHNICAL SPECIFICATION FOR 11 kV AIR BREAK SWITCH
1. SCOPE :This specification covers the design, manufacture & testing at works and supply of air break isolators
suitable for 11 kV system voltages.
2. SYSTEM VOLTAGES:The systems on which the isolators will be installed will be:
i) 11 kV, 3 phase, 50 Hz with solidly earthed neutral system.
The rated voltage shall be 12 kV
3. APPLICABLE STANDARD:Unless otherwise stipulated in these specifications, the A.B. switches shall conform to IS 9921/1985
(Part I to IV) or its latest amendment. In case of difference, if any, between this specification and the IS
9921, the provisions of this specification will hold good.
4. CURRENT CAPACITY:4.1. Current Carrying Capacity :The continuous current carrying capacity for the different system voltages shall be as under:
System Voltage
Current carrying capacity
a) 11 kV
400 Amps.
4.2. Rated short time current:The rated short time current for 1 sec. shall be 16 kA.
4.3. Rated peak withstand current:The value of peak current that the switch can withstand in the closed position shall be 40 kA.
4.4. Rated mainly active load breaking capacity:The rated mainly active load breaking capacity shall be 10 A.
4.5. Rated transformer off-load breaking capacity:The rated transformer off-load breaking capacity shall be 6.3 A (rms).
4.6. Rated line-charging breaking capacity :The rated line-charging breaking capacity shall be 2.5 A (rms).
4.7. Rated Cable charging Breaking Capacity :-
The rated cable charging breaking capacity shall be 10 A (rms).
5. NUMBER OF POSTS:Number of posts per phase for different system voltages shall be as under :TYPE "A" A.B.SWITCHES (ISOLATOR)
i) 11 kV three posts per phase. Each post having single insulator unit.
6. GENERAL REQUIREMENTS:6.1. A.B.SWITCH IN GENERAL:The A.B.switch shall be of outdoor type. They shall be of triple pole, gang operated type and shall be
suitable for horizontal or vertical installation. The A.B. switch should be with arcing horns. The sizes of
rods used for arcing horns would be 8 mm. M.S. hot dip galvanized. The current carrying connectors
should be of two-bolt type having nuts and bolts, with spring washer & plane washers. Connectors shall
be of tinned copper. All ferrous parts shall be hot dip galvanized and copper parts heavily tinned. All
current carrying parts should have current density less than 1.6 Amps/mm.sq. & the minimum cross
section for fixed contact shall be 300 sq.mm. In case of flexible copper braided tape, the weight of tape
shall be minimum 475 grams for 11 kV rating per phase including terminal bracket. All joints in current
carrying path shall be of two bolt type. Each joint shall be provided with one plane and one spring
washer of not less than 2 mm thickness even if it is not shown in the drawings.
6.2. POST INSULATORS :Design and manufacture of post insulator to be used in A.B.Switch assembly should be such as to avoid
stress concentration due to direct engagement of the porcelain with the metal fittings and retention of
water in the recesses of metal fittings. The post insulator unit shall be assembled in a suitable Jig, to
ensure the correct positioning of the top and bottom metal fittings relative to one another. The faces of
metal fittings shall be parallel and at right angle to the axis of insulator and corresponding holes on top
and bottom metal fittings shall lie in a vertical plane
containing the axis of the insulator. The cap and the pedestal must not become loose. The pedestal
should be of malleable cast iron and cap should be of malleable cast iron or aluminium. The vertical
alignment of post insulator must not vary after operations. Each post insulator shall have minimum
creepage of 320 mm and should conform to the requirements of IS: 2544/ 1973 (amended up to date).
6.3. FIXED AND MOVABLE CONTACT SYSTEM:The fixed & moving contacts material shall be electrolytic hard-drawn copper heavily tinned. The contact
shall be of high pressure and self-aligning type with positive wiping action and minimum contact
pressure shall be 1/4 lb. per amp. of current carrying capacity.
6.4. MECHANICAL STRENGTH:A.B.Switches shall withstand rated mechanical terminal load and electromagnetic forces without
impairing their operational reliability or current carrying properties.
6.5. SECURING POSITIONS :Isolators inclusive of their operating mechanism should not come out of their open or closed positions by
gravity, wind pressure, vibrations or reasonable shocks.
Isolators shall be capable of resisting in closed position the dynamic and thermic effects of the maximum
possible short circuit current at the installation point and should not open under the influence of short
circuit current.
6.6. NAMEPLATE:Isolators shall be provided with a nameplate containing following information.
a) Name of manufacturer.
b) Order reference.
c) Rated voltage-kV
d) Rated normal current in Amps.
e) Rated one second short-time current in Amps.
f) Year & Month of Manufacture.
Name of manufacturer should also be provided on the operating device. The nameplate should be
riveted to the base channel at the center of each pole and operating mechanism including parts. Sticker
may be used for parts of operating mechanism.
6.7. PHASE TO PHASE CLEARANCE:The phase to phase clearance shall be as under:System Voltage. Phase to phase clearance 11 kV 75 cm.
6.8. ISOLATION DISTANCE:The minimum distance between the fixed and the nearest part on the moving contact in the completely
open position should not be less than the following for different system voltage.
System Voltage Min. Isolating Distance 11 kV 31 cm.The withstand level across the break, shall be as
specified under type test.
6.9. OPERATING MECHANISM:-
This should comprise of `B' Class G.I. Operating pipe of 32 mm outer diameter and 6 meter length in
single piece without joint. The mechanism should give good mechanical leverage with minimum of
loose/lost motion. There should be provision for pad-locking in both `on' and `off' position.
7. CHARACTERISTICS FOR INSULATORS:The insulators should be post type insulators only and should conform to the following test voltages.
System
Power Frequency
Power frequency
Impulse
Voltage
Dry flashover
Wet flashover
flashover
11 kV
80 kV
50 kV
125 kV
The tenderer should arrange at his cost for testing of Post Insulators at any laboratory acceptable to
Company, for Acceptance Tests as per IS: 2544/1973(amended up to date) in presence of our
representative. Manufacturer's test certificate for original cemented post insulators shall also be
submitted at the time of Inspection
.
TECHNICAL
SPECIFICATION FOR 11 & 33 KV HORN GAP FUSES
1. SCOPE:This specification covers the Design, manufacture testing at works and supply of Horn Gap Fuses of 11
kV & 33 kV voltage class.
2. MATERIALS:
The various components shall conform to the following specifications:
a. M.S. Channel, flat and round (Steel) conform to I.S.:2062 amendment up to date (structural steel
standard quality having tensile strength of 42-54 kg/sq.mm.)
b. Bolt and Nuts : These shall conform to the following IS specifications :
IS : 1367 - 1980 (amended up to date)
IS : 4218 - 1976 (amended up to date)
IS : 1363 - 1984 (amended up to date)
c. For galvanizing, zinc conforming to Grade 98.50 of IS-209/1979 specification for zinc (Revised) shall
be used.
d. Arcing Horn and Connectors of one piece Aluminium strip.
e. INSULATORS : (PIN)
The pin type insulators used for the Horn Gap Fuse Unit shall conform to IS: 731-1971 (amended up to
date) in all respects with regard to mechanical and electrical requirements.
a. The electrical characteristics of the insulators shall be as follows :
Power
Frequency
Flashover
withstand
voltage in kV Impulse
System voltage in KV
withstand
Voltage
voltage in
kV
Dry
Wet
Dry
Wet
11 kV
33 kV
55
95
35
75
85
135
50
95
75
170
Creepage Distance in mm
Moderately polluted
atmosphere
230
580
Heavily
polluted Protected
atmosphere
N.A.
N.A.
N.A.
420
b. Mechanical loads : 1. Pin Insulators-540 kg. as min. failing load.
3. GENERAL REQUIREMENTS:
The Horn Gap Fuse sets are required for protection on 11 and 33 kV systems. They will be mounted
outdoors on suitable structures. These sets will be exposed to atmospheric conditions and therefore,
shall be robust in construction.
4. WORKMANSHIP:
The casting shall be of good finish and free from flaws, blow holes and other defects. The edges of the
fittings shall be smoothly rounded. The M.S. flat, round etc. before any work is done on them, shall be
carefully leveled, straightened and bent or forged to the shape given in the drawing by methods which
will not injure the materials. No rough edges shall be permitted anywhere throughout the work. Similar
parts shall be uniform and interchangeable with each other. The welding work wherever mentioned in
the drawing shall be carried out properly and the same shall not open under climatic conditions. Holes in
channel shall be drilled or machine punched. All burrs left by drilling or punch shall be completely
removed. The Bolts and Nuts shall be well forged and free from inequalities, flaws and other defects.
The heads shall be solid and in every respect well formed and shall not fail when the bolts are tested to
fracture at their full section for Tensile Stress. The washers shall be clearly cut off or punched and
entirely free from cracks after punching.
5. GALVANIZING:
All ferrous parts (Bolts, Nuts, Washers, M.S. Flats, Clamps and M.S. round holding clamps etc. for the
insulator and Horn Gap Fuses) shall be hot dip galvanized. The galvanizing shall conform to IS:
2633/1972 (amended up to date) in all respect. After galvanizing, the surfaces shall be free from all
sharp edges and metal. The threading on nut and bolt shall be cut before galvanizing. The quality of the
galvanizing shall be determined by the tests given in IS: 2633 of 1972.Wherever the welding is done, the
galvanizing shall be done after welding.
TECHNICAL SPECIFICATION FOR EARTHING SETS (A & B) TYPES
1. SCOPE :The specification covers manufacture, testing and supply of Earthing Sets, complete in all respects.
2. GENERAL REQUIREMENTS:The Earthing sets shall comprise of light class G.I. Pipe, Galvanized bolts and nuts, lead washer and
wooden / PVC plug & 8 S.W.G. GI Wire.
3. MATERIAL DESCRIPTION:The pipe used for fabrication of Earthing Set shall be " Light” class G.I. Pipe of reputed manufacture. It
shall be of continuous length without welding. The bolts and nuts should be hot dip galvanized
conforming to I.S.-1363/67 modified up to date and of reputed make.
4. H.T. EARTHING SETS: - As per REC drawing no. J-2
5. L.T. EARTHING SET:- As per REC drawing no. J-1
6. WORKMANSHIP:The workmanship and finish of the material shall be of good quality commensurate with the Industry
Standard. The Earthing Set shall not have any burrs at the cut points or at the holes.
7. TEST CERTIFICATES:The vender should submit test certificates for the following with the offer:
1. G.I. Pipe
2. Bolt and nut
3. Washers
4. Galvanizing of the Bolt, Nut and Washers
The Earthing sets shall be of continuous length in one piece without any joints visible or invisible.
8. FABRICATION TOLERANCE:Fabrication tolerance of +/- 1 % shall be permitted.
TECHNICAL SPECIFICATION FOR HT/LT STAY SETS
1. This specification covers the manufacture, testing and supply of HT & LT Stay sets in complete form.
2. GENERAL:
The stay shall comprise of stay rod, stay plate (anchor plate), turn buckle, eye bolt, thimble, nuts etc. all
the parts shall be hot dip galvanized. Guy insulator shall be provided both in HT & LT Stay sets.
3. MATERIALS:
Steel used for the construction of the stay sets shall be manufactured by the open hearth, electric
duplex or basic/oxygen process or combination of those processes with a high yield point and with high
tensile strength which should not be less than 48 kg. per sq.mm. for rods and 44 Kg per sq.mm. for
channel. It should conform to IS-1977/69 having U.T.S. 42/54/Kg per sq.mm for rods. For channel it
should conform to IS: 2062(Grade `A’) amended up to date.
4. THREADING:
The threading in the nut, eye bolt and stay rod should be the same standard thread. The threading work
shall conform to the following Indian Standards.
a) IS-1367-1961 - Technical supply conditions for threading and fastners
b) IS-1362-1962 - Dimensions for screw threads for general purpose.
c) IS-1330-1958 - General Plan for metric screw threads with TSC profile
d) IS-1363-1969 - Specification for black hexagonal bolts and nuts and black hexagonal
screws.
The threading shall be done on the eye bolts and stay rods for the lengths specified in threading. The
thread per cm. will be as follows:
Dia
Threads per cm.
16 mm
5
20 mm
4
24 mm
3.33
5. NUTS:
All nuts shall be mild steel of the qualities specified in IS: 1367-1961.
All nuts shall be machine made and hand tight on the threaded portion and shall not fix
loose on them.
6. DRILLING:
Holes in the channel and plate shall be drilled or machine punched. All burrs left by drill or punch shall
be completely removed.
7. WELDING:
The welding work shall be carried out properly and the same shall not open under the tests specified
below.
8. WORKMANSHIP:
The workman ship and finish of the material shall be of good quality. Before any work is done all rods,
channels, plates etc. shall be carefully leveled, straightened and made true by methods which will not
injure the materials. No rough edges shall be permitted anywhere on the work. The anchor plate should
be square and its edges shall be cut true and sharp. Gas cutting will not be acceptable.
9. Tolerance Schedule:The components of the HT/LT Stay sets shall be within the following tolerances:
Tolerance
Sr.No.
1
2
Item
As per I.S. 1852-73 for Dimension/size weight
Fabrication
tolerance
Stay plate
6 mm thickness +12.5%
- 5%
Stay Rod
Length 2280 mm
+/-0.5% 1830mm
Up to 25 mm dia +/- 0.5 Up to 16 mm dia +/+/-0.5% Gundi
mm
5%.above 16 mm dia +/-3% 40mm inside dia
+/-3% Threading
75mm +/-1%
----
300 x 300 +/-1%
i) Turn Buckle
Up to 25 mm dia +/- 0.5 Rod up to 16 mm dia +/-5%. Length 460 mm
mm
Above 16 mm dia +/-3%
+/- 1%
ii) Channel
Up to 25 mm size +/- 0.5
mm
Eye Bolt
Length 460 mm
+/-1%
Up to 25 mm dia +/- 0.5 Rod up to 16 mm dia +/-5%. Threading 305
mm
Above 16 mm dia +/-3%
mm +/-1% Gundi
40mm inside dia
with +/-3%
3
4
-
Length + 1%
Weights shall be as given below:
Weight without Tolerance
Weight with –ve
Tolerance
Remarks
H.T. Stay sets
14.787 Kg.
14.016 Kg.
Without nuts &
washers
L.T. Stay sets
11.809 Kg.
11.196 Kg.
Without nuts &
washers
TECHNICAL SPECIFICATION FOR G. I. WIRE (3.15/ 4/ 5 mm dia.)
1.0 Scope:
The BIS specification covers details of solid G.I. wires for use in Rural Distribution System.
2.0 Applicable Standards:
Except when they conflict with the specific requirements of the BIS specification, the G.I. wires shall
comply with the provision of B BIS:280-1978 and BBIS: 7887-1975 or the latest version thereof.
3.0 Application and sizes:
G.I. Wires covered in the BIS specification are intended for the following applications.
i)
ii)
Application
Bearer wire for service cables
Sizes (Nominal dia )
3.15 mm (for single-phase cables.
Service)
3.15, 4 & 5mm
Protection guarding at the
crossing of overhead power
lines with roads, railway
tracks and telecommunication lines.
4.0 Material:
4.1 The wires shall be drawn from the wire rods conforming to BBIS: 7887- 1975 or the latest version
thereof.
4.2 The requirements for chemical composition for the wires shall conform to BBIS: 7887-1975 or the
latest version thereof.
4.3 The wires shall be sound, free from split surface flaws, rough jagged and imperfect edges and other
detrimental defects on the surface of the wires.
5.0 Galvanizing:
The wires shall be galvanized with ‘heavy coating as per B BIS:4826- 1979 or the latest version thereof.
6.0 Grades:
G.I wires shall be conforming to the grade shown below:
Grade
Tensile strength (MPa)
Annealed
440-550
7.0 Tolerance in diameter:
The tolerance on nominal diameter at any section of the wire shall not exceed plus minus 2.5%. Further
the maximum difference between the diameters at any two cross sections of wires shall not exceed
2.5%.
8.0 TESTS: The following tests shall be carried out in accordance with BBIS 280/1978 or the latest
version thereof, as per sampling criteria stipulated therein.
i) Dimensional Check (dia) – refer Clause 7 above.
ii) Visual Inspection regarding freedom from defects refer Clause 4.3 above.
iii) Tensile Test.
iv) Wrapping Test (for wire diameters smaller than 5mm ).
v) Bend Test (for wire diameter of 5mm. only )
vi) Coating Test – refer Clause 5 above.
vii) Chemical Composition.
9.0 Packing:
The wires shall be supplied in 30-40 kg. Coils, each coil having single continuous length. Each coil of
wire shall be suitably bound and fastened compactly and shall be protected by suitable wrapping.
10.0 Marking:
Each coil shall be provided with a label fixed firmly on the inner part of the coil bearing the following
information:
Manufacturer’s name or trade mark.
(a) Lot number and coil number.
(b) Size.
(c) Grade (Annealed)
(d) Mass.
(e) Length.
(f) BISI Certification Mark. If any.
(g) Project Name: R-APDRO Part-B
11.0 Specific Technical Particulars:
These shall be as shown below.
1.
2.
3.
4.
Size ( dia )
Tolerance of size
Tensile Strength
Specification
:
:
:
:
5.
Coating ( gms ) / m2 :
6.
7.
Type of galvanizing :
BBIS for Zinc Coating:
8.
9.
No. of dips
Packing
10
Chemical composition :
:
:
3.15mm
4.00mm
5.00mm
As per Clause 7 of the specification.
440-550 MPa
BBIS-280/1978, B BIS-7887/ 1975, BBIS4826/1979 or the latest versions thereof.
270 ( for 3.15mm ),and 290 ( for 4 mm and
5.00mm)
Hot dip
BBIS-4826/ 1979 or the latest version
thereof
3 dips of 1 min. and 1 dip of 1/2 min.
30 to 40 kgs. In coils as per Clause 9 of the
specification
As per BBIS-7887/1975 Carbon 0.23% max
Sulphur 0.55% max.Phosphorus 0.055%
max.
TECHNICAL SPECIFICATION FOR G.I. STAY WIRES /4/G.I.Stay Wire/2013 1. G.I. STAY
WIRE:
Wire conforming to BIS 2141/1979 or the latest version and having tensile strength 45-55 kg. per sq.
mm. The wires shall be heavily coated with zinc as per BIS 4826/ 1979 or the latest version thereof by
Hot Dip Galvanization. The stay wires shall be of sizes shown below.
i) 7/4.0 mm
ii) 7/3.15 mm
2. PACKING:
The wires shall be supplied in coils of 30-40 Kg weight. The packing shall be done in accordance with
the provision of BIS 6594/1977 or the latest version thereof. Each coil shall be suitably bound and
fastened compactly and shall be protected by suitable wrapping.
3. SPECIFIC TECHNICAL PARTICULARS:
These shall be as per the attached Annexure-I.
5. TESTING:
All the tests specified in the above BIS specification are required to be conducted as detailed therein.
Vender must clearly indicate what testing facilities are available at the works of the manufacturer and
whether the facilities are adequate to carry out all the tests mentioned above. These facilities shall be
verified by the Employer’s Representative. If any of the tests cannot be carried out in the manufacturer’s
works, the reasons should be clearly stated.
ANNEXURE-I’
SPECIFIC TECHNICAL PARTICULARS FOR G.I. STAY WIRE
7/3.15mm
7/4.00mm
1.
Dia. of individual wire
:
3.15mm
4.00mm
2.
No. of strands
:
7
7
3.
Lay length
:
12 to 18 times strand diameter
4.
Tolerance on dia of
:
+ 2.5% + 2.5%individual wire.
5.
Minimum tensile strength
of individual wire.
:
45 Kg./sq. mm
6.
Minimum breaking load
of individual strand
:
350 kg.
7.
Minimum breaking load
8.
:
BIS 2141/ 1979 or its latest version
9.
Specification to which the
stay wire will conform
Type of zinc coating
:
Heavy coating.
10.
Method of coating
:
Hot Dip Galvanizing.
11.
Specification for
galvanizing
12.
Packing
:
As per Clause 2 of specification in coils
weighing between 30 Kg to 40 Kg.
13.
Chemical composition
:
Sulphur & Phosphorous less than 0.06%
:
:
565 kg.
2331 kg.3758 kg.of completed stay wire.
BIS 4826/ 1979 or its latest version
17.1JOINTING SLEEVE
Jointing Sleeve shall be supplied as per latest relevant IS.
17.2MIDSPAN JOINT
Mid span Joint shall be supplied as per latest relevant IS.
17.3AL BINDING WIRE
AL Binding Wire shall be supplied as per latest relevant IS.
17.4 AL BINDING TAPE
AL Binding Tape shall be supplied as per latest relevant IS.
19. BARBED WIRE
Hot dipped galvanized Barbed Wire shall be supplied as per latest relevant IS
28.0 DANGER PLATE:
As per provisions of IE Rules 1956, Danger Notice Plates in Urdu or English and, in addition, in the local
language with the sing of skull and bones are required to be provided on power line supports and other
installations. This Specification covers Danger Notice Plates to be displayed in accordance with Rule
No.35 of Indian Electricity Rules, 1956.Unless otherwise modified in this specification, the Danger
Notice Plates shall comply with IS 2551-1982 or the latest version thereof. Dimension: Two sizes of
Danger Notice Plates as follows are to be installed at each substation:
(i) For display at 33 KV (or higher Voltages) installations - 250 x 200mm. The corners of the plate shall
be rounded off. All lettering shall be centrally spaced. The dimensions of the letters, figures and their
respective position shall be as shown in figs. 1 to 4. The size of letters in the words in each language
and spacing between them shall be so chosen that these are uniformly written in the space earmarked
for them. Under Rule No. 35 of Indian Electricity Rules, 1956, the owner of every medium, high and
extra high voltage installation is required to affix permanently in a conspicuous position a danger notice
in Hindi or English and, in addition, in the local language, with the sign of skull and bones. The type and
size of lettering to be done in Hindi is indicated in the specimen danger notice plates shown in Fig. 2 and
4 and those in English are shown in Figs. 1 and 3 of REC specification. Adequate space has been
provided in the specimen danger notice plates for having the lettering in local language for the
equivalent of .Danger....33000...Volts...The plate shall be made from mild steel sheet of at least 1.6mm
thick and vitreous enameled white, with letters, figures and the conventional skull and cross-bones in
signal red colour (refer IS: 5-1978) on the front side. The rear side of the plate shall also be enameled.
TECHNICAL
SPECIFICATIONS FOR 25,63,100,250 KVA L.T. DISTRIBUTION BOX with M.C.C.Bs.
SCOPE:
Specification covers the design, manufacture, testing at works and supply of Distribution Boxes for
controlling the L.T. feeders from the L.T. side of Distribution Transformers. The system shall be A.C. 3
phase, 4 wire, 433 V, 50 HZ with effectively grounded neutral.
1.
SYSTEM DETAILS:
Distribution
Boxes are meant for control and protection of Distribution Transformers.
Particulars
Details
1
KVA rating
16 KVA
25 KVA
63 KVA 100 KVA 250 KVA 400 KVA 630 KVA
2
Voltage
433 V, 3 Ph, ( 3x 250 V)
3
Frequency
50 HZ
4
Phases
3 phase, solidly grounded neutral
No. of
5
Outgoing
2 nos
3 nos
circuits
2.
APPLICABLE STANDARDS:
a.
b.
c.
IS :13947/1993 (Part 3) for Isolator (Switch Disconnector)
IS: 13947/1993 (Part2)(amended up to date) for L.T. MCCBs.
e.
IS: 8623/1993 (amended up to date) for enclosure Box & for degree of protection provided by
enclosures of electrical equipments.
IS:4237/1982, IS:8623/1993 (amended up to date) – for general requirement of L.T.
switchgears.
IS 13703/1993 ( Part I & II amended up to date) for HRC Fuse Base and HRC Fuse Link.
5.
MANUFACTURE/CONSTRUCTION OF BOXES:
a.
Distribution Boxes shall have Main MCCB with suitable busbar arrangement and single pole
MCBs for outgoing circuits. The equipments should be ISI Marked.
d.
7.
7.1
OUTGOING CIRCUITS:
MCBs
Each distribution box shall have 6 nos. of single-pole MCBs in 63 KVA /100 KVA Box to protect
outgoing circuits. MCB shall be conforming to this specification. The supplier shall indicate the
makes and types of MCBs offered in GTP. The successful supplier shall submit Type Test
Report of the MCB as specified in Cl. No. 12.3 (IV) for approval of CE (Distribution) before
commencement of supply. The MCBs to be provided in the Distribution Box will be as per
JKPDD’s approval as given in the detailed purchase order.
MCB shall have quick make quick break mechanism. Making of MCB shall only be manual but
breaking of MCBs shall be electrical as well as manual.
The rated service short circuit breaking capacity shall be based on the rated service short circuit
test carried out at specified power factors.
While the above stipulation regarding the test power factor and the sequence of operation shall
be binding, the other procedure for making the short circuit test and circuit etc. shall generally
be in accordance with the Indian Standard applicable to the type of circuit breakers under test.
7.2
TIME CURRENT CHARACTERISTICS of MCCBs:
The L.T. MCCBs shall have time current characteristics as follows:
Multiple of normal Current Tripping time
setting
1.05
More than 2.5 hrs.
1.2
1.3
More than 10 minutes and less than 2 hrs.
Less than 30 minutes
1.4
Less than 10 minutes
2.5
Less than 1 minute
4
Not less than 2 seconds
6
Less than 5 seconds
12
Instantaneous (less than 40 milli seconds.)
For above time/current characteristic, the reference calibration temperature of the breaker shall
be 50°C. Deration, if any, up to 60°C. ambient temperature shall not exceed 10% of the current
setting indicated above.
7.3
BUSBARS AND CONNECTIONS:
The Incomer feeder should be on right side of the distribution box and all outgoing feeders will be
on left side of the distribution box, with phase sequence RYB to be maintained. The phase
busbars and feeder droppers from busbars shall be of tinplated E.C. grade copper. All busbars
and droppers shall be properly drilled and deburred. Each busbars shall be of one single strip
without any joint.
Busbars shall be provided with durable PVC insulating sleeves of standard colour code for
different phases. Corrugated/Spring & Plain washers shall be used for Nut-Bolt connections.
Minimum clearances, wherever shown, shall be as per General Arrangement Drawing enclosed
with this specifications. Other clearances shall be as per requirement of IS: 4237/1982 amended
up to date.
9
ENCLOSURE:
9.1
The base and doors of enclosure shall be individually in one piece except for fixing of the
accessories like hinges, clamps, mounting clamps, bolts etc. The Box sizes shall be as
mentioned in the drawing. Base and doors shall have flange / collars as shown in drawing. Collar
of Base and doors shall overlap by 10mm. Rubber gasket of suitable size shall be provided in
between base and doors, such that it provides proper sealing between the door and base of box
to avoid penetration of dust & ingress of water. Degree of protection shall be IP- 33 as per IS8623/1993 ( amended up to date ). Rubber Gasket shall be fixed with suitable adhesive. Hinges
on each side shall be fitted from inside of the box tofix the doors. Hinges shall be minimum 50
mm in length & made from 2mm thick sheet. Hinge pin diameter shall be 4mm. The hinges shall
not be visible from outside. On closing of doors, right door shall rest on the left door.
9.2
Four set of Louvers (two sets on each side) of suitable size shall be provided as shown in
drawing. The louvers shall be provided such that heat dissipation is proper. The perforated sheet
with 2.5 mm holes shall be fitted from inside of the louvers.
9.4
Mounting of components inside the enclosure shall allow free air circulation keeping the
clearances as per specification.
9.5
The doors shall be centrally closed with triple position locking arrangement and shall be
operational with a common handle from outside the door. Movement of handle will lock the doors
at center, top & bottom. A Nylon washer shall be provided between the handle and door to avoid
penetration of water. One central lock with brass levers shall be provided inside the door. Key
way shall be provided on the door for operating the lock from outside. Key way shall be provided
with cover.
9.6
The thickness of enclosure on load bearing side (i.e. Backside) should not be less than 3 mm
and not less than 2 mm for all other sides. The Colour will be Smoke Grey for box.
9.7
A suitable cable termination arrangement with support insulators shall be provided on Isolators
and Link Disconnectors. The bimetallic lugs of adequate size, as per enclosed specification &
drawing, shall be provided. Clearances, Creepages and convenience in making connections
shall be ensured.
9.8
Tin-plated EC grade copper Neutral Busbar capable of carrying for full load current. Neutral
Busbar shall be isolated with respect to body. The bimetallic lugs of adequate size, as per
enclosed specification & drawing, shall be provided.
9.9
Two galvanized earthing Bolts of M12 x 50 mm size shall be fitted from inside and projecting
outside of the box as shown in the drawing. There should be no powder coating on the earthing
bolts. Two Nuts with washers shall be provided on each bolt.
9.10
Three bottom plates of the size 125mm x 125mm fixed with four screws from inside shall be
provided for incoming and outgoing cables. Bottom plates shall be provided with suitable holes
and rubber glands for the cables. Rubber glands shall be made such that internal diameter of
glands provided for cables should be closed with the rubber film of minimum 1mm thickness.
Cable will go through the glands by cutting the film of the glands. Bottom plates shall also be
provided with cable clamps as shown in drawing.
9.11
Necessary fixing arrangement shall be provided at the back of the enclosure to ensure proper
fixing on double pole structure by means of suitable clamps at 4 places.
9.12
Danger Board as shown in drawing shall be embossed / debossed on the box.
9.13
The sides shall be provided with moulded construction to facilitate component mounting plate /
flats.
9.14
All joints of current carrying parts shall be bolted with 8.8 grade High Tensile MS Nuts & Bolts,
Corrugated/spring & Plain Washers. The nuts & bolts should be of hexagonal type. All the nuts,
bolts & washers should be properly zinc plated.
9.15
Each distribution box shall be supplied with proper packing in five ply - corrugated box.
9.16
Month & year of manufacturing, name of manufacturer / trade mark shall be embossed on left
side door of distribution box and “JKPDD” shall be embossed on right side door of distribution
box.
9.17
Incoming and outgoing circuit should be duly highlighted with paint by stencil printing.
9.18
Adequate slope on the top of box shall be provided to drain out rainwater from the top.
9.19
Good-quality plastic sticker leaflet should be pasted inside of distribution box door. The matter of
instruction leaflet is given along with this specification. All the instructions on leaflet should be in
English language.
10
CABLE TERMINATION:
Adequate size of lugs shall be provided for single core, LT XLPE cable on incoming side and
outgoing.
13.
TESTING & MANUFACTURING FACILITIES :
The Tenderer must clearly indicate what testing facilities are available in the works of
manufacturer and whether the facilities are adequate to carry out all Routine & Acceptance
Tests. These facilities should be available to JKPDD’s Engineers, if deputed to carry out or
witness the tests in the manufacturer's works. The tenderer must have all the in-house testing
facilities to carry out the acceptance tests on the Box.
18.
DRAWINGS:
The successful supplier shall submit set of all above drawings of the distribution box and its
components shall be submitted in triplicate to JKPDD and get approved before commencement
of supply.
SPECIFICATION OF 11 KV COMPOSITE POLYMER DISC INSULATORS
1.
SCOPE:
This specification covers the design, manufacture, testing, supply and delivery of 11KV long
rod Silicone Composite Polymer disc Insulators(Tongue & Clevis type) for conductors in tension
application at angle/cut points consisting of:-
i)
Core
It shall be a glass-fiber reinforced epoxy resin rod of high strength (FRP rod).Glass fibers and
resin shall be optimized in the FRP rod. Glass fibers shall be boron free electrically corrosion
resistant (ECR) glass fiber on boron free E Glass and shall exhibit both high electrical integrity
and high resistance to acid corrosion. The matrix of the FRP rod shall be Hydrolysis
resistant. The FRP rod shall be manufactured through Pultrusion process. The FRP rod shall be
void free.
ii)
Housing (Sheath)
The FRP rod shall be covered by a seamless sheath of a silicone elastomeric compound or
silicone alloy compound of a thickness of 3 mm minimum. It should protect the FRP rod against
environmental influences, external pollution and humidity. It shall be directly molded on the core
and shall have chemical bonding with the FRP rod. The strength of the bond shall be greater
than the tearing strength of the polymer. Sheath material in the bulk as well as in the
sealing/bonding area shall be free from voids.
iii)
Weather-sheds
The composite polymer weather-sheds made of silicone elastomeric compound or silicon alloy
shall be molded as part of the sheath and shall be free from imperfection. The weather sheds
should have silicon content of minimum 30% by weight. The strength of the weather-shed to
sheath interface shall be greater than the tearing strength of the polymer. The interface, if any,
between sheds and sheath (housing) shall be free from voids.
iv)
End Fittings
Metal end fitting made of MCI(malleable cast iron) /SGI (spheroid graphite iron)/ forged steel,
hot dip galvanized, EMS 45 KN conforming to IEC 61109, IS- 731-1971 & IS-2633/1972 (with
latest edition/ amendments, if any). End fittings transmit the mechanical load to the core. They
shall be connected to the rod by means of a controlled compression technique. The gap
between fittings and sheath shall be sealed by a flexible silicone elastomeric compound or
silicone alloy compound sealant. System of attachment of end
fitting to the rod shall provide
superior sealing performance between housing i.e. seamless sheath and metal connection. The
sealing must be moisture proof.
The dimensions of end fittings of Insulators shall be in accordance with the standard dimensions
stated in IS: 2486 /IEC60120.
2.
APPLICABLE STANDARDS:
The insulators shall comply with the requirement laid down in IEC 61109, IS- 731-1971 and IS 2633 -1972 (with latest editions/amendments, if any) and shall be suitable for use on 3 phase, 50
cycles, 11 KV power system. Following India/ International Standards, which shall mean latest
revision, with amendments/changes adopted and published, unless specifically stated otherwise
in the specification, shall be referred while accessing conformity of insulators with these
specifications.
Sr.No
Indian
Standard
Title
International
Standard
Definition, test methods and acceptance
criteria for composite insulators for A.C I.E.C:61109
overhead lines above 1000V.
1
Porcelain insulators for overhead power
lines with a nominal voltage greater than
IEC:60383
1000V
2
IS:731
3
IS:2071
Methods of High Voltage Testing
IS-2486
Specification for insulator fittings for
overhead power lines with a nominal
IEC:60120
voltage greater than 1000V. General
IEC:60372
Requirements and Tests Dimensional
Requirements Locking Devices
4
5
6
IEC60060-1
Thermal Mechanical performance test and IEC:60575
mechanical performance test on string
insulators units
IEC:60575
Guide for the selection of insulators in IEC60815
respect of polluted conditions
7
Characteristics of string insulators units of
IEC:60433
the long rod type
8
Hydrophobicity classification guide
9
Radio interference characteristics of
overhead power lines and high-voltage CISPR:18-2 part-2
equipment
10
IS:8263
Methods of RI Test of HV Insulators
STRI guide 1.92/1
IEC:60437
Standard
for
insulators-composite
ANSI C29 13-2000
Distribution Dead-end type
11
12
IS:4759
13
IS:2629
14
IS:6745
15
IS:3203
16
IS:2633
17
18
19
IS:4699
Hot dip zinc coatings on structural steel
ISO
:
and other allied products
ISO : 1461
Recommended Practice for Hot
Galvanization for iron and steel
1459
Dip ISO : 1461(E)
Determination of weight of zinc coating
on
ISO:1460
zinc coated iron and steel articles.
Methods of testing of local thickness of
ISO:2178
electroplated coating
Testing of Uniformity of coating of zinc
coated articles.
Standard specification for glass fiber
ASTMD 578-05
strands.
Standard test method for compositional
ASTME 1131-03
analysis by thermogravimetry
Specification for refined secondary zinc
iii)
Tests for the purpose of this standard shall preferably be carried out under conditions of
temperature and humidity specified in IS:196 (i.e. a temperature of 27ºC ± 2º C and relative
humidity of 65 ± 2 percent) and at the prevailing atmospheric pressure. When this is not
possible, the tests may be carried out under conditions naturally obtainable at the same time
of testing.
The barometric pressure, air temperature and humidity shall be recorded for
the purpose of correction. Corrections of test voltage for atmospheric conditions shall be as per
IEC-61109. (with latest amendments, if any).
4.
GENERAL REQUIREMENTS:
i)
The Supplier should have in house testing facilities for conducting acceptance test in accordance
with IEC 61109 and well established manufacturing facility for manufacture and supply of
polymer composite insulators.
The material of housing/ Weather sheds shall have minimum 30% Silicone content by
weight.
All parts made of Forged steel or Malleable cast iron /SGI (spheroid graphite iron) shall be
protected by hot dip galvanizing, conforming to latest edition of IS:4826. All castings shall be
free from blow holes and other casting defects such as cracks etc.
All fittings shall be designed so that the harmful bimetallic corrosion is avoided and effects of
vibration both on conductors and fittings are minimized. End fittings shall be free from crack,
seams, shrinks, air holes and rough edges. End fittings should be effectively sealed to prevent
moisture ingress; effectiveness of sealing system must be supported by test documents. All
surfaces of the metal parts shall be perfectly smooth without projecting points or irregularities,
which may cause corona. All load bearing surfaces shall be smooth and uniform so as to
distribute the loading stresses uniformly.
The insulators shall have satisfactory electrical characteristics in outdoor use, and to be free of
degradation and cracking of the housing .
The insulators shall be free of the penetration of the moisture into the interfaces of the
end fitting during long term outdoor use and shall posses long term tensile withstand load
characteristics .
The insulators shall be free of voids and other defects in the core material and be non - igniting &
non flammable when exposed to flame for short periods.
Supplier shall quote such silicone composite insulators which have proven use under similar
environmental and operating condition. The supplier shall furnish evidence in the form of
certification from the power utilities that the similar type of product supplied to them had been
performing satisfactorily.
The design of the insulators shall be such that stresses due to expansion and contraction in any
part of the insulator shall not lead to deterioration.
The core (FRP rod) shall be sound and free of cracks and voids that may adversely affect the
insulators.
ii)
ii)
iii)
iv)
v)
vi)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
5
Weather sheds shall be uniform in quality they shall be clean, Sound, smooth and free from
defects and excessive flashing at parting lines.
Insulators shall have sheds with good self-cleaning properties. Insulator shed profile, spacing,
projection etc. and selection in respect of polluted conditions shall be generally in accordance
with the recommendation of IEC-60815/IS: 13134.
The design, manufacturing process and material control at various stages shall be such as to
give maximum working load, highest mobility, best resistance to corrosion, good finish and
elimination of sharp edges and corners.
All ferrous parts shall be hot dip galvanized to give a minimum average coating of zinc equivalent
to 610 gm/sq.m. or 87 u,m thickness and shall be in according with the requirement of IS4579. The zinc used for galvanizing shall be of purity 99.5% as per IS-4699. The zinc coating
shall be uniform, adherent, smooth, reasonably bright, continuous and free from imperfections
such as flux, ash rust stains, bulky white deposits and blisters. The Galvanized metal parts shall
be guaranteed to withstand at least four successive dips each lasting for one (1) minute duration
under the standard pierce test. The galvanizing shall be carried out only after any machining.
INSULATOR CHARACTERISTICS:
The composite silicone polymer insulators shall have the dimensional, electrical and mechanical
characteristics detail as under:
i)
DIMENSIONS
The various dimensions of the polymer disc insulators shall be so designed as to suit the
electrical and mechanical characteristics given hereunder and adaptable to 11 KV power
system.
ii)
TOLERANCES ON DIMENSIONS
The tolerances on all dimensions e.g. diameter, length and creep age distance shall be allowed
as follows:+ (0.04 d + 1.5) mm when d < 300mm
+ (0.025 d + 6) mm when d > 300mm
where d being the dimensions in millimeters for diameter length or creepage distance as the
case may be. The minimum creepage distance shall be 320 mm for heavily
polluted
atmosphere. However no negative tolerance shall be applicable to creepage distance.
III)
ELECTRICAL:
The test voltage of the composite polymer insulator shall be as under:-
a)
Highest system voltage
b)
c)
d)
Nominal system voltage
11 KV
Visible Discharge voltage test
9 KV (r ms)
Dry power frequency withstand
70 KV (r ms)
voltage
Wet power frequency withstand test
35 KV (r ms)
Minimum dry lightening impulse f)
withstand voltage
75 KV(Peak) .
Dry flashover voltage
As per relevant standard
Wet flash over voltage
As per relevant standard
MECHANICAL:
The insulator shall be suitable for the minimum failing load of 70 KN.
Pin ball shank diameter
= 16 mm
INTERCHANGEABILITY.
The composite insulators including the end fitting connection shall be standard design suitable
for use with the hardware fittings of any make conforming to relevant IEC/IS standards.
e)
f)
g)
h)
iv)
a)
b)
6
12 KV (r ms)
7
CORONAL AND RI PERFORMANCE
All surfaces shall be clean, smooth, without cuts, abrasions or projections. No part shall be
subjected to excessive localized pressure. The insulator and metal parts shall be so designed
and manufactured that it shall avoid local corona formation and not generate any radio
interference beyond specified limit under the operating conditions.
8
GUARANTEED TECHNICAL PARTICULARS:
The full guaranteed technical particulars shall be given in the Performa as per AnnexureA.
9
DRAWING:
The tenderers shall submit with their tender fully dimensioned elevation, cross longitudinal
sectional drawing of insulators. All drawings shall be to the scale and fully detailed with clear
indication thereon, of the material of which each component is made.
10
MARKING:
Each insulator unit shall be legibly and indelibly marked with the following details as per IEC61109:
•
Name / Trade Mark of the manufacturer.
•
Month & year of manufacture.
•
Minimum failing load in Newton/Kg.
•
Country of manufacture.
PSPCL reserves its right to get the word ‘PSPCL’ marked on each insulator in addition to
marking as detailed above. The marking shall be on metal parts.
11.
TESTS & TEST CERTIFICATES:
The Insulators shall comply with the following tests as per IEC-61109-1992 and IS2633/1972(with latest amendments, if any, for galvanizing test):
DESIGN TEST:
The following constitute the design tests as per IEC-61109 (clause-5):



Test on interfaces and connections of metal fittings.
Assembled core load time test.
Test of housing: Tracking and Erosion test.
Test for the core material.
NOTE 1:
Type tests certificates from a Govt. approved/ recognized Test House indicating the results
of type tests conducted (before original date of opening of tender) on not less than two
insulators, identical in all essential details with those to be supplied. Type test should be
conducted on the tendered item manufactured only at work(s) from where material is to
be supplied. Purchaser, however, reserves its right to carry out the type test(s) whenever felt
necessary at firm’s cost.
NOTE 2: Additional Tests:In addition to the type tests as mentioned above, all the tenderers who possess the test reports
for following tests on not less than two insulators, identical in all essential details with those to
be supplied , from Govt. recognized test house as per IEC 61109 shall supply the same along
with the tender for additional technical qualification/ capability.
i)
ii)
iii)
12.
Tracking & Erosion Test: The test shall be carried out as per IEC:61109 Clause 5.3
Ultraviolet Test: The test shall be carried out in line with clause 7.2 of ANSI C 29.13
Ageing Test: Test reports of the accelerated Ageing Test of 5000 hours as per Appendix-C of
IEC 61109.
PACKING:
All polymer insulators shall be suitably packed in corrugated boxes with internal supports as
required. The packing shall be suitable for easy but rough handling and acceptable for road / rail
transport. The material shall be packed to withstand normal transit. Safe delivery of the
consignment shall be the responsibility of the supplier. Suitable cushioning, protective padding
or spacers shall be provided to prevent damage or deformation during transit and handling.
The supplier shall provide instructions regarding handling and storage precautions to be taken at
site on the box itself.
Each corrugated box of insulators shall be clearly marked indicating the number of units, type of
unit, test rating and order number along with instructions regarding handling as specified above
13
TOLERANCE
A tolerance of +2% (two percent) of the ordered qty. subject to maximum of 50 no. insulators
shall be allowed for recording completion of the order.
14
PLACE OF MANUFACTURE:
Place of manufacture, testing and inspection of material must be stated by the tenderer clearly.
15
PERFORMANCE:
The performance of composite polymer insulators supplied by the firms to other Govt.
recognized electrical utilities/Boards/corporations shall be taken into consideration
.
SPECIFICATIONS FOR ACCESSORIES
TECHNICAL
AND HARDWARE FITTINGS FOR HT–ABC
Summary:
10.
General conditions
11.
Tee Connections with Surge protection.
12.
Straight through Joints.
13.
Outdoor End Terminations.
14
.Anchoring clamps
15.
Suspension clamps
16.
Eye Hooks.
17.
Pole Clamps.
General Conditions
The products shall be in accordance with Indian standards and most of the European recognized standards used
in HTABC with any relevant standard.

Marking: Each product shall be clearly identified with Manufacturer name or trade mark, reference and
capacity of the item and batch No.

Packaging: Manufacturer shall mention the packaging of each item. Installation instruction should be
included in the packaging.
 Type tests: Each supplier should provide type test reports with the offer, carried out in accordance with
one of the referenced standards in NABL accredited laboratory in last 5 (five) years.
 Routine tests: Suppliers shall provide a control plan, which will be implemented on each
item.RoutineTestreportsshouldbesubmittedbythemanufacturerwiththeInspection Call.
 Quality: All suppliers should be ISO 9000 certified.
 Anchoring and Suspension clamps should be installable on existing poles using appropriate devices
(hooks, Pole clamps etc.)
All crimped connectors should be installed with mechanical or hydraulic hand crimping tools.
Specification of Tee Connection with Insulated Bus bar & Surge Protection for 11kvAB Cable
Scope
In the process of drawing HT 11KV AB cable, in between Distribution Transformers has to be charged by the help
of Tee off .While charging the Distribution Transformer it has to be noted that the main power cable is not
discontinued. In this regard Tee connection with Insulated Bus bar application with suitable Aluminium Bus bars,
Insulating Heat shrinkable bus bar tubings, Polymeric Insulators for Bus bar fixing & Polymeric Surge Arrester for
Surge/ Lightning protection are used properly. The service may be taken from the Tee connector with the help of
AAC bare/ Insulated conductor to the Distribution Transformer.
Technical requisites
Bus bars
Suitable Aluminium rectangular Bus bars of dimension 1mX50mmX6mm with provision for connecting two nos.of
Cable end termination sat both ends & tap off point at the centre of the bus bar. The Edges of the bus bars should
be free from any sharp edges/nicks.
Insulation:
The Bus bars should be fully insulated with Heat shrinkable bus bar tubing’s to Prevent any bird fault or accidental
contact.
Insulator:
Suitable polymeric pin type insulators should be used for fixing Bus bars on the Pole structure. The housing of the
Insulators should be made up of polymeric materials preferably Track resistant EVA materials &should conform the
following properties:
Mechanical Properties [kN]
Specified Cantilever Load
12.5
Maximum Design Cantilever Load
Specified Tension Load
Routine Test Load
Electrical Properties [kV]
AC Wet Withstand Voltage
AC Dry With stand Voltage
AC Wet Flash over Voltage
AC Dry Flash over Voltage
Impulse Withstand Voltage
5.5
25
12.5
61
95
72
104
137
Surge Protection:
A metal oxide surge arrester with a housing made of polymeric material preferably Silicon e rubber, without air
voids neither between the housing and the metal oxide resistors nor the housing itself .Arresters must have directly
moulded housings.
The arresters should be tested as per IEC 60099-4
& conform to the following criteria:
Rated Voltage
: 9KV
Nominal Discharge Current
: 5KA
Distribution Class
Creepage length
:> 300mm.
Impulse Voltage 1.2/50μsec
: 95KV
Power frequency with stand voltage
: 38KV
Voltage Ratings:
Nominal system voltage (kV)
Maximum system voltage (kV)
Maximum performance
:6.6KV (UE)/11KV (E) (phase to phase)
:6.6KV (UE)/11KV (E) (phase to phase)
: For 11KV (E)
QUALITYASSURANCE
The manufacturer shall be certified in accordance with ISO9001. The supplier has to provide a Copy of a valid
certificate along with his quote.
Relevant Manuals or Drawings shall be presented upon request to customer/utility.
PACKING AND SHIPMENT
Tee Jointing Kits shall be securely packed, complete with all accessories, in strong non-returnable boxes, in such
a manner as to prevent damage during shipment.
Specification of Straight through Joint for 11kv AB Cable
Scope
In the process of drawing HT 11Kv AB cable, at the end of one drum of cable ,to continue the drawing of the cable
the cable from other drum has to be joined by Mid span In line Straight through joints .In this regard ,Straight
through joint should be supplied with suitable Mechanical Connector ,proper Stress Control ,adequate Insulation
,suitable screen continuity &sufficient environmental sealing should be achieved.
Technical requisites
Conductor Connection:
Suitable Shear bolt type Al.Mechanical Connector has to be used.
Void filling:
Suitable void filling Mastic
Stress Control Environmental sealing and ant tracking:
By Heat shrinkable dual wall tube has to be used for both stress controlling and environmental sealing purpose.
Minimum (one) no. of Heat shrinkable Rain shed can be used for increasing Creepage distance. with extruded
Insulation & semiconducting layers.
Earthing Connection Continuity:
With the help of Tinned Copper braid.
Voltage Ratings:
Nominal system voltage (kV)
:6.6KV (UE)/11KV (E) (phase to phase)
Maximum system voltage (kV)
:6.6KV (UE)/11KV (E) (phase to phase)
Maximum performance
: For11KV (E)
Testing Standards:
The Outdoor End Termination should conform/with stood the following test std.Tests
Recommended Test values
AC High voltage
28.5KV(rms)
Load cycling 90ºC+5ºC(no. of cycles)
Load
cycling
under 0.25mtr.of water
Impulse voltage
900C+50C(no.
18 Cycles
of
cycles)
12 Cycles
95KV(peak)
Partial discharge voltage
At12.75KV<5pc
Thermal short circuit
For 1 sec.KA will depend on conductor size.
C voltage
38KV for 15mins.
QUALITYASSURANCE
The manufacturer shall be certified in accordance with ISO9001. The supplier has to provide a copy of a valid
certificate along with his quote.
Relevant Manuals or Drawings shall be presented upon request to customer/utility.
PACKING AND SHIPMENT
Tee Jointing Kits shall be securely packed, complete with all accessories, in strong non-returnable boxes, in such
a manner as to prevent damage during shipment.
Specification of Outdoor End Termination for 11kv AB Cable
Scope
In the process of drawing HT 11Kv AB cable, at the end of the cabling system the cable has to be connected with
the Transformer end or with the bare over headline by Outdoor end terminations. In this regard, Outdoor end
terminations should be supplied with suitable Crimping type lugs, proper Stress Control, adequate Insulation
&sufficient environmental sealing should be achieved.
Technical requisites
Conductor Connection : Suitable Crimping type Al.lugs has to be used.
Void filling
Suitable void filling Mastic.
Stress Control Environmental Sealing & Anti tracking: By Heat shrinkable dual wall single tube has to be used for
both stress controlling & Environmental sealing purpose .Minimum (one) no. of Heat shrinkable Rain shed can be
used for increasing Creepage distance.
Earthing Connection Continuity : With the help of Tinned Copper braid.
Voltage Ratings
: Nominal system voltage (kV):6.6KV(UE)/11KV(E)(phase to phase)
Maximum system voltage (kV) :6.6KV (UE)/11KV(E)(phase to phase)
Maximum performance: For 11 KV (E)
Testing Standards: The Outdoor End Termination should conform/with stood the following test std.Tests
Recommended Test values
AC High voltage
28.5KV(rms)
Load cycling 90ºC+5ºC(no. of cycles)
Load
cycling
under 0.25mtr.of water
900C+50C(no.
18 Cycles
of
cycles)
12 Cycles
Impulse voltage
95KV(peak)
Partial discharge voltage
At12.75KV<5pc
Thermal short circuit
For1sec.KA will depend on conductor size.
DC voltage
38KV for 15mins.
QUALITY ASSURANCE
The manufacturer shall be certified in accordance with ISO9001. The supplier has to provide a Copy of a valid
certificate along with his quote.
Relevant Manuals or Drawings shall be presented upon request to customer/utility.
PACKING AND SHIPMENT
Tee Jointing Kits shall be securely packed, complete with all accessories, in strong non-returnable boxes, in such
a manner as to prevent damage during shipment.
Anchoring Clamp for Bare messenger:
The clamps should be designed to anchor HT-AB Cable with Bare neutral messenger.
The clamp should consists of an Aluminium alloy corrosion resistant casted body and 3 U bolts which shall
anchor/hold the neutral messenger without damaging the conductor strands.
 The clamp should be installed properly.
 No losable part in the process of clamping arrangement.
 The clamp should conform to the standard IS 2629 & 2633.
 The clamp body should be made of Galvanized Steel to the standard IS 2629 & 2633 & wedges should be
made of corrosion resistant Aluminium alloy as per IS 617-1975.
 Clamps should be fixed with pole by Eye hooks.
 Ultimate Tensile Strength of the clamp should not be less than 20KN.
 Maximum Allowable load of the clamp should not be less than 20KN.
 Design as per furnished drawing.
Suspension clamp for bare neutral messenger:
The clamps should be designed to hang HT-AB Cables with bare neutral messengers. The neutral messengers
should be fixed by an adjustable grip device with 2 U bolts.
 The clamp should be installed properly.



No losable part in the process of clamping arrangement.
The clamp should conform to the standard IS 2629 & 2633 & REC Constr. Standard E-34.
The clamp body should be made of Galvanized Steel to the standard IS 2629 & 2633 & wedges should be
made of corrosion resistant Aluminium alloy as per IS 617-1975.
 Clamps should be fixed with pole by Eye hooks.
 Ultimate Tensile Strength of the clamp should not be less than 20KN.
 Maximum Allowable load of the clamp should not be less than 20KN.
 Design as per furnished drawing.
Eye Hooks:
 Eye hooks should be designed as to hold Suspension Clamps and Dead end Clamps on the poles:
Eye hooks should be made of forged Galvanized Steel.
 The clamps should be corrosion resistance & should confirm to the standard IS:2629 and IS:2633

Bolt and nuts should be made of hot dip galvanized steel, according to VDE 0210 and VDE 0212.
 Ultimate Tensile Strength (UTS) of the clamp should be 15KN.

Design as per furnished drawing.
Pole Clamps:
 Pole Clamps should be designed as to hold Eye hooks by two nut bolts on the poles:
Pole Clamps should be made of forged Galvanized Steel.
 The clamps should be corrosion resistance & should confirm to the standard IS:2629 and IS:2633

Bolt and nuts should be made of hot dip galvanized steel, according to VDE 0210 and VDE 0212.

It can be fabricated from 50x6mm GI flat.

Design as per furnished drawing.
A.GUARANTEED TECHNICAL PARTICULARS FOR SUSPENSION CLAMP FOR BARE
MESSENGER WIRE
Sl.No Description
1
Name & address of the Manufacturer
2
Applicable standard
3
Type of Clamp
4
Type of design
5
Voltage Grade(kV)
6
Loop anchor attachment (open/close)
7
Installation (with/wit out this-assembly)
8
Type & grade (metallic/non-metallic material)
9
Type of hot dip galvanizing & thickness of Zinc
coating
10
Marking
11
Colour of non-metallic parts
12
Dimensions
13
Approximate weight
14
Ultimate tensile strength(KN)
15
Maximum allowable load(KN)
16
Max angle of deviation of conductor (degree)
Guaranteed particulars
Authorized Signatory
B.GUARANTEED TECHNICAL PARTICULARS FOR DEAD END CLAMP FOR BARE
MESSENGER WIRE
Sl.No Description
1
Name & address of the Manufacturer
2
Applicable standard
3
Type of Clamp
Guaranteed particulars
4
Type of design
5
Voltage Grade(kV)
6
Loop anchor attachment (open/close)
7
Installation (with/without this-assembly)
8
Type & grade (metallic/non-metallic material)
9
Type of hot dip galvanizing & thickness of Zinc
coating
10
Marking
11
Colour of non-metallic parts
12
Dimensions
13
Approximate weight
14
Ultimate tensile strength(KN)
15
Maximum allowable load(KN)
Authorised signitory
C.GUARANTEED
TECHNICAL PARTICULARS FOR END TERMINATION KIT
Sl.No Description
Guaranteed particulars
1
2
3
4
5
6
7
8
Name & address of the Manufacturer
Applicable standard
Type of Cable jointing kit
Application
Nominal system voltage (kV)
Maximum system voltage(kV)
Number of main core
Number of branch conductor
9
Whether single tube is used for Stress control
and tracking
10
11
12
13
14
15
16
17
18
19
20
21
Type of insulation
Type of screening
System neutral earthing
Maximum performance
AC voltage
Load cycling 90°C+5°C(no.of cycles)
Load cycling 90°C+5°C(no.of cycles) under 0
.25 mtr of water
Impulse voltage
Partial discharge voltage
Thermal short circuit
DC voltage
Dynamic short circuit
Authorized Signatory
D.GUARANTEED TECHNICAL PARTICULARS FOR STRAIGHT JOINT FOR HT 11KV (E)
Sl.No Description
1
2
Name & address of the Manufacturer
Applicable standard
Guaranteed particulars
3
4
5
6
7
8
9
10
11
12
13
Type of Cable jointing kit
Application
Nominal system voltage (kV)
Maximum system voltage(kV)
Number of cores
Type of insulation
Type of screening
System Neutral Earthing
Maximum performance
AC voltage
Load cycling 90°C+5°C(no.of cycles)
14
Load cycling 90°C+5°C(no.of cycles) under 0 .25
mtr of water
15
16
17
18
19
Impulse voltage
Partial discharge voltage
Thermal short circuit
DC voltage
Dynamic short circuit
Authorized Signatory
E.GUARANTEED TECHNICAL PARTICULARS FOR TEE CONNECTION WITH SURGE
PROTECTION
Sl.No Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
Name & address of the Manufacturer
Applicable standard
Application
Nominal system voltage (kV)
Maximum system voltage(kV)
Number of main core
Number of branch conductor
Type of Bus bar
Type of insulation
Type of Insulators
Cantilever Load of Insulator
Max. Design Cantilever load of insulator
Creepage Length of Insulator
Specified Tension Load of insulator
AC Wet with stand voltage of insulator
AC dry with stand voltage of insulator
AC Wet flash over voltage of insulator
AC dry flash over voltage of insulator
impulse with stand voltage of insulator
Guaranteed particulars
20
21
22
23
24
25
26
Type of Surge arresters
Rated voltage of SA
Nominal Discharge Current of SA
Distribution Class of SA
Creepage Length of SA
Impulse Voltage of SA
Power frequency withstand voltage of SA
Authorized Signatory
F.GUARANTEED TECHNICAL PARTICULARS FOR EYEHOOK
Sl.No Description
1
2
3
4
5
6
7
8
9
10
11
Guaranteed particulars
Name & address of the Manufacturer
Applicable standard
Type of Clamp
Type of design
Type & grade (metallic/non-metallic material)
Type of hot dip galvanizing & thickness of Zinc coating
Marking
Colour of non-metallic parts
Dimensions
Approximate weight
Ultimate tensile strength (KN)
Authorized Signatory
G.GUARANTEED TECHNICAL PARTICULARS FOR C FIRE WEDGE CLAMP
Sl.No Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Name & address of the Manufacturer
Brand Name
Part Number
Application
Installation and Application Tooling
Connector Removal
Installation on Energized Lines
Conductor Size
Connector, Metallic Material
Connector, on-Metallic Material
Voltage/Ampacity
Operating Temperature
Marking
Industry Standards
Overall Size
Guaranteed particulars
Authorized Signatory
TECHNICAL SPECIFICATIONS FOR LT ABC CONNECTORS
CONNECTORS AND FITTINGS FOR LV – ABC
Standards: NF C 33020, 33021, 33040, 33041, 33042 & ESI 43-14
1. General Conditions
The products shall be in accordance with Indian standards and most of the European recognized
standards used in LT ABC (NFC for example) or with any relevant standard.
• Marking: Each product shall be clearly identified with Manufacturer name or trade mark, reference and
capacity of the item and batch No.
• Packaging: Manufacturer shall mention the packaging of each item. Installation instruction should be
included in the packaging.
• Type tests: Each supplier should provide type test reports with the offer, carried out in accordance with
one of the referenced standards in NABL accredited laboratory.
• Routine tests: Suppliers shall provide a control plan, which will be implemented on each item. Routine
Test reports should be submitted by the manufacturer with the Inspection Call.
• Quality: All suppliers should be ISO 9000 certified.
• Anchoring and Suspension clamps should be installable on existing poles using appropriate devices
(hooks, pigtails, brackets etc.)
• All crimped connectors should be installed with mechanical or hydraulic hand crimping tools.
2. Anchoring clamp for Insulated messenger:
The clamps should be designed to anchor LV-AB Cable with insulated neutral messenger. The clamp
should consists of an Aluminium alloy corrosion resistant castled body, bail of stainless steel and selfadjusting plastic wedges which shall anchor/hold the neutral messenger without damaging the
insulation.
• The clamp should be installed properly.
• No losable part in the process of clamping arrangement.
• The clamp should conform to the standard NF C 33041 and 042 or equivalent I.S., if any.
• The clamp body should be made of corrosion resistant Aluminium alloy, bail should be of stainless
steel and wedges should be of weather and UV resistant polymer.
• Clamps should be fixed with pole by eye hook/bracket. Bracket should be made of corrosion resistant
Aluminium alloy.
• Ultimate Tensile Strength of the clamp should not be less than 15 KN for 50/70
• Sq.mm insulated messenger wire / 10 KN for 25/35 sq.mm insulated messenger wire.
• Slip load of the clamp should not be less than 3 KN for 50/70 Sq.mm insulated messenger wire/2 KN
for 25/35 sq.mm insulated messenger wire.
• Design as per furnished drawing.
3.
Suspension clamp for insulated neutral messenger:The clamps should be designed to hang LV-AB
Cables with insulated neutral messengers. The neutral messengers should be fixed by an adjustable
grip device. A movable link should allow longitudinal and transversal movement of the clamp body.
• The clamp should be installed properly.
• No losable part in the process of clamping arrangement.
• The clamp should conform to the standard NF C 33040 or equivalent I.S., if any.
• The clamp and the link made of the Polymer should provide an additional insulation between the cable
and the pole.
• The clamps and the movable links should be made of weather and UV resistant glass fiber reinforced
polymer.
• Clamps should be fixed with pole by eye hook/bracket. Bracket should be made of corrosion resistant
aluminium alloy.
• Ultimate Tensile Strength of the clamp should not be less than 15 KN for 50/70 Sq.mm insulated
messenger wire / 4.3 KN for 25/35 sq.mm insulated messenger wire.
• Maximum Allowable load of the clamp should not be less than 20 KN for 50/70 Sq.mm insulated
messenger wire / 15 KN for 25/35 sq.mm insulated messenger wire
• The clamp should sustain to maximum angle of deviation of 60 degrees of the conductors.
• Design as per furnished drawing.
4. Service clamps
The clamps should be designed to anchor insulated service lines (armoured or unarmoured) with2/4
conductors.
• The clamps should be made of weather and UV resistant polymer.
• The clamp should be installed properly.
• No losable part in the process of clamping arrangement.
• The clamp should conform to the standard NF C 33042 or equivalent I.S., if any.
• Breaking load of the clamp should not be less than 3 KN.
• Design as per furnished drawing.
5. Transformer connections
• The connection to the transformer should be made with Pre-Insulated Lugs for Phase and Street
Lighting conductors and with an Aluminium Lug for Neutral Messenger. If the Bus Bars are of Copper,
the Lugs should be preferably Bi-metallic type.
• The Barrel of the Lug normally insulated with an Anti-UV black Thermoplastic tube sealed with a
flexible ring. Die reference, size and strip length are indicated on the plastic.
• Sizes Covered: 16 – 70 & up to 150 mm² Aluminium XLPE insulated
• Referenced standard: NFC 33 021 or equivalent I.S., if any.
• Design as per furnished drawing.
6. Junction sleeves
• The sleeves should be Pre - Insulated for Phases, neutral messengers and Street
• Lighting conductors.
• Sleeve should be made of Aluminium, insulated with an anti UV black thermoplastic tube hermetically
sealed two ends with 2 flexible rings. Die reference, size and strip length are indicated on the sleeve
itself.
• Sizes needed: 16 – 70 -& upto150 mm² for Aluminium XLPE insulated
• Referenced standard: NFC 33 021 or equivalent I.S., if any.
• Design as per furnished drawing.
7. Insulation Piercing Connectors as per the standard NF C 33020 or equivalent I.S., if any.
Scope
In the process of replacing the Bare Conductors with LT AB Cables to reduce power theft &
Transmission Losses, it is important to analyze the proper method of providing service connection from
AB Cables to our consumers without damaging the cable. Removal of Bare Conductor, Stringing of LT
AB Cable & re- establishing the service connections should be simultaneous process. In this regard the
Insulating Piercing Connectors are required as
a) for providing 1-2 service connections from 8 mtr. PCC LT pole,
b) for providing supply to Junction/ Distribution Box from AB Cable &
c) for establishing Tee connection from LT ABC to LT ABC.
This Insulating Piercing Connectors should not be exposed to any bare conductor in the
environment during connection. The connectors should be totally Weather & Moisture proof so that
no water or moisture can enter through the pierced holes on to the cable insulation.
It must have Shear Head type mechanism to control the effective Torque during connection and to
ensure perfect installation. Connectors should not have any losable parts, which may drop and then lost
while installation at overhead conditions. For individual connectors Torque required for different
conductor sizes should be mentioned in the equipment
Technical
Construction:
The connectors should be totally insulated with no loose parts. The connectors should be totally
Weather & Moisture proof so that no water or moisture can enter through the pierced holes on the cable
insulation.
Voltage Ratings:
The maximum voltage withstand capacity should be 6 KV.
Moisture Ingress:
The connectors should work at 30 cm under water bath for 30 min. & voltage applied of 6KV for 1 min.
without any flashover/ failure & moisture.
Working Temp.
Designed for installation from -10˚C up to +60˚C & operation experience with temperature from -20˚C up
to +75˚C.
7.1. Materials:
Material used in the manufacturing process of the components of this product should be specified in the
respective product drawings & can be summarized as follows:
• All the metallic part of the connector should be Corrosion resistance & should be proven in Salt Fog
chamber & Wet SO2 gas chamber & there should not be any change in contact resistance &
temperature after overloads & load cycling.
• The contact plates should be made of tinned Copper.
• Connector teeth should be factory greased & sealed to retard water or moisture ingress & corrosion.
• The insulation material should be made of weather & UV resistance, reinforced polymer.
• The outer metallic part should have potential free tightening bolts to allow safe installation on life lines.
• The bolts should be of Shear Head type so that it controls the effective applied Torque during
installation & break off at a specified torque after establishing proper connection.
• The connector should not have any losable component. The cable end cap should be attached to the
body.
7.2. Testing Standards:
Tests
Corrosion
Qualification
Test
Electrical
Ageing Test
Dielectric
Investigation
Test in Water
Mechanical
Tests
Tests Standard/ Test Procedure
As per NF C 33-020 (Jun’98), or equivalent I.S., if any. Exposure in Saline
Environment- The exposure should be carried out as per NF EN 60068211(Aug’99) std. requirement. The concentration of Saline solution must be of
5% ± 1% in mass, & the temperature of the test chamber must be
maintained at 35˚C ± 2˚C.
Exposure in Sulphur environment saturated of humidity - The exposure should be
carried out as per NFT 30 -055(Mar’74) std. requirement. SO2 concentration
in the chamber should be 0.067% in volume. The temperature of the test
chamber should be increased to 40˚C ± 3˚C.
The total test should include four identical periods of 14 days, in which 7 days of
exposure in Saline environment & in other 7 days - 8 hrs cycles i n S O2
environment & 16 hrs in laboratory environment.
As per NFC 33-020 & NF C 33-004 (Jun’98), or equivalent I.S., if any.
Total no. of cycles-200, Heating time -60 mins., Cooling time- 45mins., Pause
time
As per NF C 33 -020 (Jun’98), or equivalent I.S., if any. The connector should
be placed in an ambient temperature between 15˚C & 30˚C & relative humidity
between 25% & 75%. The tightening of the connectors should be at minimal
value of the torque indicated by the manufacturer. The sample should be placed
in tank full of water on 30cm height, after an immersion length of 30mins. The
set is subjected to a dielectric test under a voltage of 6KV at industrial frequency
during 1 min. No flashover/ breakdown should occur at 6KV during 1 min.
As per NFC 33-020 (Jun’98), or equivalent I.S., if any. For checking electrical
continuity, shear heads & mechanical behaviour of the connector’s suitable tests
as per the above specification have to conduct.
8. ABC Service main Distribution boxes
Scope
This Distribution Box should be Weather & Moisture Proof with Spring loaded Bus Bar system & should
be able to carry a current according to specified ampacity. It can have 1 /3-phase input & provision for 4
or 9 nos. of 3- phase or 1-phase outputs through single phase/TPN MCB’s. The box should have the
provision for special key for locking & Proper arrangement of sealing. The boxes should be assembled
on the pole using Metal Tapes & Buckles or Bolts. No. of Boxes per pole may vary with supporting
arrangement for more no. of service connections.
Technical requisites
Construction:
Distribution Boxes should be designed with Bus Bars with spring action contact, or nut-bolt technique is
required to connect section of the conductor into the specified place of the Bus bar for proper
connection. It should be used for multiple connections (3-phase or 1-phase) in low voltage Distribution
Network. The boxes should be suitable for 1/ 3-phase (4 cores) inputs & provision for 4 or 9 nos. of 3phase or 1-phase outputs. Bus bars should be with a continuous pair of contact bars with colour code to
facilitate the identification of the correct energy phase. The box should be able to incorporate the input
or output cable dia. of maximum 16mm. (Equivalent to 120Sqmm.)
The box shall also with MCB’s of suitable rating as per REC norms. The Boxes should consist of special
type Lock & key system as well as provision for sealing for complete protection of the service connection
contacts.
Current Ratings:
The maximum current rating should be 140A/ 200A/ 250A. & concerned authority should have the liberty
to choose among the above ratings as per their requirement.
Voltage Ratings:
The maximum voltage withstand capacity should be 600V.
Working Temp
Safe working temperature should be around 80˚C for Outer Box & 100˚C for inner box.
8.1. Materials:
Material used in the manufacturing process of the components of this product should be specified in the
respective product drawings & can be summarized as follows:
• Outer Box (Base & Cap): With UV protection & Flame retardant
characteristics (HB, as per UL 94- Tests for Flammability of Plastic materials) & preferably
made up of ASA (Acrylonitrile Styrene Acrylate).
• Cable Grommets: Ethylene-Propylene Rubber.
• Safety Key: PA 6.6 (Nylon).
• Safety Screw: Stainless Steel or Plating Finished steel.
• Insulator protection as per IP 44
• Bus bars or Terminal Blocks: PA 6.6 (Nylon), Stainless Steel & Copper.
• Button & Cable Holder: PA 6.6 (Nylon) with 50% Glass Fibre.
• Bus bar Insulation: Polyamide.
8.2. Locking System:
The boxes should consist of Special type Lock & Key arrangement as well as provision
for sealing for complete protection of the service connection contacts.
8.3. Testing Standards:
Impact Resistance should be according to UL 746C. Insulation Protection should be as per IP 44. The
Outer Plastic box should conform to following std.Test
Standard
I
Requirements
Test
Degree
of IP 44- Protected against the penetration of solid First Digit: A 1.0 mm diameter
Protection objects exceeding 1.0 mm in diameter and against test wire should not penetrate in
IEC 60529 penetration of water jets that may affect the product any apparent opening (force = 1
operation.
N :!:10%) Second Digit: A spray
nozzle is used to spread a water
jet in all possible directions.
Impact
After the test the product should not show any The impact should be generated
Resistance evidence of:
by dropping a steel ball with a dia
UL 746-C
of 0.535 kg from a specified
height sufficient to produce an
impact energy of 6.8 J(0.6913 kg
m)
- Live electrical parts accessible to the test probe,
as described in this test specification.
- Any results, which may
affect the mechanical performance of the product
- Any results, which may increase the probability of
electrical shocks.
UV
The sample physical properties average value - According to ASTM G26,
Resistance after an accelerated aging with UV radiation - Exposure Method 1, Xenon
UL 746-C
should not be lower than 70% of its initial value,
without aging, that is,a variation of :!: 30% is Arc Lamp Type B or ASTM G155,
Exposure
Cycle
1,
with
allowed.
continuous exposure to light and
intermittent exposure to water
jets, with programmed cycles of
120 minutes, consisting of a 102
minutes light-only exposure and a
18 minutes exposure to light and
water jets
Withstanding Product should withstand the specified voltage.
Voltage UL
746-C
A 5 kV voltage should be applied
to the samples after the 40 hours
conditioning cycle at 23°c ± 2ºc
and 50% ± 5% relative humidity
plus 96 lluur ctl35 2ºc urtl 90.5%
relative humidity
Flammability After the UV radiation accelerated aging, the The test can be applied to test
UL 94
material should maintain the same original samples molded with the same
flammability level (HB).
material used for the base and
the cap of the box or taking a
piece of these components.
Flexural
After UV radiation accelerated aging, the average A group of test samples without
Strength
value for this test should not be lower than 70% of aging should be tested and the
ASTM D790 the original value, that is, a maximum variation of average
values
calculated.
UL 746-C
30% is allowed.
Another group should be aged
under UV radiation, then it should
be tested and the new average
should
be
calculated
and
compared to the initial average
value.
Tensile
After aging with UV radiation, the average value One of the test bodies must be
strength
should not be less than 70% of the initial values, tested without being Submitted to
ASTM D638 that is a maximum variation of 30% is allowed.
accelerated
aging
and
is
UL 746-C
computed over mean values.
Another group is submitted to the
radiation induced aging and the
new mean value is computed and
compared to the first computed
mean value.
9. Eye Hooks:
Eye hooks should be designed as to hold Suspension Clamps and Dead end Clamps and to be installed
with the Pole Clamps:• Eye hooks should be made of forged Galvanized Steel.
• The clamps corrosion resistance should confirm to the standard dip galvanized steel,
according to VDE 0210 and VDE0212.
• Ultimate Tensile Strength (UTS) of the clamp should be 20 KN.
10. TECHNICAL DATA SHEETS
10.1. GUARANTEED TECHNICAL PARTICULARS for pre- moulded Straight joint FOR LT 1.1kv grade
Cable.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
Name & address of the Manufacturer
Applicable standard
Type of Cable jointing kit
Application
Nominal system voltage (kV)
Maximum system voltage (kV)
Number of cores
Type of insulation
Type of screening
System Neutral Earthing
Maximum performance
AC voltage
Load cycling 900C + 50C (no. of cycles)
Impulse voltage
Partial discharge voltage
Thermal short circuit
DC voltage
Dynamic short circuit
10.2. Guaranteed Technical Particulars for Insulating Piercing Connectors
Sl No
Type
1
Name of the
2
Is manufacturer of accessories as ISO
9001 - 2000 company
For Street
Light
For DB
Charging
For ABC to ABC
TEE
a) Copies of
Certificate Enclosed
b) Are GA Drawing enclosed
3
Applicable standard
4
Type of connectors
5
Application
6
Is any metallic part carrying potential in
operation exposed
7
Are end caps of branch
a) slide on type b) Rigid
8
Are torque limiting shear heads provided
to tightening bolts
9
Range of cable sizes accommodated for
main & branch
10
Min. & Max. torque
11
Torque for establishing
between main and branch
12
Max. tensile load for no breakdown of
main conductor (for each cross- section)
13
Max. tensile load on branch conductor
for no break / slippage
14
Voltage withstand under water emersion
15
Is electrical Ageing test report enclosed
16
No. of Cycles
17
Max. temp at each cycle
18
Marking and
connector
cable
connection
embossing
on
the
10.3. Guaranteed Technical Particulars for Eye Hook
Sl No
Particulars
1
Type of Clamp
2
Name of the Manufacturer
3
Place of Manufacture
4
Type of design
Type & grade
material
5
Unit
Metallic
/
Bidder’s Offer
Nonmetallic
6
Type of hot dip galvanizing & thickness of
Zinc coating
7
Dimensions
mm
8
Approximate weight
Kg
9
Ultimate tensile strength
KN
10.4. Guaranteed Technical Particulars for Suspension Clamps suitable for Insulated Messenger wire
Sl No
Particulars
1
Type of Clamp
2
Name of the Manufacturer
3
Place of Manufacture
4
Type of design
5
Standard
6
Loop anchor attachment (Open/Close)
7
Installation (with/without disassembly)
8
Type & grade Metallic / Nonmetallic material
9
Marking
10
Colour of Nonmetallic parts
11
Dimensions
Unit
Bidder’s
Offer
Bidder’s
Offer
Mm
10.5. Guaranteed Technical Particulars for Dead end Clamps suitable for Insulated Messenger wire
Sl No
Particulars
1
Type of Clamp
2
Name of the Manufacturer
3
Place of Manufacture
4
Range of conductor size
5
Standard
6
Type of design
7
9
Installation (with/without disassembly)
Type & grade Metallic / Nonmetallic
material
Marking
10
Colour of Nonmetallic parts
11
Dimensions
Mm
12
Approximate weight
Kg
13
Ultimate tensile strength
KN
14
Maximum allowable load
KN
15
Slip load
KN
8
Unit
Bidder’s Offer
Sq mm
10.6. GUARANTEED TECHNICAL PARTICULARS for Waterproof pre insulated compression type
bimetallic socket FOR LT 1.1kv Grade Cable.
Sl No
Particulars
1
Name & address of the Manufacturer
2
Applicable standard
3
Type of Cable jointing kit
4
Application
5
Nominal system voltage (kV)
6
Maximum system voltage (kV)
7
Number of cores
8
Type of insulation
9
Type of screening
10
System Neutral Earthing
11
Maximum performance
12
AC voltage
13
Load cycling 900C + 50C (no. of cycles)
14
Impulse voltage
15
Partial discharge voltage
16
Thermal short circuit
17
DC voltage
18
Dynamic short circuit
Bidder’s Offer
10.7. GUARANTEED TECHNICAL PARTICULARS (GTP) MULTI CONNECTION AC DISTRIBUTION
SYSTEM
Sl No
Particulars
1
Name of the Manufacturer
2
Place of Manufacture
3
Type of Box
4
Type of design
5
Application
6
Installation
7
Type & grade Metallic / Nonmetallic materials for
Inner Contact Region
8
Type of material for Outer Box
9
Maximum Current Ratings
10
Maximum Voltage withstand capacity
11
Safe Working Temperature
12
Insulation Protection
13
Impact Resistance
14
Range of cable sizes can be accommodated
15
Are special keys Available for theft protection
16
Provision for Lead sealing
17
Marking
18
Colour of Non metallic parts
19
Dimensions
Bidder’s offer
ANNEXURE - III
TECHNICAL SPECIFICATION OF SINGLE PHASE POLY-CARBONATE METER BOX
1. SCOPE:
This specification covers design, manufacturing, testing and supply of fully transparent poly-carbonate
Meter Box suitable for Single phase Static Energy meter. The meter box shall be suitable for wall
mounting and indoor or outdoor application.
2. APPLICABLE STANDARDS:
Unless otherwise modified in this specification the meter box shall generally conform to IS: 14772/2000
(amended up to date).
3. DESIGN AND CONSTRUCTION:
3.1. The meter box shall be so constructed as to have roof tapering down on both sides for easy flow of
rain water and box shall be totally transparent poly-carbonate material natural white colour and having
good workmanship.
3.2. The meter box shall be made of anti corrosive, dust proof, weather proof, unbreakable, scratch
resistant, water proof, ultra violet stabilized and flame retardant high grade poly-carbonate material
having good dielectric and mechanical strength.
3.3. The box material must be UV stabilized to ensure that the base and cover does not get ‘Yellow’
over a period of time. The surface appearance or part must be smooth, non porous and homogeneous,
free of ripples, defects & marks. No fillers/fibers shall be visible at any place.
3.4. a) The meter box shall be made from Poly-carbonate as per IS: 14772 /2000 and as per
requirement of this specification.
b) The wall thickness of meter box shall be minimum 3 mm on load bearing side and cover shall be 2
mm.
3.5. The internal dimensions of meter box shall be such that there shall be minimum 60 mm clearance at
the bottom, 30 mm clearance on three sides, 15 mm clearance on front and 10 mm clearance from back
of the meter.
3.6. The meter box shall not change in colour, shape, size, dimension when subjected to 200 hours on
UV ageing test. Also it shall be capable of withstanding temperature of boiling water for five minutes
continuously without distortion or softening.
3.7. The cover shall be made overlapping type having collars on all four sides. The cover of the box
shall be provided with semi circular / circular gasket of sufficient size to completely fit in the grooves of
the base. The gasket shall be made of neoprene rubber or equivalent good quality rubber.
3.8. The cover shall be made overlapping type having collars on all four sides. The cover of meter box
shall have 4 nos. of non-detachable self-locking push fit type arrangement. It shall have suitable nondetachable fitting to base such that if pushed once inside, the cover shall rest on the base of box in such
a way that any access from outside to the meter is not possible. The locking (press fit) knob shall get
completely contained in the locking hub inside the meter box. The locking hub shall be closed at its
base.
3.9. Meter box shall confirm IP-51.
3.10. The meter base support inside the box shall be raised by about 10 mm in the box for easy wiring.
While fixing the meter, the meter screws shall not protrude outside.
3.11. Suitable circular holes shall be provided at the bottom of the box for inlet and outlet cables with
glands of 6 or 8 mm size made of brass or poly- carbonate material for the cable securely fixed to the
bottom of the box on both sides by chuck nuts with rubber grommet. All the screws and washers shall
be properly zinc plated.
3.12. For fixing the box to wall or wooden board 4 nos. key holes of min. 5 mm diameter shall be
provided at the four corners of meter box. The meter is to be installed in the box and the box in
assembled condition shall have provision to fix it to pole or a wall. The 4 nos. screws of size 5 mm
diameter and 37.5 mm long with suitable washers shall be provided with each meter box.
3.13. The tolerance permissible on the various dimensions of the meter box shall be ±3%.
3.14. The surface appearance of part must be smooth, non-porous and homogeneous, free of
ripples, defects and marks. No fillers or fibers shall be visible at any place.
3.15. The meter box shall be provided with earth terminal to which armor of service line cable
shall be terminated.
3.16. Meter shall be protected against Electrostatic discharge and shall be immune to 35kV.
4. TESTS:
The meter box shall have been successfully type tested as per IS: 14772 / 2000 from NABL Accredited
independent testing laboratories such as CPRI/ERDA. The type test report shall clearly indicate the
constructional features of the type tested meter box. The tenderer shall also furnish certificate from
laboratories where type test carried out. The requisite test facility available in house for that particular
test shall be approved by NABL. The type tests conducted in manufacturer’s own laboratory and
certified by testing institute shall not be acceptable. The tenderer shall also furnish the particulars giving
specific required details of meter box in schedule ‘A’ attached (As per Guaranteed Technical Particulars
uploaded on e - Tendering site). The offers without the details in schedule ‘A’ and Type Test reports
stands rejected.
5. TESTING AND MANUFACTURING FACILITIES
5.1. The manufacturer shall have necessary machinery for production of polycarbonate meter box.
5.2. The manufacturer shall have in house testing facilities for carrying out following tests:
S. No.
Test Details
Reference standard
1
Flammability (V2)
UL 94 or IS :11731 ( pt.II)
2
Heat deflection temp. at (min.
ISO 75
150°C) 0.45 SUB MPA Load
3
Glow wire test
4
Ball pressure test
IEC–695–2-1
pt.2/sec.1)
IEC: 335
5
Water absorption
IS: 14772
6
Mechanical Strength
Marking
Dimensions
construction
I Spirit burner test
IS: 14772
7
8
and
or
IS:
11000
(
IS: 14772
IS: 4249
6. DRAWING /SAMPLE:
The detailed dimensional drawing showing clearly the dimensions and material for meter box and its
constructional features shall be invariably furnished with the offer.
7. MARKING / EMBOSSING:
The following information shall be clearly and indelibly embossed (not printed) on the cover of the meter
box except Sr. No. which may be indelibly printed with inkjet printing on the base and cover of the meter
box. The meter box Sr. No. shall be same as that of the meter Sr. No. fitted inside the meter box.
i) Order number and date.
ii) Year and month of manufacture.
iii) Purchaser's name: J&K PDD
iv) Guarantee 5.0 Years.
v) Sign of danger.
vi) Code name of manufacturer
vii) Meter box Sr. No. [Printed on both the base and cover of meter box]
8. PACKING:
The meter box shall be suitably packed in corrugated boxes in order to avoid damage during transit or
handling.
9. GUARANTEE:
The supplier shall have to give 5 years guarantee of meter box from date of installation to J&K PDD.
141
GTP FOR METER BOX.
142
MANUFACTURER'S
/
SUPPLIER'S
ADDRESS WITH WORKS ADDRESS
143
TRANSPARENT
POLY-CARBONATE
MATERIAL
NATURAL WHITE COLOUR USED FOR BASE AND
COVER OF METER BOX (YES/NO)
144
WALL THICKNESS OF METER BOX ON LOAD BEARING
SIDE 3 MM (YES/NO)
145
THICKNESS OF SHEET OF COVER 2 MM (YES/NO)
146
LIFE EXPECTED IS 5.5 YEARS (YES/NO)
NAME
AND
147
APPLICABLE IS 14772
AMENDMENT) (YES/NO)
/
2000
(WITH
LATEST
148
FURNISH PHYSICAL WATER ABSORPTION VALUE
149
FURNISH THERMAL HDDT VALUE
150
FURNISH FLAMMABILITY VALUE
151
FLAMMABILITY V2 (YES/NO)
152
GLOW WIRE TEST AT 650° C (YES/NO)
153
TENSILE STRENGTH
154
FLEXURE STRENGTH
155
MODULUS OF ELASTICITY
156
IZOD IMPACT STRENGTH NOTCHED 23° C
157
DIMENSIONS OF BOX IN MM (LXBXH)
158
MINIMUM CLEARANCE OF 40 MM FROM THREE SIDES
OF METER (YES/NO)
159
MINIMUM CLEARANCE OF 25 MM FROM METER
FRONT SIDE (YES/NO)
160
MINIMUM CLEARANCE OF 10 MM FROM BACK OF
METER (YES/NO)
161
MINIMUM CLEARANCE OF 60 MM FROM BOTTOM OF
METER (YES/NO)
162
WEIGHT OF COMPLETE BOX IN KGS
163
AS PER C LAUSE 4 .6 OF AN NEXURE III, I .E. T
ECHNICAL SPECIFICATION FOR METER BOX, UV
AGEING TEST IS CARRIED OUT (YES/NO)
164
METER BOX IS TYPE TESTED (YES/ NO)
165
TYPE TEST REPORT NOS.
166
INHOUSE TESTING FACILITY AS PER CLAUSE NO. 6.0
(YES/NO)
167
AS PER C LAUSE 4 .6 OF AN NEXURE III, I .E. T
ECHNICAL SPECIFICATION FOR METER BOX, UV
AGEING TEST IS CARRIED OUT (YES/NO)
168
WHETHER YOU AGREE TO SUPPLY METERS AS PER
ANEXURE-D, I.E. TECHNICAL SPECIFICATIONS OF
THE TENDER. (YES/NO)
169
WHETHER TYPE TEST REPORTS ALONGWITH COPY
OF SAME IN TWO CDS ARE SUBMITTED (YES/NO)
TECHNICAL SPECIFICATION 16mmsq 1.1 KV GRADE TWO CORE PVC INSULATED &
PVC SHEATHED LT ARMOURED CABLES.
1. SCOPE:
1.1. This section provides for manufacture, testing before dispatch, and supply of 16mmsq 1.1 KV
GRADE Two Core PVC insulated and PVC sheathed armored circular cables with aluminum conductor
suitable for working voltage up to & including 1100 Volts ISI marked & conforming to IS 1554 (Part-I)
1988 with latest amendments.
2. STANDARDS:
1.1. IS: 1554(Part- I)/1988
PVC insulated (heavy duty) electric cable for working
1.2. IS: 8130/1984
Conductor for insulated cables.
1.3. IS: 5831/1984
PVC insulation and sheath of electric cables.
1.4. IS: 10810/1984
Method of test for cables
1.5. IS: 3975/19879
Galvanized steel wire/strips
1.6. IS: 10418/1982
Drums for electric cables.
3. GENERAL REQUIRMENT:
3.1. The ISI marked PVC insulated Armored cables shall conform to IS: 1554 (Part-I) /1988 with latest
amendment and bear BIS certification mark. The material used for construction of the cables shall be of
best qualities complying with the requirement of IS: 1554(Part-I)/1988 and other relevant standards. The
cables shall be suitable for outdoor/indoor installation free in air and shall be capable of withstanding the
normal stresses associated with transportation, erection, reeling and unreeling operations without
getting deformed.
3.2. The cable shall be suitable for use where combination of ambient temperature and temperature rise
due to load results in a conductor temperature not exceeding 70 degree C under normal operation and
160 degree C under short circuit condition.
3.3. The PVC insulated Armored LT Cable shall be ISI marked. The bidder (MANUFACTURER) must
furnish valid ISI certificate along with offer.
Technical Particulars of 16 mm sq 1.1 Twin Core Aluminium conductor PVC insulated, inner sheathed
armoured PVC Sheathed FRLS Cable conforming to IS:1554 (part-I) Amended up to date against Nit
No. CEMREJMU/07 of 2013 dated 30-10-2013.
S. No
Type
16mmsq twin Core Cable
1
Voltage Grade
1.1 KV
2
No of Cores
2
3
Material of Conductor
Aluminum H2 Grade conforming to IS
8130 of 1984 (amended up to date)
4
Size of Main Core in mm sq
16 mm sq (7/1.70 mm) conforming to
IS:1753 of 1967 amended up to date
5
Material of Insulation
Type C, PVC as per IS:5831 of
1984(amended up to date)
1.00 Conforming to IS:1554 Part-I of
1984 amended up to date
PVC conforming to IS:5831 of 1984
(amended up to date) Type ST-2
6
7
8
9
Nominal thickness of insulation in mm
Material of Outer Sheath
Thickness if inner Sheath in (mm)
0.3 conforming to IS:1554 Part-I of 1984
Thickness of outer sheath in mm
2
(i) Nominal
1.40 conforming to IS:1554
(ii) Minimum
Part-I of 1984 amended up to date
10
Maximum conductor resistance ohm/Km 1.91conforming to IS:8130 of 1984
at 2 degree C
amended up to date
11
Volume Resistivity (min) at 27 degree C 1x10¹³ Conforming to IS:5831 of 1984
in (ohm-cm)
amended up to date
12
Tensile strength of insulation and 12.5 conforming to IS:5831 of 1984
sheath without ageing min in (N/mm sq) amended up to date
13
%age elongation o f insulation and 150 conforming to IS:5831 of 1984
sheath without ageing
amended up to date
14
15
Climatic Conditions
Installation
Colour to Cores.
at
Place
of
From-15degree to 45 degree
Red & Black
4. MATERIAL:
4.1. CONDUCTOR:
The conductor shall be composed of stranded circular aluminum wire complying with IS; 8130/1984 with
latest amendments.
4.2. INSULATION:
Insulation shall be Type- C PVC
4.3. FILLERS:
4.3.1. The filler shall be of vulcanized rubber, un-vulcanized rubber or Thermoplastic material and shall
be provided to fill the gaps between cores.
4.3.2. The filler material shall be so chosen so as to be compatible with temperature of the cable and
shall have no deleterious effect on other components of the cable. These shall not be harder than PVC
used for insulation and outer sheath respectively.
4.4. ARMOURING:
Armoring shall be of galvanized steel strips.
4.5. OUTER SHEATH:
The outer sheath shall consist of type ST-2 PVC Compound conforming to the requirements of IS:
5831/1984.
5. CONSTRUCTION:
5.1. CONDUCTOR:
The construction of the conductor shall be stranded circular aluminium conductor
5.2. INSULATION:
The conductor shall be provided with Type-‘C’ PVC compound insulation applied by extrusion. The
insulation shall be so applied that it fits closely on the conductor and it shall be possible to remove it
without damage to the conductor. The thickness and tolerance on thickness of insulation shall be as per
clause No. 9.2 of IS: 1554(Part- I)/1988.
5.3. CORE IDENTIFICATION:
The core shall be identified by different coloring of PVC insulation as per clause No. 10.1 of IS:
1554(Part-I)/1988.
5.4. LAYING UP OF CORES:
The core shall be laid up together with the suitable right hand lay. The interstices shall be filled with nonhygroscopic material.
5.5. INNER SHEATH (COMMON COVERING):
5.5.1. The laid up cores shall be provided with an inner sheath applied by extrusion. It shall be ensured
that it is as circular as possible. The thickness of inner sheath shall be as given in Table-4 of IS:
1554(Part- I)/1988.
5.5.2. The inner sheath shall be so applied that it fits closely on the laid up cores and it shall be possible
to remove it without damage to the insulation.
5.6. ARMOURING:
5.6.1. APPLICATION
Armouring shall be applied over the inner sheath. The armour wires/strips shall be applied as closely as
possible. The direction of lay of armour shall be left hand. A binder tape may be provided on the armour.
5.6.2. TYPE OF ARMOUR & DIMENSION:
It shall be galvanized steel strips as specified in Table-6 of IS: 554(Part-I)/1988.
5.6.3. JOINTS:
The joints in the armour wire/strips shall be made by brazing or welding and the surface irregularities
shall be removed. A joint in any wire/strips shall be at least 300 mm from the nearest joint in any other
armour / wire in the completed cable.
5.7. OUTER SHEATH:
5.7.1. The outer sheath consists of type ST-2 PVC compound & shall be applied by extrusion over the
armouring.
5.7.2. The color of the outer sheath shall be black.
5.7.3. The minimum thickness of PVC outer sheath shall not fall below the thickness specified in Table-7
of IS: 1554(Part-I)/1988.
6. TESTS AND TEST CERTIFICATES:
6.1. The cable should meet the requirement of all tests including optional tests as specified at clause
No. 15.4 of IS: 7098 (Part-I)/1988.
6.1.1. The following shall constitute routine tests:
6.1.1.1. Conductor resistance test.
6.1.1.2. High Voltage test.
6.1.2. The following shall constitute Acceptance tests:
6.1.2.1. Tensile test (for Aluminum).
6.1.2.2. Wrapping test (for Aluminum).
6.1.2.3. Conductor resistance test.
6.1.2.4. Test for thickness of Insulation & Sheath.
6.1.2.5. Tensile strength & elongation at break of Insulation & sheath.
6.1.2.6. Insulation resistance test.
6.1.2.7. High Voltage test at room temperature.
6.1.2.8. Cold Bend Test.
6.1.2.9. Cold Impact Test
6.1.2.10. Armourd resistance Test.
6.1.2.11. Flammability test
6.1.3. The following shall constitute type tests:
6.1.3.1. Tests of Conductor
6.1.3.2. Tensile test (for aluminum)
6.1.3.3. Wrapping test (for aluminum)
6.1.3.4. Conductor resistance test.
6.1.3.5. Test for Armouring Wires/Strips
6.1.3.6. Test for thickness of insulation and sheath
6.1.4. Physical test for insulation:
6.1.4.1. Tensile strength and elongation at break of insulation and sheath.
6.1.4.2. Ageing in air oven.
6.1.4.3. Hot Deformation Test.
6.1.4.4. Shrinkage Test.
6.1.4.5. Loss of Mass in Air oven.
6.1.4.6. Heat Shock test.
6.1.4.7. Thermal Stability Test.
6.1.5. Physical test for Outer Sheath:
6.1.5.1. Tensile strength and elongation at break of insulation and sheath..
6.1.5.2. Ageing in air oven.
6.1.5.3. Loss of mass in air oven.
6.1.5.4. Shrinkage Test.
6.1.5.5. Hot Deformation Test.
6.1.5.6. Heat shock Test.
6.1.5.7. Thermal Stability.
6.1.6. Insulation resistance test
6.1.7. High Voltage test (Water Immersion Test)
6.1.8. High voltage test at room temperature.
6.1.9. Flammability test.
6.2. The bidder shall furnish latest complete type test and optional test certificates as specified in Clause
No 15.4 of IS: 1554 (Part-I)/1988 (not older than three years as on the date of tender opening) for
16mmsq size of offered LT PVC ARMOURED CABLES from NABL accredited testing laboratory or
CPRI, Bangalore/ CPRI, Bhopal/ CPRI, Muradnagar with the tender offer otherwise their offer is likely to
be ignored.
6.3. The bidder must also clearly indicate various testing facilities available with the manufacturer must
have a testing Lab having valid BIS licence to carry out all the require test in house.
7. Inspection:
7.1. The inspection may be carried out at any stage of manufacture. The manufacturer shall grant free
access to the purchaser’s representatives at a reasonable time when the work is in progress. Inspection
and acceptance of any equipment / material under this specification by the purchaser shall not relieve
the contractor of his obligation of furnishing material in accordance with the specification and shall not
prevent subsequent rejection if the material is found to be defective.
7.2. The contractor shall keep the purchaser informed in advance about the manufacturing program so
that arrangement can be made for inspection.
7.3. The acceptance tests as per IS: 1554(Part-I)/1988 shall also be conducted by the manufacturer
before dispatch in the presence of our Representative/ Inspecting Officer as per relevant clause of
“General Conditions of Contract” along with verification of lengths & weight and checking the
manufacturing defects, if any of samples coils. The mass of aluminum, XLPE, PVC & Filler in sample
coils shall also be verified by the inspecting officer(s). Cold bend/cold impact test (IS: 5831/1984) shall
constitute the optional tests and shall be conducted on each offered lot of the cables of each size as per
Clause No. 15.4 of IS; 1554(Part-I)/1988.
7.4. Type Tests:
The first lot offered shall not be less than 10% of ordered quantity of 16 mm sq LT PVC/FRLS
ARMOURED CABLE.
One sample from the 1st lot of LT PVC/FRLS ARMOURED cable as received at site store of contractor
shall be selected and sealed by the inspecting officer nominated by purchaser’s for getting it type tested
at any NABL accredited testing laboratory. The charges incurred towards type test of the material
received shall be borne by contractor.
In case sample from the first lot fails then:
7.4.1. Contractor shall have to replace the full quantity of the respective inspected lot received in various
site stores.
7.4.2. For the quantity already utilized against the order in field a deduction @ 15% (Fifteen Percent) of
F.O.R. Destination prices of the material supplied shall be made.
7.4.3. Sample from next lot shall be selected again for type test. All test charges incurred towards type
test of the material for second time shall be borne by the contractor. In case sample again fails in the
type test then further supplies shall not be accepted.
7.5. The purchaser reserves the right to insist for witnessing the acceptance /routine tests of the bought
out items.
7.6. At least 5% of total numbers of drums subject to minimum of 2 in each lot put up for inspection shall
be selected at random to ascertain the length/workmanship of cable by the following method:
At the work of the manufacture, the cable shall be transferred from one drum to another for checking
any manufacturing defects in the cable drum selected for conducting acceptance tests, at the same time
measuring its length with the help of the graduated pulley & cyclometer. The difference in the average
length thus obtained from the declared length by the contractor in the packing list shall be applied to all
the drums if the cable is found short during checking the sample lot (s).
7.7. The contractor shall present the latest calibration certificate (s) of testing instruments/equipments to
be used for the testing of the material covered in the purchase order to the authorized inspecting officer /
inspecting agency of the purchaser. The testing instruments/ meter / apparatus etc. should be got
calibrated by the contractor from time to time from an independent testing laboratory / house having
valid accreditation from National Accreditation Board for testing and calibrating laboratories for the
testing equipment or from original manufactures having trace ability to NABL / NPL. The calibration
certificate(s) should not in any case be older than one year at the time of presenting the same to the
inspecting officer/inspecting agency of the purchaser. The testing instruments/equipment should be duly
sealed by the Calibrating Agency and mention thereof shall be indicated in the calibration certificate(s).
7.8. Test checking of material at stores:
7.8.1. Sampling:
7.8.1.1. One number out of each lot / sub-lot of 25 Nos. drums or part thereof.
7.8.2. Tests:
The following tests shall be carried out:
7.8.2.1. Measurement of Resistance of conductor.
7.8.2.2. Tensile & Elongation test for insulation.
7.8.2.3. Thickness of Insulation.
7.8.3. Criteria for Acceptance:
7.8.3.1. If the measured conductor resistance of the sample (s) exceeds beyond 2% as per the
resistance specified in the contract, the material shall be rejected and the same shall be rejected and
the same shall have to be replaced by the contractor.
7.8.3.2. If the measured conductor resistance of the sample(s) exceeds the value specified in the
contract but does not exceed by more than 2% of the resistance value specified in the contract, the
material pertaining to the relevant lot/sub-lot to shall be accepted with a deduction @ 1.5% of the cost of
cable for increase in resistance for every 1% or part thereof.
7.8.3.3. If the sample (s) fails in any other test, the material contained in the pertinent lot/sub-lot shall be
rejected and shall have to be replaced by the contractor.
7.9. Test Charges:
All test charges incurred towards test checking of the material received in site stores of contractor shall
be borne by the contractor.
8. Identification:
8.1. The Manufacture shall be identified through-out the length of cables as per clause No. 17.1 of IS:
1554(Part-I)/1988.
8.2. The cable code shall be provided as per Clause No. 17.3 of IS: 1554 (Part- I)/1988.
8.3. The cable shall also be required to be embossed with the word name of manufacture or trade
name, cable code, voltage grade, JKPDD, size of cable, year of manufacture and ISI certification mark
at every meter length for which no extra charges shall be paid. Further cable shall be sequencely
marked at every meter length
9. Packing and Marking:
9.1. The cables shall be wound on non-returnable wooden drums conforming to IS:10418/1982 of
suitable size and packed. The ends of the cable shall be sealed by means of non-hygroscopic sealing
material. Only one cable length shall be supplied on a drum.
9.2. The cable shall carry the following information stenciled / painted on the drum:
9.2.1. Manufacturer’s name, Brand name or trade mark.
9.2.2. Type of cable and voltage grade.
9.2.3. Number of cores.
9.2.4. Nominal Cross-sectional area of the conductor.
9.2.5. Cable code.
9.2.6. Length of cable on the drum.
9.2.7. Approximate gross weight.
9.2.8. Year of manufacture.
9.2.9. BIS Certification marks.
9.2.10. Name of the consignee and full destination.
9.2.11. Order No.
9.2.12. The word SUITABLE FOR OUTDOOR USE & LOW TEMPERATURE CONDITIONS.
10. Standard Length:
10.1. The cables shall be supplied in the standard length of 1000 meters.
10.2. A tolerance (+/-) 5% shall be allowed in standard length.
10.3. Only one cable length shall be acceptable by non-standard length measuring not less than 50% of
standard length to complete the ordered quantity in each size.
11. Guaranteed Technical Particulars:
The bidder shall furnish guaranteed technical particulars in the relevant schedule.
12. Constructional Drawings:
The bidder is required to furnish the detailed construction drawing of the cable clearly showing shape of
core, type and size of fillers / interstices along with centre filler etc. In absence of this the tender is likely
to be ignored.
13. Challenge Clause:
The material offered / received after the inspection by the authorized inspection officer may again be
subject to the test for losses or any other parameter from any testing house /in house technique of the
purchaser department & the results if found deviating unacceptable or not complying to approved GTPs
the contractor shall arrange to supply the replacement with in thirty (30) days of such detection at his
cost including to and fro transportation.
ANNEXUREIII
Guaranteed Technical And Other Particulars For The Supply Of 16mmsq 1.1 KV Grade 2
Core aluminium conductor PVC insulated & PVC Sheathed Armoured FRLS type
Confirming to IS: 1554 (Part-I) amended up to date. Cables.
S. No
1
2
Particulars
Name
of
the
Manufacturer & Trade
name
Rated Voltage
16 mm sq 1.1 KV Grade 2 Core
aluminum conductor PVC insulated
& PVC Sheathed Armored FRLS
type confirming to IS:1554 (Part-I)
amended up to date.
3
Standards Referred
Conductor
4
A
Material
B
Nominal area of Cross
Section (Sq mm)
C
No./Nominal
wires
D
Shape of Conductor
E
No of wires
F
Grade of Aluminium
dia
of
Insulation
5
A
Material
B
Nominal
(mm)
C
App.
Di
elecric
strength (KV/mm)
D
Suitability with regards
to temp. moisture,
acid, oil and alkaline
surrounding
Thickness
Inner Sheath
6
A
Material
B
Min.
thickness
sheath (mm)
of
Armouring
7
A
Material & Type
B
Nominal Dia of armour
wires/dimensions
of
strip
Outer Sheath.
8
A
Material
B
Nominal Thickness of
sheath (mm)
9
App. Overall dia of
cable
10
Method
of
Identification
Core
Electrical Proprieties
A
Max. d.c resistance of
conductor 20degree c
(ohm/Km)
11
B
C
D
Max.
premissible
conductor temp (o C
under full load)
Rated Volatge
Max.
Operating
voltage
E
Premissible
variation
F
Rated frequency
G
Premissible frequency
Variation
H
voltage
Minimum
Specific
insulation resistance
85oC (Ohm/Km)
I
Continuous
current
carrying capacity as
per IS:3961 PT-11/67
J
When Cable laid in air
at 40oC temp. (Amp.)
TECHNICAL SPECIFICATION FOR H.T./L.T. WEDGE TYPE LINE CONNECTORS
1. SCOPE:
The specification covers design, manufacture, shop testing, packing & delivery of HT & LT Wedge Type
overhead line connectors for Jumpers, cut-points, T-connections and service connections.
2. STANDARDS:
Unless otherwise specified elsewhere in this specification, the rating as well as performance and testing
of the HT & LT overhead line connectors shall conform to the latest revisions available at the time of
placement of order of all the relevant standards as listed below:a) ANSI C 119.4
b) I.S.5561/1970.
3. GENERAL TECHNICAL REQUIREMENTS FOR HT WEDGE CONNECTORS (AMPACT TYPE):3.1. WEDGE CONNECTORS
The connector shall confirm to ANSI C 119.4. It consists of a spring ' C ' member and a Wedge, both
made from a special Aluminium alloy of high ductility and electrical conductivity. The ' C ' member and a
Wedge shall be factory coated with a conductive inhibitor containing abrasive particles to help in
cleaning the contact surface during installation.
The connector shall be useful for the conductor size of diameter more than 10.05 mm such as
RACCON, DOG, and PANTHER AND above.
AMPACT Wedge type connectors shall use a power-activated cartridge for installation with proper
conductor combinations. During the assembly, the wedge shall be inserted at a speed of about 40 m/s
(130 ft/s) using the specified tool. High-speed insertion with the specified inhibitor shall be very effective
in abrading all sliding surfaces and in disrupting surface oxide film to generate large number of contact
spot in the electrical surfaces.
When connected, this tap shall provide a reliable electrical and mechanical connection for solid,
stranded or compressed conductor combinations including AAC, AAAC and ACSR.
3.2. C " MEMBER:
The C member shall be formed from extruded aluminium so that the grain (extrusion direction) runs
perpendicular to the conductor (e.g. from C-groove end to C-groove end).This orientation of grain
direction provides for lower rates of stress relaxation in the metal and will maintains the level of contact
pressure at or near the value at initial installation for the life of connection. Susceptibility to stress
corrosion cracking will also improve.
The material used shall be specially designed with tighter tolerances on the chemical composition to
ensure consistency of the C- member production regarding dimensions and mechanical properties.
3.3. WEDGE:
The dimensions for the wedges are manufactured to close tolerances to ensure repeatability and
reliability of the connection.
3.4. INHIBITOR:
An oxidation inhibitor shall be applied to the surface there by elimination of oxidation of metallic surface.
The chemical composition of the inhibitor shall be synthetic and compatible with the rubber gloves used
by the utilities. This inhibitor shall contain special Aluminium abrasive particles, optimized in size and
quantity, to ensure repeatability and reliability of the electrical contact made in every connection.
3.5. The connector shall be cartridge fired ‘C’ wedge type confirming to ANSI-C119.4 (AA): Extra Heavy
Duty Class tested. The connectors shall have maximum contact surface with conductor and, extremely
low and stable contact resistance and minimum power loss. These shall maintain constant force within
the connection for the life of the connector/clamp while compensating for thermal expansion or creep
and increased life span.
The mechanical stresses generated during the wedge insertion shall cause plastic deformation of the Cclamp and shall increase the geometrical confirmation of the clamp to the conductor.
3.6. TOOL:The tool is having 4 moving parts: the ram, the power unit, the breech cap and the gas release knob.
The gas produced by the cartridge during the installation is captive inside the power unit. This allows the
tool to remain self-supporting on the lines during installations until the gas release knob is turned
counterclockwise. This allows the gas produced by the cartridge to be released and the tool to be
removed. Tool is to be used on conductors above Rabbit only.
3.7. CARTRIDGE: Power charge repeatability (PCR) is critical to the supply of a reliable product, which can be applied
safely and consistently every time. These cartridges are designed with the primer cap enclosed to
ensure that it can only be used with the specified tool and to ensure that there is no accidental firing.
Cartridges are to be used on conductors above Rabbit only.
4. FREEDOM FROM DEFECTS: 4.1. The wedge type connectors shall be smooth and free from cavities, blowholes, and such other
defects, which would likely cause them to be unsatisfactory in service.
4.2. The wedge type connectors shall be so designed and proportioned that they are capable of safely
withstanding stresses to which they may be subjected (including those due to short circuit and climatic
conditions) and that the effects of vibration both on conductor and connector itself are minimized. They
shall be designed, manufactured, and finished so as to avoid sharp radius of curvature, ridges and
excrescences, which might lead to, localized pressure on or damage to the conductor in service.
4.3. Bimetallic connectors shall be used to connect conductors of two dissimilar metals.
4.4. Sufficient contact pressure should be maintained at the joint by the provision of the required number
of bolts or other fixing arrangements. But the contact pressure should not be so great as to cause
relaxation of the joint by cold flow. The joint should be such that the pressure is maintained within this
range under all conditions of service.
5. TESTS:
5.1. TYPE TESTS: The following Type Tests shall be carried out on three samples as per I.S. 5561/1970.
a. Tensile Test.
b. Resistance Test
c. Temperature Rise Test.
d. Short Time Current Test.
e. Dimensional Check.
5.2. TEST CERTIFICATE:
The tenderer shall furnish detailed type test reports of the offered Wedge Type Connector for the tests
as per clause 7.1 of this specification. All the above Type Tests shall be carried out as per the relevant
standards at laboratories which are accredited by the National Accreditation Board of Testing and
Calibration Laboratories (NABL) of Government of India to prove that the Wedge Type Connector
offered meet the requirements of the specification. These type tests should have been carried out within
five years prior to the date of opening of this tender.
i.
their offered Wedge Type Connector are already fully type tested at Laboratories accredited by
the National Accreditation Board for Testing and Calibration Laboratories (NABL).
ii.
there is no change in the design of type tested Wedge Type Connector and those offered against
this tender
5.3. ACCEPTANCE TESTS:
a) Tensile Test.
b) Resistance Test.
c) Dimensional check
The acceptance tests are to be carried out in presence of Company's representative. The supplier shall,
therefore, give sufficient advance notice to the Company for arranging witnessing of the tests.
5.4. ROUTINE TESTS:
a) Visual inspection.
b) Dimensional Check.
5.5. TESTING FACILITIES AND DETAILS OF EQUIPMENTS:
The supplier / tenderer shall clearly state as to what testing facilities are available in the works of
manufacturer and whether the facilities are adequate to carry out type, routine and acceptance tests as
per specification. The bidder shall provide the facilities to purchaser’s representative for witnessing the
tests in the manufacturer’s works. If any test cannot be carried out at manufacturer’s works reason
should be clearly stated in the tender.
6. MARKING:
6.1. Each C- member and wedge is marked with distinct identification code. This identification code is
also marked on the packaging to ensure that the correct parts are used for the application. The installer
can make a quick visual check before installing.
6.2. On each wedge the distinct identification code is located on the side of the largest radius groove to
ensure consistent and error-free installation.
7. PACKING:
7.1. For packing, wooden cases / Boxes / Double Gunny bags shall be used. The packing shall be fit to
withstand rough handling during transit and storage at destination. The heads and threaded portion of
fasteners fitting should be properly protected against damage. The gross weight of the packing shall not
normally exceed 50 kg per box or case. All different fitting components shall be packed in different
cases and shall be completed with minor accessories fitted in places. All Nuts shall be hand- tightened
over the bolts and screwed up to the farther point. The tenderer should be approved the packing list
before dispatching the material.
8. The vendor shall furnish the 4yrs satisfactory performance from govt end utility.
Group – A : Sl. No. - 1) 11 KV 200 Amp 3 Pole AB Switch
Technical Specification
01.0 Scope: This specification covers manufacturing testing and supply of 11KV 200 AMPS
50HZ Air Break switches for out door installation in horizontal configuration. The
switches are suitable for operation under off load conditions only and are
intended for use on Distribution Sub – stations and tapping sectionalizing points
of 11 KV lines.
02.0 Description of the materials: The 11KV A.B. Switch sets shall confirm to the following parameters: a. Number of poles 3
b. Number of Post insulator per pole 2nos12KVpostinsulator.
c. Nominal system voltage 11KV
d. Highest system voltage 12KV
e. Rated frequency 50Hz
f. System earthling effectively earthed.
g. Rated nominal current 200 amps
h. Altitude of installation Not exceeding1000M
The post insulators used in the A.B. Switches shall have the following ratings :a. Power frequency withstand voltage (dry) 25KV (RMS)
b. Power frequency withstand voltage(wet) 35KV (RMS)
c. Implies withstand voltage(dry) 75KV
d. Power frequency puncture withstand 1.3
03.0 Standards: The AB Switch Set shall conform to the following standards: a. IS-9920 (Part-I to V)
b. IS-2544/1973 (for porcelain post insulators)
c. IS-2633, (for galvanization of ferrous parts.) or its latest amendments if
any.
04.0 Insulator make: 12KV post insulators complete with post and cap duly cemented to be used in
the AB Switch Set conforming to IS-2544/1973.
The bidder shall furnish the type test certificate of the post insulators from their
manufacturer for reference and scrutiny.
The bidder shall mention make, type of insulation materials, metal fittings,
Creepage distance, protected Creepage distance, tensile Strength, compressing
strength, torsion strength and cantilever strength.
05.0 Climatic condition: The A.B. Switch set shall be suitable for operation under the following climatic
conditions.
a. Maximum ambient air temperature 45 o C
b. Maximum daily average air temperature 35 o C
c. Maximum yearly average ambient air temperature 30 o C
d. Maximum temperature attainably by a body
e. Exposed to the Sum. 50 o C
f. Minimum ambient air temperature 0 o C
g. Maximum relative humidity 100%
h. Minimum number of rainy days per annum 70
i. Average number of rainy days per annum 120
j. Average annual rain fall 150cm.
k. Number of months of tropical monsoon conditions 4
l. Maximum wind pressure 260Kg./mm2
m. Degree of exposure to atmospheric pollution normally
n. Atmosphere. Polluted.
06.0 Other technical details: 06.01 General: - The 11KV A.B. Switch Set shall be the gang operated rotating single
air break type having 2 post insulators per phase. The operating mechanism
shall be suitable for manual operation from the ground level and shall be so
designed that all the three phases shall open or close simultaneously. The
Switches shall be robust in construction, easy in operation and shall be protected
against over travel or staining that might adversely affect any of its parts. The
required base M.S. Channel (hot dip galvanized) phase coupling rod, operation
rod with intermediate guide braided with flexible electrolytic copper, tail piece of
required current carrying capacity and operation mechanism with ‘ON’ & ‘OFF’
positions shall be provided. The operation rod shall be medium gage of 32mm
diameter nominal bore G.I. pipe single length 6 meters. The phase coupling rod
for gang operation shall be of medium gauge 25mm dia nominal bore G.I. pipe.
The Rating post insulators shall be provide with suitable bearing mounted on a
base channel with 8mm dia thrust collar and 6mm split pin made out of stainless
steel. The operating down rod shall be coupled to the spindle (minimum dia –
32mm) for gang operation through another suitable bearing by two numbers
10mm dia stainless steel bolts with double nuts. All the bearings shall be
provided with grease nipple. All metal (ferrous) parts shall be galvanized an
polished. The pipe shall be galvanized in accordance with IS-4736/1968.The post
insulators should be fixed with the base channel using Galvanized Nuts and
Bolts.
06.02. Mounting:- The A.B. Switches shall be suitable for horizontal mounting in double
pole sub-station structures. MS Galvanized base Channel & base support
channel should be of min. size 75x40x6 mm.
06.03. Switching Blades: - It shall be made out of electricity copper with silver plated.
The approximate size shall be 220mm X 50X 6mm. The Switch shall have such a
spring mechanism so as to ensure that the speed of the opening of contact is
independent of speed of manual operation.
06.04 Fixed Contracts: - The Fixed Jaw type female contracts shall be made of
electrolytic copper (minimum 95% copper composition) duly silver coated
controlled by stainless steel high pressure spring housed in robust G.I. Cover. It
is essential that provision shall be made in fixed female contracts to take the
shock arising from the closing of move contract blade without the same being
transmitted to the post insulator. The arrangement made in this regard shall be
specifically shown in the drawing.
06.05 Arcing Horn: - As the switches are generally meant for isolating transmission
line and distribution transformers, suitable arcing horns shall be provided for
breaking the charging current horn shall be made of 10mm dia G.I. Rod with
spring assisted operation.
06.06 Terminal Connectors: - Terminal connectors shall be robust in design. The size
of fixed connector shall be (80 X 50 X 6 mm) and size of movable connector shall
be of (80 X 50) X (80 X 50) X 6mm of copper casting with uniform machine
finishing duly silver plated made out of minimum 95% copper composition with 2
nos. 12mm dia holes provided with suitable brass bolts and double nuts, flat
washers & 2nos. bimetallic solder less sockets suitable upto 80 mm2 conductor.
06.07 Spacing: - The minimum clearance between phases to the switch shall be
760mm. The operation down rod shall be at a transverse distance of 300mm from
the outer limb of the switch. The centre spacing between two post insulator sof the
same phase shall be 380mm. In the open position of the A.B. switches the moving
blade shall rotate through 90 o. This shall be exhibited in the drawing.
06.08 Sample, Drawing & Literatures: - Sample of each items 11KV 200 amps. A.B.
Switch shall be furnished and three copies of drawings item similar to the sample
shall be furnished along with the tender.
06.09 The details of construction and materials of different parts of the A.B. Switch shall
clearly be indicate in the tender and illustrative pamphlet / literature for the same
shall be submitted along with the tender.
07.0 TEST & TEST CERTIFICATE: 07.01 Type Test: - Certificate for the following type tests conducted on a prototype set
of A.B. Switch in a NABL approved test house/CPRI shall have to be submitted
along with offer.
Dielectric Test (impulse and one minute were power frequency withstand voltage
test.)
• Temperature rise test (for contracts and terminals)
• Shorts Time current and peak withstand current test.
• Mainly active load breaking capacity test.
• Transformer off-load breaking capacity test.
• Line charging breaking capacity test.
• Cable charging breaking test.
• Operation and mechanical endurance test.
• Mechanical strength test for post insulator, as per IS-2444/1937 shall be
furnished.
• Test for galvanization of metal (ferrous) parts.
07.02 Routine /Acceptance Test: The inspection may be carried out by the Purchaser at any stage of manufacture.
The successful bidder shall grant free access to the Purchaser’s representative
at a reasonable time when the work is in progress. The following routine tests
shall have to be conducted on each set and results are to be furnished for
consideration of deputing inspecting officer for inspection and conduction testing
of the materials at the works of the manufacturer. the supplier shall give fifteen
days advance intimation to the Purchaser to enable him to depute his
representative for witnessing the tests.
1. Power frequency voltage dry test.
2. Measurement of resistance of main circuit.
3. Tests to prove satisfactory operation.
4. Dimension Check
5. Galvanization test.
6. Operational test.
08.00 Guaranteed Technical Particulars: The bidder shall furnish the guaranteed technical particular duly filled in the
format along with the tender.
09.0 Completeness of Equipment: All fittings, accessories of apparatus which may not have been specifically
mentioned in this specification but which are usual or necessary in equipment of
similar plat shall be deemed to be included in the specification and shall be
supplied by the Tender without extra charge. All plant and equipment shall be
completed in all details whether such details are mentioned in the specification or
not.
clamp should be installed properly.
No losable part in the process of clamping arrangement.
The clamp should conform to the standard NF C 33041 and 042 or equivalent I.S., if any.
The clamp body should be made of corrosion resistant Aluminium alloy, bail should be of stainless steel and
wedges should be of weather and UV resistant polymer.
Clamps should be fixed with pole by eye hook/bracket. Bracket should be made of corrosion resistant Aluminium
alloy.
Ultimate Tensile Strength of the clamp should not be less than 15 KN for 50/70 Sq.mm insulated messenger wire /
10 KN for 25/35 sq.mm insulated messenger wire.
Slip load of the clamp should not be less than 3 KN for 50/70 Sq.mm insulated messenger wire/2 KN for 25/35
sq.mm insulated messenger wire.
Design as per furnished drawing.
Technical Specification
Accessories related to L.T. Arial Bunch Cable
CONNECTORS AND FITTINGS FOR LV – ABC
Page 1 of 8
Standards: NF C 33020, 33021, 33040, 33041, 33042 & ESI 43-14
Summary:
1.
2.
3.
4.
5.
6.
7.
8.
9.
General conditions
Anchoring clamps
Suspension clamps
Service clamps
Transformer connections
Junctions
Insulation Piercing Connectors
Distribution boxes
Eye Hooks
1. General Conditions
The products shall be in accordance with Indian standards and most of the European recognised standards
used in LT ABC (NFC for example) or with any relevant standard.
Marking: Each product shall be clearly identified with Manufacturer name or trade mark, reference and
capacity of the item and batch No.
Packaging: Manufacturer shall mention the packaging of each item. Installation instruction should be
included in the packaging.
Type tests: Each supplier should provide type test reports with the offer, carried out in accordance with
one of the referenced standards in NABL accredited laboratory.
Routine tests: Suppliers shall provide a control plan, which will be implemented on each item. Routine
Test reports should be submitted by the manufacturer with the Inspection Call.
Quality: All suppliers should be ISO 9000 certified.
Anchoring and Suspension clamps should be installable on existing poles using appropriate devices
(hooks, pigtails, brackets etc.)
All crimped connectors should be installed with mechanical or hydraulic hand crimping tools.
2. Anchoring clamp for Insulated messenger:
The clamps should be designed to anchor LV-AB Cable with insulated neutral messenger. The
clamp should consists of an Aluminium alloy corrosion resistant casted body, bail of stainless steel
and self-adjusting plastic wedges which shall anchor/hold the neutral messenger without damaging
the insulation.
The clamp should be installed properly.
No losable part in the process of clamping arrangement.
The clamp should conform to the standard NF C 33041 and 042 or equivalent I.S., if any.
The clamp body should be made of corrosion resistant Aluminium alloy, bail should be of
stainless steel and wedges should be of weather and UV resistant polymer.
Clamps should be fixed with pole by eye hook/bracket. Bracket should be made of corrosion
resistant Aluminium alloy.
Ultimate Tensile Strength of the clamp should not be less than 15 KN for 50/70 Sq.mm
insulated messenger wire / 10 KN for 25/35 sq.mm insulated messenger wire.
Slip load of the clamp should not be less than 3 KN for 50/70 Sq.mm insulated messenger
wire/2 KN for 25/35 sq.mm insulated messenger wire.
Design as per furnished drawing.
1
Technical Specification
Accessories related to L.T. Arial Bunch Cable
Page 2 of 8
3. Suspension clamp for insulated neutral messenger:
The clamps should be designed to hang LV-AB Cables with insulated neutral messengers. The neutral
messengers should be fixed by an adjustable grip device. A movable link should allow longitudinal and
transversal movement of the clamp body.
The clamp should be installed properly.
No losable part in the process of clamping arrangement.
The clamp should conform to the standard NF C 33040 or equivalent I.S., if any.
The clamp and the link made of the Polymer should provide an additional insulation between the
cable and the pole.
The clamps and the movable links should be made of weather and UV resistant glass fibre
reinforced polymer.
Clamps should be fixed with pole by eye hook/bracket. Bracket should be made of corrosion
resistant aluminium alloy.
Ultimate Tensile Strength of the clamp should not be less than 15 KN for 50/70 Sq.mm insulated
messenger wire / 4.3 KN for 25/35 sq.mm insulated messenger wire.
Maximum Allowable load of the clamp should not be less than 20 KN for 50/70 Sq.mm insulated
messenger wire / 15 KN for 25/35 sq.mm insulated messenger wire
The clamp should sustain to maximum angle of deviation of 60 degrees of the conductors.
Design as per furnished drawing.
4. Service clamps
The clamps should be designed to anchor insulated service lines (armoured or unarmoured) with 2/4
conductors.
The clamps should be made of weather and UV resistant polymer.
The clamp should be installed properly.
No losable part in the process of clamping arrangement.
The clamp should conform to the standard NF C 33042 or equivalent I.S., if any.
Breaking load of the clamp should not be less than 3 KN.
Design as per furnished drawing.
5. Transformer connections
The connection to the transformer should be made with Pre-Insulated Lugs for Phase and Street
Lighting conductors and with an Aluminium Lug for Neutral Messenger. If the Bus Bars are of
Copper, the Lugs should be preferably Bi-metallic type.
The Barrel of the Lug normally insulated with an Anti-UV black Thermoplastic tube sealed with a
Flexible ring. Die reference, size and strip length are indicated on the plastic.
Sizes Covered: 16 – 70 & up to 150 mm² Aluminium XLPE
insulated Referenced standard: NFC 33 021 or equivalent I.S., if any.
Design as per furnished drawing.
.
2
Technical Specification
Accessories related to L.T. Arial Bunch Cable
Page 3 of 8
6. Junction sleeves
The sleeves should be Pre - Insulated for Phases, neutral messengers and Street Lighting
conductors.
Sleeve should be made of Aluminium, insulated with an anti UV black thermoplastic tube
hermetically sealed two ends with 2 flexible rings. Die reference, size and strip length are indicated
on the sleeve itself.
Sizes needed: 16 – 70 -& upto150 mm² for Aluminium XLPE insulated
Referenced standard: NFC 33 021 or equivalent I.S., if any.
Design as per furnished drawing.
7. Insulation Piercing Connectors as per the standard NF C 33020 or equivalent I.S., if any.
Scope
In the process of replacing the Bare Conductors with LT AB Cables to reduce power theft
& Transmission Losses, it is important to analyze the proper method of providing service
connection from AB Cables to our consumers without damaging the cable. Removal of
Bare Conductor, Stringing of LT AB Cable & re-establishing the service connections
should be simultaneous process. In this regard the Insulating Piercing Connectors are
required- a) for providing 1-2 service connections from 8 mtr. PCC LT pole, b) for
providing supply to Junction/ Distribution Box from AB Cable & c) for establishing Tee
connection from LT ABC to LT ABC.
This Insulating Piercing Connectors should not be exposed to any bare conductor in the
environment during connection. The connectors should be totally Weather & Moisture
proof so that no water or moisture can enter through the pierced holes on to the cable
insulation.
It must have Shear Head type mechanism to control the effective Torque during connection
and to ensure perfect installation. Connectors should not have any losable parts, which may
drop and then lost while installation at overhead conditions. For individual connectors
Torque required for different conductor sizes should be mentioned in the equipment.
Technical
requisites
Construction:
The connectors should be totally insulated with no loose parts. The connectors should be
totally Weather & Moisture proof so that no water or moisture can enter through the
pierced holes on the cable insulation.
Voltage Ratings: The maximum voltage withstand capacity should be 6 KV.
Moisture Ingress: The connectors should work at 30 cm under water bath for 30 min. & voltage applied of
6KV for 1 min. without any flashover/ failure & moisture ingress in it.
Working Temp.: Designed for installation from -10˚C upto +60˚C & operation experience with temperature
from -20˚C upto +75˚C.
3
Technical Specification
Accessories related to L.T. Arial Bunch Cable
Materials:
Page 4 of 8
Material used in the manufacturing process of the components of this product should be
specified in the respective product drawings & can be summarized as follows:
All the metallic part of the connector should be Corrosion resistance & should be
proven in Salt Fog chamber & Wet SO2 gas chamber & there should not be any
change in contact resistance & temperature after overloads & load cycling.
The contact plates should be made of tinned Copper.
Connector teeth should be factory greased & sealed to retard water or moisture
ingress & corrosion.
The insulation material should be made of weather & UV resistance, reinforced
polymer.
The outer metallic part should have potential free tightening bolts to allow safe
installation on life lines.
The bolts should be of Shear Head type so that it controls the effective applied
Torque during installation & break off at a specified torque after establishing
proper connection.
The connector should not have any losable component. The cable end cap should
be attached to the body.
4
Technical Specification
Accessories related to L.T. Arial Bunch Cable
Testing
Standards:
Page 5 of 8
The Insulating Piercing Connector should conform to following std.Tests
Tests Standard/ Test Procedure
Corrosion
As per NF C 33-020 (Jun’98), or equivalent I.S., if any.
Qualification Test Exposure in Saline Environment- The exposure should be carried
out as per NF EN 60068-2-11(Aug’99) std. requirement. The
concentration of Saline solution must be of 5% ± 1% in mass, &
the temperature of the test chamber must be maintained at 35˚C ±
2˚C.
Exposure in Sulphur environment saturated of humidity - The
exposure should be carried out as per NF T 30-055(Mar’74) std.
requirement. SO2 concentration in the chamber should be 0.067%
in volume. The temperature of the test chamber should be
increased to 40˚C ± 3˚C.
The total test should include four identical periods of 14 days, in
which 7 days of exposure in Saline environment & in other 7 days
- 8 hrs cycles in SO2 environment & 16 hrs in laboratory
environment.
Electrical Ageing As per NF C 33-020 & NF C 33-004 (Jun’98), or equivalent I.S.,
Test
if any.
Total no. of cycles-200, Heating time -60 mins., Cooling time45mins., Pause time – 2 mins.
Dielectric
As per NF C 33-020 (Jun’98), or equivalent I.S., if any.
Investigation Test The connector should be placed in an ambient temperature
in Water
between 15˚C & 30˚C & relative humidity between 25% & 75%.
The tightening of the connectors should be at minimal value of the
torque indicated by the manufacturer. The sample should be
placed in tank full of water on 30cm height, after an immersion
length of 30mins. The set is subjected to a dielectric test under a
voltage of 6KV at industrial frequency during 1 min. No
flashover/ breakdown should occur at 6KV during 1 min.
Mechanical Tests
As per NF C 33-020 (Jun’98), or equivalent I.S., if any.
For checking electrical continuity, shear heads & mechanical
behaviour of the connector’s suitable tests as per the above
specification have to conduct.
Capacity needed:
For ABC 16 to 95 mm2
Model 1 for customer service
Main 16 to 95 mm2
Tap 2.5 to 10 mm2 (For Street lighting)
Design as per furnished drawing.
Main 16 to 95 mm2
Tap 04 to 35 mm2 (For distribution box charging)
Design as per furnished drawing.
Model 3 for customer service Main 25 to 95 mm2
Tap 25 to 95mm2 (For ABC to ABC Tee Joint)
Design as per furnished drawing.
Referenced standard: NFC 33 020 or equivalent I.S., if any.
Model 2 for customer service
5
Technical Specification
Accessories related to L.T. Arial Bunch Cable
Page 6 of 8
8. ABC Service main Distribution boxes
Scope
This Distribution Box should be Weather & Moisture Proof with Spring loaded Bus Bar
system & should be able to carry a current according to specified ampacity. It can have
1 /3-phase input & provision for 4 or 9 nos. of 3- phase or 1-phase outputs. The box
should have the provision for special key for locking & Proper arrangement of sealing.
The boxes should be assembled on the pole using Metal Tapes & Buckles or Bolts.
No. of Boxes per pole may vary with supporting arrangement for more no. of service
connections.
Technical
requisites
Construction:
Current Ratings:
Voltage Ratings:
Working Temp.:
Materials:
Locking System:
Distribution Boxes should be designed with Bus Bars with spring action contact, so that
no screw-bolt technique is required to operate & only insertion of the conductor into the
specified groove of the Busbar is sufficient for proper connection. It should be used for
multiple connections (3-phase or 1-phase) in low voltage Distribution Network.
The boxes should be suitable for 1/ 3-phase (4 cores) inputs & provision for 4 or 9 nos.
of 3- phase or 1-phase outputs. Bus bars should be with a continuous pair of contact
bars with colour code to facilitate the identification of the correct energy phase.
The box should be able to incorporate the input or output cable dia. of maximum
16mm. (Equivalent to 120Sqmm.)
The Boxes should consist of special type Lock & key system as well as provision for
sealing for complete protection of the service connection contacts.
The maximum current rating should be 140A/ 200A/ 250A. & concerned authority
should have the liberty to choose among the above ratings as per their requirement.
The maximum voltage withstand capacity should be 600V.
Safe working temperature should be around 80˚C for Outer Box & 100˚C for metallic
Bus bars.
Material used in the manufacturing process of the components of this product should be
specified in the respective product drawings & can be summarized as follows:
Outer Box (Base & Cap): With UV protection & Flame retardant
characteristics (HB, as per UL 94- Tests for Flammability of Plastic materials)
& preferably made up of ASA (Acrylonitrile Styrene Acrylate).
Cable Grommets: Ethylene-Propylene Rubber.
Safety Key: PA 6.6 (Nylon).
Safety Screw: Stainless Steel or Plating Finished steel.
Insulator protection as per IP 44
Bus bars or Terminal Blocks: PA 6.6 (Nylon), Stainless Steel & Copper.
Button & Cable Holder: PA 6.6 (Nylon) with 50% Glass Fibre.
Busbar Insulation: Polyamide.
The boxes should consist of Special type Lock & Key arrangement as well as provision
for sealing for complete protection of the service connection contacts.
6
Technical Specification
Accessories related to L.T. Arial Bunch Cable
Testing
Impact Resistance should be according to UL 746C. Insulation Protection should be as per IP
Standards
44. The Outer Plastic box should conform to following std.-
:
7
Page 7 of 8
Technical Specification
Accessories related to L.T. Arial Bunch Cable
Page 8 of 8
9. Eye Hooks:
Eye hooks should be designed as to hold Suspension Clamps and Dead end Clamps and to be installed with the
Pole Clamps:Eye hooks should be made of forged Galvanised Steel.
 





The clamps corrosion resistance should confirm to the standard IS: 2629 and IS: 2633

Bolt and nuts should be made of hot dip galvanised steel ,according to VDE 0210 and VDE 0212.
Ultimate Tensile Strength (UTS) of the clamp should be 20 KN.

Design as per furnished drawing.


8
Technical Specification Accessories related to L.T. Arial
Bunch Cable 1 Page 1 of 8
CONNECTORS AND FITTINGS FOR LV – ABC Standards: NF C 33020, 33021, 33040, 33041,
33042 & ESI 43-14 Summary:
1. General conditions
2. Anchoring clamps
3. Suspension clamps
4. Service clamps
5. Transformer connections
6. Junctions
7. Insulation Piercing Connectors
8. Distribution boxes
9. Eye Hooks
1. General Conditions
The products shall be in accordance with Indian standards and most of the European recognised standards
used in LT ABC (NFC for example) or with any relevant standard.
Marking: Each product shall be clearly identified with Manufacturer name or trade mark, reference and
capacity of the item and batch No.
Packaging: Manufacturer shall mention the packaging of each item. Installation instruction should be
included in the packaging.
Type tests: Each supplier should provide type test reports with the offer, carried out in accordance with
one of the referenced standards in NABL accredited laboratory.
Routine tests: Suppliers shall provide a control plan, which will be implemented on each item. Routine
Test reports should be submitted by the manufacturer with the Inspection Call.
Quality: All suppliers should be ISO 9000 certified.
Anchoring and Suspension clamps should be installable on existing poles using appropriate devices
(hooks, pigtails, brackets etc.)
All crimped connectors should be installed with mechanical or hydraulic hand crimping tools.
2. Anchoring clamp for Insulated messenger:
The clamps should be designed to anchor LV-AB Cable with insulated neutral messenger. The clamp
should consists of an Aluminium alloy corrosion resistant casted body, bail of stainless steel and selfadjusting plastic wedges which shall anchor/hold the neutral messenger without damaging the insulation.
The clamp should be installed properly.
No losable part in the process of clamping arrangement.
The clamp should conform to the standard NF C 33041 and 042 or equivalent I.S., if any.
The clamp body should be made of corrosion resistant Aluminium alloy, bail should be of stainless steel
and wedges should be of weather and UV resistant polymer.
Clamps should be fixed with pole by eye hook/bracket. Bracket should be made of corrosion resistant
Aluminium alloy.
Ultimate Tensile Strength of the clamp should not be less than 15 KN for 50/70 Sq.mm insulated
messenger wire / 10 KN for 25/35 sq.mm insulated messenger wire.
Slip load of the clamp should not be less than 3 KN for 50/70 Sq.mm insulated messenger wire/2 KN for
25/35 sq.mm insulated messenger wire.
Design as per furnished drawing.
Technical Specification Accessories related to L.T. Arial Bunch
Cable 2 Page 2 of 8
3. Suspension clamp for insulated neutral messenger:
The clamps should be designed to hang LV-AB Cables with insulated neutral messengers. The neutral
messengers should be fixed by an adjustable grip device. A movable link should allow longitudinal and
transversal movement of the clamp body.
The clamp should be installed properly.
No losable part in the process of clamping arrangement.
The clamp should conform to the standard NF C 33040 or equivalent I.S., if any.
The clamp and the link made of the Polymer should provide an additional insulation between the cable
and the pole.
The clamps and the movable links should be made of weather and UV resistant glass fibre reinforced
polymer.
Clamps should be fixed with pole by eye hook/bracket. Bracket should be made of corrosion resistant
aluminium alloy.
Ultimate Tensile Strength of the clamp should not be less than 15 KN for 50/70 Sq.mm insulated
messenger wire / 4.3 KN for 25/35 sq.mm insulated messenger wire.
Maximum Allowable load of the clamp should not be less than 20 KN for 50/70 Sq.mm insulated
messenger wire / 15 KN for 25/35 sq.mm insulated messenger wire
The clamp should sustain to maximum angle of deviation of 60 degrees of the conductors.
Design as per furnished drawing.
4. Service clamps
The clamps should be designed to anchor insulated service lines (armoured or unarmoured) with 2/4
conductors.
The clamps should be made of weather and UV resistant polymer.
The clamp should be installed properly.
No losable part in the process of clamping arrangement.
The clamp should conform to the standard NF C 33042 or equivalent I.S., if any.
Breaking load of the clamp should not be less than 3 KN.
Design as per furnished drawing.
5. Transformer connections
The connection to the transformer should be made with Pre-Insulated Lugs for Phase and Street Lighting
conductors and with an Aluminium Lug for Neutral Messenger. If the Bus Bars are of Copper, the Lugs
should be preferably Bi-metallic type.
The Barrel of the Lug normally insulated with an Anti-UV black Thermoplastic tube sealed with a
Flexible ring. Die reference, size and strip length are indicated on the plastic.
Sizes Covered: 16 – 70 & up to 150 mm² Aluminium XLPE insulated
Referenced standard: NFC 33 021 or equivalent I.S., if any.
Design as per furnished drawing.
. Technical
Specification Accessories related to L.T. Arial Bunch
Cable
6. Junction sleeves
The sleeves should be Pre - Insulated for Phases, neutral messengers and Street Lighting conductors.
Sleeve should be made of Aluminium, insulated with an anti UV black thermoplastic tube hermetically
sealed two ends with 2 flexible rings. Die reference, size and strip length are indicated on the sleeve itself.
Sizes needed: 16 – 70 -& upto150 mm² for Aluminium XLPE insulated
Referenced standard: NFC 33 021 or equivalent I.S., if any.
Design as per furnished drawing.
7. Insulation Piercing Connectors as per the standard NF C 33020 or equivalent I.S., if any.
In the process of replacing the Bare Conductors with
Scope
LT AB Cables to reduce power theft & Transmission
Losses, it is important to analyze the proper method
of providing service connection from AB Cables to
our consumers without damaging the cable. Removal
of Bare Conductor, Stringing of LT AB Cable & reestablishing the service connections should be
simultaneous process. In this regard the Insulating
Piercing Connectors are required- a) for providing 12 service connections from 8 mtr. PCC LT pole, b)
for providing supply to Junction/ Distribution Box
from AB Cable & c) for establishing Tee connection
from LT ABC to LT ABC. This Insulating Piercing
Connectors should not be exposed to any bare
conductor in the environment during connection. The
connectors should be totally Weather & Moisture
proof so that no water or moisture can enter through
the pierced holes on to the cable insulation. It must
have Shear Head type mechanism to control the
effective Torque during connection and to ensure
perfect installation. Connectors should not have any
losable parts, which may drop and then lost while
installation at overhead conditions. For individual
connectors Torque required for different conductor
sizes should be mentioned in the equipment.
Technical requisites
Construction:
The connectors should be totally insulated with no
loose parts. The connectors should be totally Weather
& Moisture proof so that no water or moisture can
enter through the pierced holes on the cable
insulation.
Voltage Ratings:
The maximum voltage withstand capacity should be
6 KV.
Moisture Ingress:
The connectors should work at 30 cm under water
bath for 30 min. & voltage applied of 6KV for 1 min.
without any flashover/ failure & moisture ingress in
it.
Working Temp.:
Designed for installation from -10˚C upto +60˚C &
operation experience with temperature from -20˚C u
Technical Specification Accessories related to L.T.
Arial Bunch Cable 4 Page 4 of 8 Materials:
Material used in the manufacturing process of the
components of this product should be specified in the
respective product drawings & can be summarized as
follows:
All the metallic part of the connector should be
Corrosion resistance & should be proven in Salt Fog
chamber & Wet SO2 gas chamber & there should not
be any change in contact resistance & temperature
after overloads & load cycling.
The contact plates should be made of tinned Copper.
Connector teeth should be factory greased & sealed
to retard water or moisture ingress & corrosion.
The insulation material should be made of weather &
UV resistance, reinforced polymer.
The outer metallic part should have potential free
tightening bolts to allow safe installation on life
lines.
The bolts should be of Shear Head type so that it
controls the effective applied Torque during
installation & break off at a specified torque after
establishing proper connection.
The connector should not have any losable
component. The cable end cap should be attached to
the body.
Technical Specification Accessories related to L.T. Arial
Bunch Cable 6 Page 6 of 8
8. ABC Service main Distribution boxes
Scope
Technical requisites
Construction:
This Distribution Box should be Weather & Moisture
Proof with Spring loaded Bus Bar system & should
be able to carry a current according to specified
ampacity. It can have 1 /3-phase input & provision
for 4 or 9 nos. of 3- phase or 1-phase outputs. The
box should have the provision for special key for
locking & Proper arrangement of sealing. The boxes
should be assembled on the pole using Metal Tapes
& Buckles or Bolts. No. of Boxes per pole may vary
with supporting arrangement for more no. of service
connections.
Distribution Boxes should be designed with Bus Bars
with spring action contact, so that no screw-bolt
technique is required to operate & only insertion of
the conductor into the specified groove of the Busbar
is sufficient for proper connection. It should be used
for multiple connections (3-phase or 1-phase) in low
Current Ratings:
Voltage Ratings:
Working Temp.:
Materials:
Locking System:
voltage Distribution Network. The boxes should be
suitable for 1/ 3-phase (4 cores) inputs & provision
for 4 or 9 nos. of 3- phase or 1-phase outputs. Bus
bars should be with a continuous pair of contact bars
with colour code to facilitate the identification of the
correct energy phase. The box should be able to
incorporate the input or output cable dia. of
maximum 16mm. (Equivalent to 120Sqmm.) The
Boxes should consist of special type Lock & key
system as well as provision for sealing for complete
protection of the service connection contacts.
The maximum current rating should be 140A/ 200A/
250A. & concerned authority should have the liberty
to choose among the above ratings as per their
requirement.
The maximum voltage withstand capacity should be
600V.
Safe working temperature should be around 80˚C for
Outer Box & 100˚C for metallic Bus bars.
Material used in the manufacturing process of the
components of this product should be specified in the
respective product drawings & can be summarized as
follows:
Outer Box (Base & Cap): With UV protection &
Flame retardant characteristics (HB, as per UL 94Tests for Flammability of Plastic materials) &
preferably made up of ASA (Acrylonitrile Styrene
Acrylate).
Cable Grommets: Ethylene-Propylene Rubber.
Safety Key: PA 6.6 (Nylon).
Safety Screw: Stainless Steel or Plating
Finished steel.
Insulator protection as per IP 44
Bus bars or Terminal Blocks: PA 6.6 (Nylon),
Stainless Steel & Copper.
Button & Cable Holder: PA 6.6 (Nylon) with 50%
Glass Fibre.
Busbar Insulation: Polyamide.
The boxes should consist of Special type Lock &
Key arrangement as well as provision for sealing for
complete protection of the service connection
contacts.
TECHNICAL SPECIFICATION OF MOBILE SERVICE CENTER
INTRODUCTION
A Mobile Service Center is required for quick replacement of a faulty Distribution Transformer in
the distribution network of the concerned area.
BASIC CONFIGURATION
It will contain a pickup truck type 2 Tonner 4 wheeler (TATA 407 type) with a half cabin for the
driver and the helper. The remaining back portion shall have a open floor with a half gate of 1.5
ft height on the backside with bolting arrangement on both sides The floor shall be of corrugated
steel sheet with an underneath steel frame of strength suitable to bear load of a 400 KV
Distribution Transformer and for standing 4 persons along with weight of around 50 m length of
11 KV 3 core 40 sq.mm XLPE cable and 50 m length of LT XLPE 3.5 core 185 sq.mm. Cable.
The remaining 3 sides of the van shall be covered with 1.5 ft height corrugated steel sheet.
While the back side shall remain open, remaining Left and Right sides shall have a cage
construction made of 1” sq steel section of height 6 ft. making a mesh of 1 ft x 1 ft.
ACCESSORIES
Apart from the usual accessories provided by the manufacturer of the pickup van for the van
following electrical accessories shall also be provided:
1.
2.5 KV Megger with 500 VDC arrangements.
2.
Tong Tester for measuring LT Current with a range up to 500 Amp
3.
Multimeter to measure LT Voltage and Resistance
4.
Rubberized Hand Gloves of 11 KV Rating – 4 pairs
5.
Toolkit containing Spanners, Screw Drivers, Pliers, Nose Pliers, Hammer,
6.
Manila rope 1 “ dia 50 ft long.
7.
Helmets – 4 Nos.
8.
Safety belt – 2 Nos.
9.
11 KV Discharge rods – 6 Nos.
All the items shall be provided as per latest revised version of relevant BIS or international
standards. The procurement shall be made only after approval of the Employer.
4-in-1 & 6-in-1 DEEP DRAWN METAL METER BOX WITH MULTIPLE OUTGOING CONNECTOR (MOC) FOR
SINGLE PHASE ENERGY METERS
1. SCOPE
This specification covers the design, manufacture, testing, pre-dispatch inspection by purchaser and supply
of outdoor type MS sheet, Deep Drawn Metal Meter Box from the manufacturers having satisfactory
performance with Power Utilities in last 5 years. Metal Meter box shall be used for housing 4Nos. & 6Nos.
single phase energy meters respectively of any make for electric connections of General categories.
2. CONSTRUCTIONAL AND TECHNICAL PARTICULARS:
2.1
Metal Meter Box (MMB) shall be corrosion free. It should be suitable for housing four single phase energy
meters of any make. The MMB shall conform to attached drawings. The overall dimensions of MMB shall be
560x425x140mm (i.e. height x width x depth) for 4-in-1 Meter Box and 920x425x140mm (i.e. height x width
x depth) for 6-in-1 Meter Box.
2.2
The Metal Meter Box (MMB) shall be made from 18 SWG CRCA MS sheet by Deep drawn method. The
base and cover of the MMB shall be individually in one piece without any welding joint. The fixing of the
accessories like hinges, clamps, handle etc. shall be spot-welded. The cover of MMB shall be fixed with
three tamper proof hinges welded inside and not visible from outside. The hinge pin diameter shall be
3mm. Hinges shall be made from 1.6mm MS sheet. The pins of hinges shall have head on top so that it
does not fall down after wear & tear. The door of MMB shall open from right to left by a minimum of 900.
The collar of the door (cover) in closed position shall rest on the collar of the body (base) of MMB. The
collar of the door shall overlap the collar of the body of MMB by 8mm. The collar of the body shall be
provided with good quality rubber gasket lining of minimum 4mm thickness. Thickness of rubber lining shall
be such that it provides proper sealing between the cover & base of MMB to avoid penetration of dust &
ingress of water. Rubber lining should be fixed with good quality adhesive so that the same does not get
removed on opening of the door. Three numbers ‘U’ shaped latch arrangement shall be provided to Seal the
cover with base as shown in drawing. 2mm & 8mm diameter hole shall be provided in U-shaped latch for
sealing wires & padlock. Holes provided for sealing & padlock should be aligned when latch is in closed
position. Strips of U-latch shall be welded from inner side of the box. Complete U-latch arrangement shall be
made from sheet thickness of 1.6mm and stainless steel rivet.
2.3
Viewing window openings of the size 90x100mm as indicated in the drawing shall be provided to facilitate
taking of meter readings. Each Viewing window shall be provided with toughened glass of 5mm thickness.
Glass shall have scratchproof logo on the right side top corner of the glass. Each glass shall be fixed inside
the cover of MMB, with powder coated single piece drawn metal frame (Glass Holder) made of 20 SWG MS
sheet fixed with min. four welded screws & nuts. The glass holder screws & nuts shall be inside the cover so
that it cannot be opened from outside. Glass holder shall have rectangular cuttings as per details shown in
drawing. The size of toughened glass shall be 110mm x 120mm so as to provide overlap of 10mm. The
glass has to be fitted with a wrap around good quality rubber ring without joint having minimum depth of
8mm, so that it can with stand weather effect.
2.4
A handle of minimum 75mm length, 10mm width and 20 SWG sheet thickness should be provided for
opening and closing of the cover at the place as shown in the drawing.
2.5
There shall be independent mounting arrangement for each meter as shown in the drawing. The meter
mounting arrangement shall consist of two slotted strips & hanger bracket welded on the base of box as
shown in drawing. The meter mounting arrangement should be raised from the base of Metal Meter Box
(MMB) body by 15mm. Zinc plated adjustable strip shall be provided on meter mounting arrangement for
fixing of the meters. Hanger bracket shall be provided with a screw of M4 threads and adjustable strip shall
be provided with two nuts of M4 threads and 25mm long screws for fixing of the meters.
2.6
Four Nos. pole-mounting holes of 10mm diameter at the back of Metal Meter Box (MMB) shall be provided
to fix the MMB on Poles. For fixing of MMB on poles, suitable clamps complete with nut, bolts & washers
shall be provided with each box. For mounting of MMB on poles, 2 Nos. zinc plated / powder coated
clamping strips shall be provided to fix the MMB with pole. Nuts & bolts shall be properly zinc plated.
Louvers for ventilation shall be provided on the sidewalls of the box as shown in drawing. 20SWG perforated
sheet shall be welded from inside of the louvers suitable for IP-33 protection class.
2.7
2.8
Two holes for incoming cable (For Loop in and Loop out) shall be provided as shown in drawing. For
outgoing cables 4Nos. holes for 4-in-1 Meter Box and 6Nos. holes for 6-in-1 Meter Box shall be provided as
shown in the drawing. Cable holes shall be provided with superior quality rubber / plastic cable glands.
Internal diameter of incoming gland shall be 30mm (minimum), and for outgoing gland shall be 20mm.
Glands shall be made such that internal diameter of glands provided for cables should be closed with the
film of minimum 1mm thickness. Cable will go through the cable glands by cutting the film of the glands.
2.9
Multiple Outgoing Connectors (MOC) for Phase and Neutral shall be provided at the top of the MMB as
indicated in drawing. The Multiple Outgoing Connectors (MOC) shall be rated for minimum 300 Amp and
1100 Volts. Current carrying parts of MOC shall be protected & enclosed in a fire resistant insulated casing.
The insulation shall be made of suitable material capable of durably withstanding the mechanical, electrical
and thermal stresses to which it may be subjected in service. MOC shall be provided with the holes for
incoming & outgoing cables. MOC shall be such that the external conductors inserted in the holes of MOC
shall be connected by means of 2 Nos. screws which ensure that the necessary contact pressure
corresponding to the current rating of MOC is maintained. Current carrying parts of Multiple Outgoing
Connector including screws shall be at a safe distance from the outer edge of the insulation and shall not be
accessible by hand / finger. Multiple Outgoing Connectors (MOC) used for Phase and Neutral shall have
provision for fixing of one Nos. main incoming & one Nos. main outgoing cable and 4 Nos. outgoing for 4-in1 and 6Nos. outgoing for 6-in-1 Meter Box. MOC shall be suitable for size of outgoing cable up to 10mm2
and main incoming & main outgoing cable up to 25mm2. Multiple Outgoing Connectors (MOC) shall be
provided in Red color for Phase and black color for neutral. The Multiple Outgoing Connectors (MOC) shall
be raised from the back side by minimum 25mm.
2.10
MMB shall be adequately protected against rust, water and corrosion both from inside and outside. The
MMB shall be powder coated with Light Admiralty Grey colour (as per IS-5:1993 Colour No. 697).
2.11
Powder Coating: The surface of the MMB shall be properly pre-treated and cleaned in 7 tank process and
shall be applied with a powder coating of 40 micron thickness on outer side and inside. The facility for 7Tank Phosphating & powder coating shall be in house of the tenderer / manufacturer to ensure proper
quality since these boxes are for outdoor applications.
2.12
Two earthing bolts of diameter 8mm and 25mm long shall be welded from inside of the box and shall be
provided with 2 nuts & washer. Earth marking shall be duly embossed near the earth bolts. There shall be
no powder coating on the earthing bolts.
2.13
All the screws, nuts and washers shall be properly zinc plated.
2.14
The tolerance permissible on the overall dimension of the Metal Meter Box (MMB) shall be (±) 3.5% and
permissible tolerance on weight shall be -2%. Any weight on positive side will be acceptable. However, the
tolerance for the fittings shall be (±) 3%. In case of an order, the actual weight of sample shall be
mentioned for supplies.
2.15
Danger Marking shall be provided on the box in red colour.
2.16
Utility name and manufacturer name shall be provided on the door of meter box.
3. The box shall comply with the requirement of IP33. The box shall be fully type tested along with dimensions, as
per the requirement of IS 13947 (Part-1):1993. The type test shall be carried out from the govt.-approved
laboratories & shall be submitted along with the tender failing which Part-III of tender (Price Bid) of the firm
shall not be opened. Government approved laboratories should be accredited by the National Board of
Testing & Calibration Laboratories (NABL) of Govt. of India. The type test report shall not be older than 3
years.
4.
INSPECTION:
The manufacturer / supplier shall give minimum 14 days advance notice about the readiness of material at
his works. Representative of the Power Utility will inspect the material for conformity with specification
before the same is accepted.
5.
TESTS:
Following tests shall be performed on the box during inspection:
5.1
Visual Examination: The MMB shall be inspected visually, externally and internally for proper Powder Coating layer, fitting of all
the components in accordance with technical Specification.
5.2
Verification of dimensions: Verification of dimensions, external / internal clearances will be carried out as per technical specifications.
5.3
Verification of fittings: Components like insulated Multiple Outgoing Connectors, screws etc will be verified as per technical
specification and usage requirement.
5.4
High voltage withstand test at 2.5KV: The A.C. voltage of 2.5KV, 50HZ shall be applied for one minute as follows:
a) Between Phase & Neutral
b) Between Phase and earth screw
c) On the insulation of Multiple Outgoing Connector.
There shall not be any puncture or flash over during this test.
5.5
Current Carrying Capacity: The Current of 300 AMP shall be applied for 30 minutes through high current source on each Multiple
Outgoing Connector. There shall not be overheating of the Connectors during this test.
6.
PACKING:
The Metal Meter Box (MMB) shall be suitably packed in 3 ply corrugated boxes in order to avoid damage in
transit.
7.
PAST EXPERIENCE:
The firm must have supplied the NIT quantity or similar item to any Power utility in any one financial year in
last 5 years. Past performance of the manufacturer firm with Power utilities should be satisfactory both in
quality and adhering to delivery schedule in last 5 years. Supporting documents shall be submitted along
with the tender.
8.
Prototype & Drawings:The manufacturer has to manufacturer the prototype Unit for each rating as per this specification before
bulk manufacturing. The manufacturer should intimate the readiness of prototype to employer. The Project
Manager will inspect the prototype for approval. The manufacturer should submit the final drawings in line
with this specification and prototype to employer for approval before bulk manufacturing. The approval of
prototype & drawings shall be a responsibility of manufacturer/Contractor. Tentative drawing of box is
enclosed herewith
20-in-1 Meter Pillar Box (MPB) for single phase meters
1.
SCOPE:
This specification covers the design, manufacture, inspection, testing and supply of outdoor type M.S. sheet,
Meter Pillar Box from the manufacturers having satisfactory performance with power utilities in last 5 years.
Meter Pillar Box shall be used for housing Single Phase meters for electric connections of general category.
2.
CONSTRUCTIONAL AND TECHNICAL PARTICULARS:
2.1
The meter pillar box shall conform to tender drawings. It should be suitable for housing 20 Nos. single
phase energy meters of any make. The overall dimensions of the Meter Pillar Box shall be
1280mmx1115mmx200mm (i.e. height x width x depth) with suitable canopy at the top. A sliding bolt of
20mm width, 6mm thickness & 245mm length to be provided for extra locking as well as sealing
arrangement to be provided as shown in Annexure-1& 8. Hole of 8mm shall be provided in the sliding bolt
to provide the padlock. Other parts of the latch shall be made from 2mm thick MS sheet. The sliding bolt
shall be duly powder coated. Suitable openings to drain out rain water, of minimum size be provided at
bottom so that no reptile is able to enter pillar box.
2.2
Pillar box shall be fabricated from 18 SWG (1.2mm), M.S sheet by die-press method and having bottom
frame made out of MS angle 40mmx40mmx5mm.The MS Angle Iron used should be manufactured by any
'BIS' approved manufacturer. The name of the manufacturer shall be marked on the angle iron and the
document showing BIS approval of the manufacturer shall be shown to the inspecting officers and attached
with the inspection report. Single piece of MS sheet be used for three side of box i.e. back, left and right
side be of one piece. Top side of the same sheet must be bent at 90 0 from all three sides by 15mm and
shall be welded at corners for strengthening of the box. For fabricating the box, maximum 4 Nos. of pieces
should be used i.e. one piece for three sides, second piece for bottom side third & fourth piece for top side
with canopy. In addition to this, left & right doors (as shown in Annexure 2 & 3) have to be fixed with
hinges. All the welding joints should have 15mm overlapping. The meter pillar box shall have door (with left
& right side partition) for facilitating access to meter reading from outside. Two holes of about 6mm
diameter shall be provided on each side of upper canopy (as shown in drawing ) for fixing cable spacers at
site.
2.3
All the steel sections used in fabrication shall be carefully leveled and straightened before any work is done
on them. No rough edges shall be permitted anywhere throughout the work. The material shall be capable
to withstand mechanical, electrical and thermal stresses as well as the effects of humidity, which are likely
to be encountered during its service. Welding shall be MIG welding or spot welding only. Welding work shall
be done carefully so as to avoid over heated spots, cavities, porosity, burns and dents etc.
2.4
The hinge arrangement of the door shall consist of three-tamper proof inside hinges not visible from
outside. Each door shall have minimum three hinges. One end of Hinges should be welded on inside of the
door and other end should be fixed with Pillar Box by minimum three screws. Hinges arrangement shall be
made from 16SWG (1.6 mm) M.S. Sheet. For extra strengthening of the doors, C-shaped channels shall be
spot welded/ MIG welded from inside of the box (as shown in tender Drawing). Two no. such Channels shall
be provided on the left door and one no. on the right door. The thickness of the sheet of channels shall be
1.2 mm. Viewing window opening of the size 90x100 mm as indicated in drawing (Drawing) shall be
provided on the doors to view meter readings of Meters installed inside the Pillar Box. Viewing window shall
be provided with toughened glass of 5mm thickness fixed from inside of the doors. Glass shall have
scratchproof logo of utility of minimum 10mm height on the right side top corner of the glass. This glass
shall be fixed from inside of the doors of pillar box, with single piece drawn metal frame with powder
coating (Glass Holder) made of 20 SWG (0.9 mm) MS sheet fixed with min. four screws. Glass holder shall
have rectangular cuttings as per details shown in Drawing. The size of toughened glass shall be 110x120mm
so as to provide overlap of 10mm with viewing window. Glass has to be fitted with a wraparound rubber
ring, in one piece, having minimum depth of 8 mm, made from good quality rubber so that it can withstand
weather effect.
2.5
Door shall be provided with M.S. handle and locking arrangement (with one key) and suitable gasket, in 4
no. pieces (one piece for each side) with no gap at the joints, to make vermin proof as indicated in drawing
(Drawing). Door shall be provided with three point locking arrangement. M.S locking rod of diameter 10mm
(±0.5mm) with protrude of minimum 10mm at top & bottom, provided to prevent opening of the door in
locked condition. Locking Patti should be provided from inside of door at the center, for locking purpose so
that box gets locked from top, bottom & center in locked condition. The 3-point locking arrangement Patti
should move inside the slot provided in the left & right door. Movement of locking Patti & locking rods
should be linked with movement of outer handle. Locking rod shall lock the doors by sliding over the rollers
provided on the top and bottom of the pillar box. Latch of suitable size, duly powder coated shall be
provided on top and bottom on inside of the left door having utility name or logo. There should be a
rubber/nylon washer in one piece, fixed with adhesive, between handle and the door to avoid penetration of
rain water in Pillar Box through handle. One central lock with brass levers shall be provided inside the door.
Key way shall be provided on the door for operating the lock from outside. Key way shall be provided with a
cover. Locking arrangement shall be provided with Cover from inside. Keys provided shall be Master key
type for ease of handling by utility staff. The handles provided should be of removable type.
2.6
Insulated Aluminium Bus bars for 3 Phases and Neutral shall be provided at the top of Pillar box as indicated
in drawing. Three Nos. Aluminium bus bars of minimum 300 mm² with suitable length for R, Y and B phase
and one Aluminium bus bar of 400mm² with suitable length shall be provided for neutral. Minimum
clearance between each insulated bus bar shall be 60mm & end clearance from pillar box wall shall be
minimum 75mm. These insulated bus bars shall be raised from the backside by minimum 25mm. Bus bars
shall be protected & enclosed in a fire resistant insulated casing rated for 1100 V. The insulation shall be
made of suitable material capable of durably withstanding the mechanical, electrical and thermal stresses to
which it may be subjected in service. The insulated bus bars shall be provided with the holes for incoming &
outgoing cables in such a way that the external conductors inserted in the holes of bus bars shall be
connected by means of bolts/studs which ensure that the necessary contact pressure corresponding to the
current rating of insulated bus bars is maintained. Aluminium bus bars including all live parts shall be at a
safe distance from the outer edge of the insulation and shall not be accessible by hand. These insulated bus
bars used for R-Y-B Phases and Neutral shall provide connections for 20 energy meters to be installed in the
Pillar box. Each insulated bus bar shall have arrangement for fixing of 2Nos.main 4 Core XPLE cable of size
up to 95mm2 from the upper side of each bus bar by providing suitable arrangement/mechanism in such a
manner that the main cable shall be connected from the upper side of bus bars and do not hang on the
insulated bus bars. Each cable up to 95mm2 shall be fixed with 2 Nos. M12 bolts / studs. Insulated bus bars
shall be provided in Red, Yellow, Blue and Black color for R-Y-B Phases and neutral respectively.
2.7
There should be independent mounting arrangement for each meter and it should be raised from the back
side of pillar box by 35mm. Each meter mounting arrangement shall be provided with the 6mm thick fire
resistant insulating, hanger strip and adjustable strip as per drawings. Meter shall be fixed on these
insulated strips. The supplier shall supply three mounting M.S. Screw, one screw with 4mm diameter for
Hanger point and two Screws (M4 x 35mm) with nuts in the slots of each adjustable strip. The insulation
provided should be fire resistant and sufficient gap should be provided so that the screws used for fixing the
meters do not touch metal plate at the back or the metal strip.
2.8
For outgoing service cables, 20 Nos. holes with rubber cable glands of internal diameter 19mm shall be
provided on both side walls of the pillar box (10 Nos. on each side wall). All cable glands shall have grooves
of minimum 5mm depth for proper fixing with pillar box sheet. The glands shall be fixed with the central
groove over the pillar box sheets, so that half of the gland is inside the pillar box with the other half outside
the pillar box. The fire resistant insulation sheet shall be fixed firmly on inside the pillar box, on both sides
for the outgoing service cables (each sheet having 10no. holes corresponding to the cable glands). The dia.
of the holes in the fire resistant sheets shall be 20 mm. and the diameter of the holes in the pillar box for
fixing of cable glands for outgoing service cables shall be 25mm.
The diameter of holes for main incoming and outgoing main cables shall be 60 mm with cable gland of
internal diameter 45mm to be provided in the lower wall of the pillar box. All rubber cable glands shall be
properly fixed with suitable adhesive such that, the same does not get removed from Pillar box. Rubber
glands shall be made such that internal diameter of glands provided for cables should be closed with the
Rubber film of approximately 1mm thickness. Cable will go through the cable glands by piercing the rubber
film of the glands.A fire resistant insulation sheet corresponding to the main incoming and outgoing main
cables shall be firmly fixed on inside of the pillar box. The diameter of the holes in the insulation sheet shall
be about 50mm.3NosFire resistant perforated insulation sheets (with requisite undercuts for easy movement
of outgoing cables from meters) shall be provided as vertical partition between each meter column for
better heat dissipation.
2.9
Suitable cable clamps as shown in the drawing shall be provided in the pillar box to hold the main cables.
2.10
Louvers for ventilation shall be provided on the sidewalls of the pillar box, top of the front and back side
below the canopy as shown in drawing. Louvers shall also be provided in the lower wall of the pillar box.
20SWG (0.9 mm) perforated sheet shall be welded from inside of the louvers.
2.11
Bolts of diameter 10 mm and 35 mm length with 2 Nos. plain washers and two no. nut are to be provided
on both the sides for earthing the metallic body of the pillar box (Drawing). Earthing bolts is to be provided
on the earth clamps welded on both sides of the meter pillar box. The earthing bolt should be provided from
inside of the earth clamp. Earthing nut bolt & washer should be zinc plated. There should be no powder
coating on top surface of earth clamp and earthing bolts. The thickness of the sheet of the earth clamp (as
shown in Drawing) shall be 2mm.
2.12
40mmx40mmx5mm angle iron frame with 4 Nos. 750 mm length must be provided as legs of pillar box. The
Angle Iron to be used for frame and the legs shall be manufactured by any 'BIS' approved manufacturer.
The name of the manufacturer shall be marked on the angle iron and the document showing BIS approval
of the manufacturer shall be shown to the inspecting officers and attached with the inspection report.Eight
nos. (3 no. each on front & backside and one no. each on left & right sides) Mounting bolts of M10 should
be welded on the top of base angle frame to hold the pillar box. Bolts shall be welded to angle frame such
that it moves inside the mounting holes made at the bottom of the pillar box and is fixed from inside with
nuts & washers. Angle frame should be interchangeable with all pillar boxes. The pillar box should fit on
inside of the angle frame, on top of the legs. Further, the legs should be welded with overlap with the angle
iron frame. Also there should be anchors of M.S. sheet of square shape with 4" sides of 2.5mm thickness,
fixed on bottom of legs.
2.13
The tolerances permissible on various dimensions of the pillar box shall be  2%.
2.14
Rubber sealing/lining at least be 3mm thick shall be provided on 4 sides of the box in 4 no. pieces (one
piece for each side) with no gap at the joints. to ensure proper closing of the outer door and to avoid
ingress of water. It should be properly glued on the surface with the help of suitable adhesive so that the
same does not get removed by itself on opening the door.
2.1
2.15
The pillar boxes (including Glass Holders) should be powder coated with light admiralty grey shade
(Shade No-697 as per IS: 5:2007) suitable for outdoor use. The surface of the pillar boxes and Glass
Holders shall be properly pre-treated and cleaned in 7 tank process and shall be applied with a powder
coating of about 40 micron thickness on outer side and inside. The facility for 7-Tank Phosphating & powder
coating shall be in house of the tenderer / MMB manufacturer to ensure proper quality.
3.0
WIRING OF PILLAR BOX:
For Internal wiring of Pillar Box, 'ISI' marked PVC insulated, unsheathed Copper cable of 10mm 2, shall be
used. Copper cable shall have 140 strands of Copper wire with 0.3mm diameter. Red, Yellow & Blue colour
wires shall be used for Phases R, Y, and B respectively. White or black colour wires shall be used for neutral
connections. All technical parameters of the offered copper cable shall be as per IS: 694 and the tenderer
shall mention in tender, all these technical parameters, including those not specified in the ISS. Each wire
shall have pin lugs at meter end. Lugs should have compression joint with cable to establish a good
electrical and mechanical contact. Lugs should be suitable for cable of 10mm 2 and should be made of
Copper and coated with tin. Other end of each wire shall be fixed to Insulated bus bars with 2 Nos. M6 bolt
/ stud duly zinc plated. Length of each wire shall be such that the Pin lug end of wire should be suitable for
smallest and biggest meter. All the wires shall be properly dressed & tied together with cable nylon tie. The
ends of cable should be provided with suitable cover to avoid short circuit in case of spare cables.
4.0
TESTING FACILITIES:
The tenderer must have the following minimum testing facilities in house: -
i)
High Voltage Tester.
ii)
High Current Source.
iii)
Megger
iv)
Powder Coating thickness Measuring instrument.
v)
Measuring instruments like Vernier, Micrometer, Measuring Tapes / Scales.
vi)
Facility for carrying out acceptance tests on copper cable as per IS: 694. In case a firm do not have this
facility, the said tests on the copper cable shall be got carried out from Govt. / Independent test house/
works of the cable manufacturer, (subject to availability of the complete acceptance tests facilities) if a firm
so desires.
5.0
SAMPLING PLAN:
One no sample per 100 nos pillar boxes of the offered lot shall be taken for carrying out pre-dispatch
inspection by the inspecting officers.
6.0
MARKING:
Utility Name or Logo as shown in the drawing shall be embossed on the outer door and on the side
opposite to the door on which door handle is fixed. Also manufacturers name should be embossed on the
outer door with handle. Danger Notice as per Drawingshould be printed in Red on outer door.
P.O. NO. & date and Sr. No. of MPB shall also be indelibly marked or embossed at a suitable place on the
left door of MPBs, which should be of minimum 5mm height and clearly visible.
7.0
INSPECTION:
Each lot offered shall be inspected at the works of manufacturer by the inspecting officers of purchaser. The
manufacturer shall give minimum 14 days’ notice about readiness of material at his works for pre-dispatch
inspection by the purchaser. The material shall be inspected for conformity with the specification before the
same is accepted.
8.0
TESTS:
Following acceptance tests shall be carried out while inspecting lot of material offered.
a)
Visual Examination:
The Meter Pillar box will be inspected visually, externally and internally for proper Powder Coating layer,
fitting of all the components in accordance with technical Specification.
b)
Verification of dimensions:
Verification of dimensions, external / internal clearances will be carried out as per technical specifications.
c)
Verification of fittings:
Components like insulated bus bars, Lugs, Glass, Locks etc will be verified as per technical specification.
Inspecting officers shall check that Angle Iron used for the angle iron frame & legs is manufactured by any
'BIS' approved manufacturer and record the same in inspection reports. A copy of ISI license of the angle
iron shall be enclosed with inspection reports
d)
High voltage withstand test at 2.5KV:
The A.C. voltage of 2.5KV, 50HZ shall be applied for one minute as follows:
i)
Between live parts of each insulated bus bars.
ii)
Between live part of each insulated bus bar and earthing bolts
iii)
On insulation of bus bars.
iv)
On PVC coating of PVC wires.
There shall not be any puncture or flash over during this test.
e)
Current Carrying Capacity:
i) The Current of 60Amp shall be applied for 30 minutes through high current source on the PVC cables.
There shall not be overheating of the PVC cables during this test.
ii) The current of 300Amp shall be applied for 30 minutes through high current source on each insulated bus
bar. There shall not be overheating of the insulated bus bar during this test.
f)
Earth Continuity Checking Test:
Earth Continuity shall be checked by Megger between two earthing terminals brought out on either side of
Meter Pillar Box.
g)
From the lot offered by the firm for inspection, sample of PVC cable shall be tested for complete acceptance
tests as per IS-694:1990, at the works of the firm (if facility available). In case the testing facilities are not
available with the firm, the samples shall be got tested from any Govt./ Independent Test House, for which
samples shall be sealed by inspecting officers, at the cost of firm. Out of the offered lot of Pillar Boxes, 2 no.
samples of copper cable shall be taken from 2 no sample pillar boxes for testing, which shall be to supplier's
account. One no sample shall be tested/ sealed for sending the same to test house. The second sample
shall be retained as counter sample. The tenderers shall indicate whether they propose in house acceptance
testing of cable or from test house. Alternatively, the acceptance tests on the samples of copper cable can
also be got carried out by inspecting officers at works of the cable manufacturer, (subject to availability of
the complete acceptance tests facilities) if a firm so desires.
Inspecting officers shall check original documents regarding procurement of corresponding quality of ISI
marked PVC copper cables for the offered lot of pillar boxes and attach an attested/signed photocopy of the
said documents with each lot's inspection report. A copy of BIS license of the cable shall also be enclosed.
9.0 The box shall comply with the requirement of IP-33. The box shall be fully type tested for IP-33 with
dimensions as per the requirement and IS 13947: 1993/other relevant standards, if any. The type test shall be
carried out from the govt. approved laboratories. Government approved laboratories should be accredited by the
National Board of Testing & Calibration Laboratories (NABL) of Govt. of India. The type test certificates must not
have been issued earlier than three years from the original date of order.
10.0
PACKING:
Pillar Box shall be suitably wrapped to avoid damage in transit and handling. The Pillar boxes shall be
suitably wrapped in 6mm to 8mm Expandable Poly Ethylene (EPE) foam and then shrink wrapped with
Polythene Plastic sheet in order to avoid damage in transit and handling.
11.0
Prototype & Drawings:The manufacturer has to manufacturer the prototype Unit for each rating as per this specification before
bulk manufacturing. The manufacturer should intimate the readiness of prototype to employer. The Project
Manager will inspect the prototype for approval. The manufacturer should submit the final drawings in line
with this specification and prototype to employer for approval before bulk manufacturing. The approval of
prototype & drawings shall be a responsibility of manufacturer/Contractor. Tentative drawing of box is
enclosed herewith.
TESTING STANDARDS: Impact Resistance should be according to UL 746C.Isulation Protection should be as
per IP44. The outer Plastic box should confirm to following std.
Test/ Standard
Rrquirements
Test procedures
Degree of protection
IP 44-Protected against the
penetration of solid objects
exceeding 1.0mm in diameter and
against the penetration of water jets
that may affect product operation
First Digit: A1.0mm diameter test
wire should not penetrate in any
apparent opening (Force=1N+/10%)
After the test the product should not
show any evidence of :
The impact should be generated by
droping a steel ball-with a diameter
of 50.8mm and a mass of 0.535kg
from a specified height sufficient to
produce an impact energy of 6.8
J(0.6913kg.m)
IEC 60529
Impact resistance
UL 746-C
-Live electrical parts accessible to the
test probe , as described in this test
specification
Second Digit: A spray nozzle is used
to spread a water jet in all possible
directions.
-Any results which may affect the
mechanical performance of the
product.
-Any results which may increase the
probability of electrical shocks.
UV Resistance
UL 746-C
The sample physical properties
average value- after and accelerated
Aging with UV radiation-should not
be lower 70% of the initial value ,
without aging, that is, a variation of
+/-30% is allowed.
According to ASTM G26, Exposure
method1, Xenon Arc lamp Type B or
ASTM G155, Exposure cycle1, with
continuous exposure to light and
intermittent exposure to water jets,
with programmed cycles of 120
minutes,
Consisting of a 102 minutes light –
only exposure and a 18 minutes
exposure to light and water jets.
Withstanding voltage
UL 7.6-C
Product should withstand the
specified voltage
A 5kv voltage should be applied to
the samples after the 40hours
conditioning cycle at 23+/-2 degree
C and 50+/- 5% relative humidity
plus 96 hours at 35+/- 2 degree C
and 90+/- 5% relative humidity.
Flammability
UL94
Flexural strength
ASTM D790
UL746-C
Tensile strength
ASTM D638
UL 746-C
9.
After the UV radiation accelerated
aging, The material should maintain
the same original flammability
level(HB)
The test can be applied to test
samples molded with the same
material used for the base and the
cap of the box or taking a piece of
these components.
After UV radiation accelerated aging,
the average value for this test should
not be lower than 70% of the
original value, i.e, a maximum
variation of 30% is allowed.
A group of test samples without
aging should be tested and the
average values calculated. Another
group should be aged under UV
radiation, then it should be tested
and the new average should be
calculated and compared to the
initial average value
After aging with UV radiation the
average value should not be lower
70% of the initial values ,I,e, a
maximum variation of 30% is
allowed
One of the test bodies must be
tested without being submitted to
accelerated aging and is computed
over mean values. Another group is
submitted to the radiation induced
aging and then tested and the new
mean value is computed and
compared to the first computed
mean value.
Eye Hooks:
Eye hooks should be designed as to hold Suspension Clamps and Dead end Clamps and to be installed with the
Pole Clamp:
Eye hooks should be made of forged galvanised Steel.

The clamps corrosion resistance should confirm to the standards IS:2629 and IS:2633

Bolts and nuts should be made of hot dip galvanised steel, according to VDE 0210 and VDE o212.

Ultimate Tensile Strenght (UTS) of the clamp should be 20 KN.

Design as per furnished drawing.