Volume-II, Section 5B – ACSR-Bison Conductor Marsyangdi Corridor 220 kV Transmission Line Project

TECHNICAL SPECIFICATIONS
SECTION-VB
Technical Description of ACSR 'BISON' /AACSR ‘BISON’ Conductor

CONTENTS
1.0 Technical Description of ACSR 'BISON' /AACSR ‘BISON’ Conductor................................................... 1
1.1.A Details of ACSR Conductor .................................................................................................................. 1
1.1.B Details of AACSR Conductor ............................................................................................................... 2
1.2 Workmanship ........................................................................................................................................ 3
1.3 Joints in Wires ....................................................................................................................................... 3
1.4 Tolerances ............................................................................................................................................. 4
1.5 Materials ................................................................................................................................................ 4
1.6 Standard Length..................................................................................................................................... 5
2.0 Tests and Standards..................................................................................................................................... 6
2.1 Type Tests ............................................................................................................................................. 6
2.2 Acceptance Tests ................................................................................................................................... 6
2.3 Routine Test........................................................................................................................................... 7
2.4 Tests during Manufacture ...................................................................................................................... 7
2.5 Testing Expenses ................................................................................................................................... 7
2.6 Additional Tests..................................................................................................................................... 8
2.7 Sample Batch for Type Testing ............................................................................................................. 8
2.8 Test Reports ........................................................................................................................................... 8
2.9 Inspection .............................................................................................................................................. 8
2.10 Test Facilities......................................................................................................................................... 9
2.11 Packing .................................................................................................................................................. 9
2.12 Marking ................................................................................................................................................11
2.13 Verification of Conductor Length ........................................................................................................12
2.14 Standards ..............................................................................................................................................12
ANNEXURE-A ..................................................................................................................................................... 13

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 Volume-II, Section 5B – ACSR-Bison Conductor Marsyangdi Corridor 220 kV Transmission Line Project

TECHNICAL SPECIFICATIONS
SECTION-5B
1.0 Technical Description of ACSR 'BISON' /AACSR ‘BISON’
Conductor

1.1.A Details of ACSR Conductor

1.1.A.1 The ACSR Conductor shall generally conform to BS:215(Part-2) /IS : 398
(Part-II) except where otherwise specified herein.
1.1.A.2 The details of the ACSR BISON Conductor are tabulated below :

a) Designation as per BS-215(Part-2)

b) Stranding and wire diameter 54/3.00 mm
Aluminium
+7/3.00 mm steel
c) Number of Strands
Steel core 1
1st steel layer 6
1st Aluminium layer 12
2nd Aluminium layer 18
3rd Aluminium layer 24
d) Sectional area of Aluminium 381.80 sq. mm
e) Total sectional area 431.30 sq. mm
f) Overall diameter 27.00 mm
g) Approximate mass 1444 (Kg/ KM)
h) Calculated D.C. resistance at 20 deg. 0.07573 Ohm/KM
Centigrade
i) Minimum UTS 120.90 kN
j) Direction of lay of outer layer Right hand

1.1.A.3 The details of Aluminium strand are as follows:

a) Minimum breaking load of strand before 1.17 kN
stranding
b) Minimum breaking load of strand after 1.11 kN
stranding
c) Maximum D.C. resistance of strand at 0.004079 Ohm/meter
20 deg. Centigrade

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1.1.A.4 The details of steel strand are as follows:

a) Minimum breaking load of strand before 9.29 kN
stranding
b) Minimum breaking load of strand after 8.83 kN
stranding
c) Minimum number of twists to be withstood in 18 ( Before stranding)
torsion test when tested on a gauge length of 16 ( After stranding
100 times diameter of wire

1.1.B Details of AACSR Conductor

1.1.B.1 For crossings involving longer spans, Aluminium Alloy Conductor Steel Reinforced
shall be used in this project. The Aluminium Alloy of Silicon-Magnesium (6201)
shall be used.

1.1.B.2 The AACSR Conductor shall generally conform to IS: 398 –Part 4 except where
otherwise specified herein.
1.1.B.3 The details of the AACSR BISON Conductor are tabulated below :

a) Designation as per IS: 398 –Part 4 -

b) Stranding and wire diameter 54/3.00 mm
Aluminium Alloy
+7/3.00 mm steel
c) Number of Strands
Steel core 1
1st steel layer 6
1st Aluminium Alloy layer 12
2nd Aluminium Alloy layer 18
3rd Aluminium Alloy layer 24
d) Sectional area of Aluminium Alloy 381.80 sq. mm
e) Total sectional area 431.30 sq. mm
f) Overall diameter 27.00 mm
g) Approximate mass 1444 (Kg/ KM)
h) Calculated D.C. resistance at 20 deg. 0.07603 Ohm/KM
Centigrade (Min)
i) Minimum UTS 160.20 kN

j) Direction of lay of outer layer Right hand

1.1.B.4 The details of Aluminium strand are as follows:

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a) Minimum breaking load of strand before 1.60 kN

stranding
b) Minimum breaking load of strand after 1.55 kN
stranding
c) Maximum D.C. resistance of strand at 0.004179 Ohm/meter
20 deg. Centigrade

1.1.B.5 The details of steel strand are as follows:

a) Minimum breaking load of strand before 9.29 kN
stranding
b) Minimum breaking load of strand after 8.83 kN
stranding
c) Minimum number of twists to be 18 ( Before stranding)
withstood in torsion test when tested on a 16 ( After stranding
gauge length of 100 times diameter of wire

1.2 Workmanship

1.2.1 All the Aluminium /Aluminium Alloy and steel strands shall be smooth, uniform and
free from all imperfections, such as spills and splits, die marks, scratches, abrasions,
etc., after drawing and also after stranding.

1.2.2 The finished conductor shall be smooth, compact, uniform and free from all
imperfections including kinks (protrusion of wires), wire cross over, over riding,
looseness (wire being dislocated by finger/hand pressure and/or unusual bangle noise
on tapping), material inclusions, white rust, powder formation or black spot (on
account of reaction with trapped rain water etc.), dirt, grit etc.

1.2.3 The steel strands shall be hot dip galvanized and shall have a minimum zinc coating of
260 gms/sq.m after stranding. The zinc coating shall be smooth, continuous, of
uniform thickness, free from imperfections and shall withstand minimum three dips in
standard Preece test. The steel wire rods shall be of such quality and purity that, when
drawn to the size of the strands specified and coated with zinc, the finished strands and
the individual wires shall be of uniform quality and have the same properties and
characteristics as prescribed in IEC: 888.

1.2.4 The steel strands shall be preformed and post formed in order to prevent spreading of
strands in the event of cutting of composite core wire. Care shall be taken to avoid,
damages to galvanization during pre-forming and post-forming operation.

1.3 Joints in Wires

1.3.1 Aluminium /Aluminium Alloy Wires

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1.3.1.1 During stranding, no Aluminium/Aluminium Alloy wire welds shall be made for the
purpose of achieving the required conductor length.

1.3.1.2 No joints shall be permitted in the individual wires in the outer most layer of the
finished conductor. However joints are permitted in the 12 wire and 18 wire inner layer
of the conductor unavoidably broken during stranding, provided such breaks are not
associated with either inherently defective wire or with the use of short lengths of
Aluminium/Aluminium alloy wires. Such joints shall not be more than four (4) per
conductor length and shall not be closer than 15 meters from joint in the same wire or
in any other Aluminium/Aluminium alloy wire of the completed conductor.

1.3.1.3 Joints shall be made by cold pressure butt welding and shall withstand a stress of not
less than the breaking strength of individual strand guaranteed.

1.3.2 Steel Wires

There shall be no joint of any kind in the finished wire entering into the manufacture of
the strand. There shall also be no strand joints or strand splices in any length of the
completed stranded steel core of the conductor.

1.4 Tolerances

The manufacturing tolerances to the extent of the following limits only shall be
permitted in the diameter of individual aluminium and steel strands and lay-ratio of the
conductor:

a) Diameter of Aluminium and Steel Strands

Standard Maximum Minimum

Aluminium/Aluminiu
m 3.00 mm 3.03 mm 2.97 mm
Alloy
Steel 3.00 mm 3.06 mm 2.94 mm

b) Lay ratio of Conductor

Maximum Minimum
Steel 6 wire layer 28 13
Aluminium/Aluminiu
m 12 wire layer 17 10
Alloy
18 wire layer 16 10
24 wire layer 14 10
1.5 Materials

1.5.1 Aluminium and Aluminium Alloy

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The Aluminium strands shall be hard drawn from electrolytic Aluminium rods having
purity not less than 99.5% and a copper content not exceeding 0.04%. They shall have
the same properties and characteristics as prescribed in IEC: 889.
Aluminium Alloy Strands shall be drawn from Silicon-Magnesium Alloy rods(6201)
with appropriate tampering followed by solution treatment.

1.5.2 Steel

The steel wire strands shall be drawn from high carbon steel wire rods produced by
either the acid or the basic open-hearth process, the electric furnace process, or the
basic oxygen process and shall conform to the following requirements as to the
chemical composition:

Element % Composition
Carbon 0.50 to 0.85
Manganese 0.50 to 1.10
Phosphorous Not more than 0.035
Sulphur Not more than 0.045
Silicon 0.10 to 0.35

The Steel wire strands shall have the same properties and characteristics as prescribed
for regular strength steel wire in IEC: 888.

1.5.3 Zinc

The zinc used for galvanizing shall be electrolytic High Grade Zinc of 99.95% purity.
It shall conform to and satisfy all the requirements of IS: 209.

1.6 Standard Length

1.6.1 The standard length of the conductor shall be 1800 meters. A tolerance of +/-5% on
the standard length offered by the Bidder shall be permitted. All lengths outside this
limit of tolerance shall be treated as random lengths. Not less than 90% total quantity
of the conductor shall be supplied in standard lengths. For valley crossings specific
single length conductor will be required for which length shall be intimated after tower
spotting.
1.6.2 Random lengths will be accepted provided no length is less than 70% of the standard
length and the total quantity of such random lengths shall not be more than 10% of the
total quantity ordered. When one number random length has been manufactured at any
time, five (5) more individual lengths each equivalent to the above random length with
a tolerance of +/- 5% shall also be manufactured and all the above six random lengths
shall be dispatched in the same shipment. At no point, the cumulative quantity supplied
of such random lengths shall not be more than 12.5% of the total cumulative quantity
supplied including such random lengths. However, the last 20% of the quantity ordered
shall be supplied only in standard lengths as specified.

1.6.3 Bidder shall also indicate the maximum single length, above the standard length, he

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can manufacture in the guaranteed technical particulars of offer. This is required for
special stretches like river crossing etc. The Employer reserves the right to place orders
for the above lengths on the same terms and conditions applicable for the standard
lengths during the pendency of the Contract.

2.0 Tests and Standards

2.1 Type Tests

The following tests shall be conducted once on a sample/samples of conductor for

every 1000 kms. of production from each manufacturing facility:

a) DC resistance test on stranded conductor

b) UTS test on stranded conductor
As per Annexure-A
c) Radio interference voltage test (dry)
d) Corona extinction voltage test (dry)
e) Test on Wooden Drum
i) Barrel batten strength test IS: 1778-1980

2.2 Acceptance Tests

a) Visual and dimensional check on drum

Visual check for joints cratches etc. and
b) length measurement of conductor by As per Annexure-A
rewinding
Dimensional check on steel and
c)
Aluminium/Aluminium alloy strands
d) Check for lay-ratios of various layers
Galvanizing test on steel strands
e)
Check for lay-ratios of various layers
f)
As per Annexure-A
Torsion and Elongation tests on steel strands
g)
Breaking load test on steel and
h) Aluminium/Aluminium alloy strands

Wrap test on steel & Aluminium/Aluminium

i) IEC: 888 & 889
Alloy strands
DC resistance test on Aluminium/Aluminium
j) IEC: 889
Alloy strands
k) Procedure qualification test on welded joint of As per Annexure-A

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Aluminium/Aluminium Alloy strands

Drum marking check
l)

Note: All the above tests except (j) shall be carried out on aluminium and steel strands
after stranding only.

2.3 Routine Test

a) Check to ensure that the joints are as per Specification

b) Check that there are no cuts, fins etc., on the strands.
c) Check that drums are as per Specification
d) All acceptance test as mentioned above to be carried out on each coil

2.4 Tests during Manufacture

a) Chemical analysis of zinc used for galvanizing
b) a) Chemical analysis of Aluminium
/Aluminium Alloy used for making strands
As per Annexure-A
c) Chemical analysis of steel used for making steel
strands

2.5 Testing Expenses

2.5.1 The break-up of the testing charges for the type tests specified shall be indicated
separately.

2.5.2 Bidder shall indicate the laboratories in which they propose to conduct the type tests.
They shall ensure that adequate facilities are available in the laboratories and the tests
can be completed in these laboratories within the time schedule guaranteed by them.

2.5.3 In case of failure in any type test the Supplier is either required to manufacture fresh
sample lot and repeat all the tests successfully once or repeat that particular type test
three times successfully on the sample selected from the already manufactured lot at
his own expenses. In case a fresh lot is manufactured for testing then the lot already
manufactured shall be rejected.

2.5.4 The entire cost of testing for the acceptance and routine tests and Tests during
manufacture specified herein shall be treated as included in the quoted unit price of
conductor, except for the expenses of the inspector/Employer's representative.

2.5.5 In case of failure in any type test, if repeat type tests are required to be conducted, then

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all the expenses for deputation of Inspector/Employer's representative shall be

deducted from the contract price. Also if on receipt of the Supplier's notice of testing,
the Employer's representative does not find 'plant' to be ready for testing the expenses
incurred by the Employer for re-deputation shall be deducted from contract price.

2.6 Additional Tests

2.6.1 The Employer reserves the right of having at his own expenses any other test(s) of
reasonable nature carried out at Supplier’s premises, at site or in any other place in
addition to the aforesaid type, acceptance and routine tests to satisfy himself that the
materials comply with the Specifications.

2.6.2 The Employer also reserves the right to conduct all the tests mentioned in this
specification at his own expense on the samples drawn from the site at Supplier’s
premises or at any other test centre. In case of evidence of noncompliance, it shall be
binding on the part of Supplier to prove the compliance of the items to the technical
specifications by repeat tests, or correction of deficiencies, or replacement of defective
items all without any extra cost to the Employer.

2.7 Sample Batch for Type Testing

2.7.1 The Supplier shall offer material for selection of samples for type testing only after
getting Quality Assurance Plan approved from Employer’s Quality Assurance Deptt/
Consultant. The sample shall be manufactured strictly in accordance with the Quality
Assurance Plan approved by Employer/Consultant.

2.7.2 The Supplier shall offer at least three drums for selection of samples required for
conducting all the type tests.

2.7.3 The Supplier is required to carry out all the acceptance tests successfully in presence of
Employer’s representative before sample selection.

2.8 Test Reports

2.8.1 Copies of type test reports shall be furnished in at least six copies along with one
original. One copy will be returned duly certified by the Employer only after which the
commercial production of the material shall start.

2.8.2 Record of routine test reports shall be maintained by the Supplier at his works for
periodic inspection by the Employer’s representative.

2.8.3 Test Certificates of tests during manufacture shall be maintained by the Supplier.
These shall be produced for verification as and when desired by the Employer.

2.9 Inspection

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2.9.1 The Employer’s representative shall at all times be entitled to have access to the works
and all places of manufacture, where conductor shall be manufactured and
representative shall have full facilities for unrestricted inspection of the Supplier’s
works, raw materials and process of manufacture for conducting necessary tests as
detailed herein.

2.9.2 The Supplier shall keep the Employer informed in advance of the time of starting and
of the progress of manufacture of conductor in its various stages so that arrangements
can be made for inspection.

2.9.3 No material shall be dispatched from its point of manufacture before it has been
satisfactorily inspected and tested, unless the inspection is waived off by the Employer
in writing. In the latter case also the conductor shall be dispatched only after
satisfactory testing for all tests specified herein have been completed.

2.9.4 The acceptance of any quantity of material shall in no way relieve the Supplier of any
of his responsibilities for meeting all requirements of the Specification, and shall not
prevent subsequent rejection if such material is later found to be defective.

2.10 Test Facilities

2.10.1 The following additional test facilities shall be available at the Supplier’s works:

a) Calibration of various testing and measuring equipment including tensile testing

machine, resistance measurement facilities, burette, thermometer, barometer etc.

b) Standard resistance for calibration of resistance bridges.

c) Finished conductor shall be checked for length verification and surface finish on
separate rewinding machine at reduced speed (variable from 8 to 16 meters per
minute). The rewinding facilities shall have appropriate clutch system and free of
vibrations, jerks etc. with traverse laying facilities.

2.11 Packing

2.11.1 The conductor shall be supplied in non-returnable, strong, wooden drums provided
with lagging of adequate strength, constructed to protect the conductor against all
damage and displacement during transit, storage and subsequent handling and stringing
operations in the field. The Supplier shall be responsible for any loss or damage during
transportation handling and storage due to improper packing. The drums shall
generally conform to IS: 1778, except as otherwise specified hereinafter.

2.11.2 The drums shall be suitable for wheel mounting and for letting off the conductor under
a minimum controlled tension of the order of 5 KN.

2.11.3 The general outline of the drum for conductor shall be as in the annexed drawings. The
Bidder should submit their proposed drum drawings along with the bid.
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2.11.4 For conductor, one standard length shall be wound on each drum.

2.11.5 All wooden components shall be manufactured out of seasoned soft wood free from
defects that may materially weaken the component parts of the drums. Preservative
treatment shall be applied to the entire drum with preservatives of a quality which is
not harmful to the conductor.

2.11.6 The flanges shall be of two ply construction with each ply at right angles to the
adjacent ply and nailed together. The nails shall be driven from the inside face flange,
punched and then clenched on the outer face. The thickness of each ply shall not vary
by more than 3mm from that indicated in the figure. There shall be at least 3 nails per
plank of ply with maximum nail spacing of 75mm. Where a slot is cut in the flange to
receive the inner end of the conductor the entrance shall be in line with the periphery
of the barrel.
2.11.7 The wooden battens used for making the barrel of the conductor shall be of segmental
type. These shall be nailed to the barrel supports with at least two nails. The battens
shall be closely butted and shall provide a round barrel with smooth external surface.
The edges of the battens shall be rounded or chamfered to avoid damage to the
conductor.
2.11.8 Barrel studs shall be used for the construction of drums. The flanges shall be holed and
the barrel supports slotted to receive them. The barrel studs shall be threaded over a
length on either end, sufficient to accommodate washers, spindle plates and nuts for
fixing flanges at the required spacing.
2.11.9 Normally, the nuts on the studs shall stand protruded of the flanges. All the nails used
on the inner surface of the flanges and the drum barrel shall be counter sunk. The ends
of barrel shall generally be flushed with the top of the nuts.
2.11.10 The inner cheek of the flanges and drum barrel surface shall be painted with a bitumen
based paint.
2.11.11 Before reeling, card board or double corrugated or thick bituminized water-proof
bamboo paper shall be secured to the drum barrel and inside of flanges of the drum by
means of a suitable commercial adhesive material. After reeling the conductor, the
exposed surface of the outer layer of conductor shall be wrapped with water proof
thick bituminized bamboo paper to preserve the conductor from dirt, grit and damage
during transport and handling.
2.11.12 A minimum space of 75 mm for conductor shall be provided between the inner surface
of the external protective tagging and outer layer of the conductor.
2.11.13 Each batten shall be securely nailed across grains as far as possible to the flange, edges
with at least 2 nails per end. The length of the nails shall not be less than twice the
thickness of the battens. The nails shall not protrude above the general surface and
shall not have exposed sharp, edges or allow the battens to be released due to
corrosion.
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2.11.14 The nuts on the barrel studs shall be tack welded on the one side in order to fully
secure them. On the second end, a spring washer shall be used.

2.11.15 A steel collar shall be used to secure all barrel studs. This collar shall be located
between the washers and the steal drum and secured to the central steel plate by
welding.

2.11.16 Outside the protective lagging, there shall be minimum of two binder consisting of
hoop iron/galvanized steel wire. Each protective lagging shall have two recesses to
accommodate the binders.

2.11.17 The conductor ends shall be properly sealed and secured on the side of one of the
flanges to avoid loosening of the conductor layers during transit and handling.

2.11.18 As an alternative to wooden drum Bidder may also supply the conductors in non-
returnable painted steel drums. After preparation of steel surface according to IS: 9954,
synthetic enamel paint shall be applied after application of one coat of primer.
Wooden/Steel drum will be treated at par for evaluation purpose and accordingly the
Bidder should quote in the package.

2.12 Marking

Each drum shall have the following information stenciled on it in indelible ink along
with other essential data:
(a) Contract/Award letter number.
(b) Name and address of consignee.
(c) Manufacturer’s name and address.
(d) Drum number
(e) Size of conductor
(f) Length of conductor in meters
(g) Arrow marking for unwinding
(h) Position of the conductor ends
(i) Distance between outer-most Layer of conductor and the inner
surface of lagging.
(k) Barrel diameter at three locations & an arrow marking at the location of the
measurement.
(l) Number of turns in the outer most layer.
(m) Gross weight of drum after putting lagging.
(n) Tear weight of the drum without lagging.
(o) Net weight of the conductor in the drum.
(p) Material Inspection & Clearance certificate No.

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The above should be indicated in the packing list also.

2.13 Verification of Conductor Length

The Employer reserves the right to verity the length of conductor after unreeling at
least ten (10) percent of the drums in a lot offered for inspection.

2.14 Standards

2.14.1 The conductor shall conform to the following Indian/International Standards, which
shall mean latest revisions, with amendments/changes adopted and published, unless
specifically stated otherwise in the Specification.

2.14.2 In the event of the supply of conductor conforming to standards other than specified,
the Bidder shall confirm in his bid that these standards are equivalent to those
specified. In case of award, salient features of comparison between the standards
proposed by the Supplier and those specified in this document will be provided by
the Supplier to establish their equivalence.

Sl. Indian Title International

No. Standard Standard
1. IS: 209-1992 Specification for zinc BS: 3436-1986
Specification for Aluminium IEC: 1089-1991
2. IS: 398-1982 conductors for Overhead BS: 215-1970
Transmission Purposes
IS: 398-1990 Part-II Aluminum Conductor Galvanized BS: 215-1970
3. and IS:398-1994 Steel Reinforced and All Aluminium IEC: 1089-1991
Part-4 Alloy Conductors
4. IS: 1778-1980 Reels and Drums for Bare Conductors BS: 1559-1949
5. IS: 1521-1991 Method of Tensile Testing of Steel ISO 6892-1984
Wire
6. IS: 2629-1990 Recommended Practice for Hot Dip
Galvanizing of Iron and Steel
7. IS: 2633-1992 Method of Testing Uniformity of
Coating on Zinc Coated Articles
8. IS: 4826-1992 Galvanized Coating on Round Steel IEC: 888-1987 BS:
Wires 443-1969
Methods of Determination of Weight BS: 433-1969 ISO
9. IS: 6745-1990 of Zinc Coating of Zinc Coated Iron 1460 - 1973
and Steel Articles
Method of Radio Interference Tests IEC: 437-1973
10. IS: 8263-1990 on High Voltage Insulators NEMA: 107-1964
CISPR
11. Zinc Coated steel wires for stranded IEC: 888-1987
Conductors
12. Hard drawn Aluminium wire for IEC: 889-1987
overhead line conductors

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Project

ANNEXURE-A

1. Tests on Conductor

1.1 UTS Test on Stranded Conductor

Circles perpendicular to the axis of the conductor shall be marked at two places
on a sample of conductor of minimum 5 m length between fixing arrangement
suitably fixed on a tensile testing machine. The load shall be increased at a
steady rate upto 50% of minimum specified UTS and held for one minute. The
circles drawn shall not be distorted due to relative movement of strands.
Thereafter the load shall be increased at steady rate to minimum UTS and held
for one minute. The Conductor sample shall not fail during this period. The
applied load shall then be increased until the failing load is reached and the
value recorded.

1.2 Corona Extinction Voltage Test

The samples of a bundle of two conductor of 5 m length shall be strung with

spacing of 450 mm between them at a height not exceeding 7.5 m above
ground. The sample assembly when subjected to power frequency voltage shall
have a corona extinction voltage of not less than 154 kV (rms) line to ground
under dry condition. There shall be no evidence of corona on any part of the
samples. The test should be conducted without corona control rings. However,
small corona control rings may be used to prevent corona in the end fittings.
The voltage should be corrected for standard atmospheric conditions.

1.3 Radio Interference Voltage Test

Under the conditions as specified under (1.2) above, the conductor samples shall
have radio interference voltage level below 1000 microvolts at one MHz when
subjected to 50 Hz AC voltage of 154 kV line to ground under dry conditions.
This test may carried out with corona control rings and arcing horns.

1.4 D.C. Resistance Test on Stranded Conductor

On a conductor sample of minimum 5m length two contact-clamps shall be

fixed with a predetermined bolt torque. The resistance shall be measured by a
Kelvin double bridge by placing the clamps initially zero metre and
subsequently one metre apart. The test shall be repeated at least five times and
the average value recorded. The value obtained shall be corrected to the value at
200C as per IS: 398-(Part-IV)-1982. The resistance corrected at 200C shall
conform to the requirements of this Specification.

1.5 Chemical Analysis of Aluminium/Aluminium Alloy and Steel

Samples taken from the Aluminium/Aluminium Alloy and steel

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ingots/coils/strands shall be chemically/spectrographically analyzed. The same

shall be in conformity to the requirements stated in this Specification.

1.6 Visual and Dimensional Check on Drums

The drums shall be visually and dimensionally checked to ensure that they
conform to the requirements of this Specification.

1.7 Visual Check for Joints, Scratches etc.

Conductor drums shall be rewound in the presence of the Employer. The

Employer shall visually check for scratches, joints etc. and that the conductor
generally conform to the requirements of this Specification. Ten percent (10%)
drums from each lot shall be rewound in the presence of the Employer's
representative.

1.8 Dimensional Check on Steel and Aluminium/Aluminium Alloy Strands

The individual strands shall be dimensionally checked to ensure that they

conform to the requirement of this Specification.

1.9 Check for Lay-ratios of Various Layers

The lay-ratios of various layers shall be checked to ensure that they conform to
the requirements of this Specification.

1.10 Procedure Qualification test on welded Aluminium/Aluminium Alloy

strands.

Two Aluminium/Aluminium Alloy wire shall be welded as per the approved

quality plan and shall be subjected to tensile load. The breaking strength of the
welded joint of the wire shall not be less than the guaranteed breaking strength
of individual strands.

1.11 Chemical Analysis of Zinc

Samples taken from the zinc ingots shall be chemically/ spectrographically

analyzed. The same shall be in conformity to the requirements stated in the
Specification.

1.12 Galvanizing Test

The test procedure shall be as specified in IEC: 888. The material shall conform
to the requirements of this Specification. The adherence of zinc shall be checked
by wrapping around a mandrel four times the diameter of steel wire.

1.13 Torsion and Elongation Tests on Steel Strands

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The test procedures shall be as per clause No. 10.3 of IEC: 888. In torsion test,
the number of complete twists before fracture shall not be less than 16 on a
length equal to 100 times the standard diameter of the strand. In case test sample
length is less or more than 100 times the stranded diameter of the strand, the
minimum number of twists will be proportioned to the length and if number
comes in the fraction then it will be rounded off to next higher whole number.
In elongation test, the elongation of the strand shall not be less than 4% for a
gauge length of 250 mm.

1.14 Check on Barrel Batten strength of Drums

The details regarding barrel batten strength test will be discussed and
mutually agreed to by the Supplier & Employer.

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